Service Manual

E LECTROSURGICAL G ENERATOR
 LIMITED WARRANTY
For a period of two years following the date of delivery,
CONMED Corporation warrants the CONMED System
2450™ Electrosurgical Generator against any defects in
material or workmanship and will repair or replace (at
CONMED’s option) the same without charge, provided
that routine maintenance as specified in this manual has
been performed using replacement parts approved by
CONMED. This warranty is void if the product is used
in a manner or for purposes other than intended.

© 2013 CONMED Corporation

525 French Road
Utica, New York 13502-5994 USA

U.S. Patent Numbers 6,830,569 - 6,875,210 - 6,948,503 -

D552241 and other patents pending.

For Technical Service or Return Authorization Phone:

303-699-7600 / 1-800-552-0138 Extension 5274
Fax 303-699-1628

For Customer Service or to order parts phone:

1-800-448-6506 / 315-797-8375 / Fax 315-735-6235
or contact your CONMED Representative.

European Authorized Representative

MDSS GmbH
Schiffgraben 41
D - 30175 Hannover
Germany

The revision level of this manual is specified by the

highest revision letter found on either the inside front cover
or enclosed errata pages (if any).

Manual Number 60-2454-ENG Rev. F

Unit Serial Number

 Table of Contents
& List of Illustrations

Section Title Page

1.0 General Information.....................Refer to Operator’s Manual (60-2451)
2.0 Specifications...............................Refer to Operator’s Manual (60-2451)
3.0 Theory of Operation...............................................................................3-1
3.1 Mode Descriptions..............................................................................................3-1
3.1.1 Cut Major Modes................................................................................................................ 3-1
3.1.2 Coag Major Modes.............................................................................................................. 3-1
3.1.3 Bipolar Major Modes.......................................................................................................... 3-1
3.2 System Overview.....................................................................................................3-1
3.2.1 RF Power Supply (RFPS)................................................................................................... 3-4
3.2.2 RF Amplifier and Transformer..........................................................................................3-4
3.2.3 Electrosurgical Outputs...................................................................................................... 3-4
3.2.4 Activation Command Sensing............................................................................................ 3-5
3.2.5 Automatic Return Monitor (A.R.M.).................................................................................3-5
3.2.6 System Controllers and Monitor........................................................................................3-5
3.2.7 Low Voltage Power Monitoring.........................................................................................3-5
3.2.8 Operator Control Panel...................................................................................................... 3-5
3.2.9 Activation Tones................................................................................................................. 3-6
3.2.10 Activation Relay Connector................................................................................................ 3-6
3.3 Optional System Configurations......................................................................3-6
4.0 Maintenance............................................................................................4-1
4.1 General Maintenance Information........................................................................4-1
4.2 Maintenance Personnel...........................................................................................4-1
4.3 Cleaning...............................................................................................................4-1
4.4 Periodic Inspection.............................................................................................4-1
4.5 Periodic Performance Testing...............................................................................4-1
4.5.1 Chassis Ground Integrity.................................................................................................... 4-1
4.5.2 Displays, Alarms and Commands......................................................................................4-1
4.5.3 Output Power...................................................................................................................... 4-2
4.5.4 RF Leakage Measurement..................................................................................................4-3
4.5.5 Line Frequency Leakage..................................................................................................... 4-4
4.5.6 Automatic Return Monitor (A.R.M.) Check......................................................................4-5
4.5.7 Output Coupling Capacitor Check.....................................................................................4-5
4.6 System Calibration..................................................................................................4-6
4.6.1 Calibration Preliminaries................................................................................................... 4-6
4.6.2 Selecting the Mode to Calibrate.........................................................................................4-6
4.6.3 Calibrating a Monopolar Mode..........................................................................................4-8
4.6.4 Calibrating Bipolar Modes................................................................................................. 4-8
4.6.5 Calibrating A.R.M............................................................................................................... 4-8
4.6.6 Completing Calibration...................................................................................................... 4-9
4.7 Last Fault Code Retrieval & Clear.......................................................................4-9
4.7.1 Last Fault Code Retrieval................................................................................................... 4-9
4.7.2 Clearing Last Fault Codes.................................................................................................. 4-9
4.8 Displaying Optional System Configuration....................................................4-9
Section Title Page
4.9 DACview............................................................................................................4-12
4.10 Troubleshooting................................................................................................4-12
4.10.1 HVPS Troubleshooting Hints........................................................................................... 4-14
4.11 Parts Ordering Information................................................................................4-14
4.12 Assembly Breakdown/Parts Access.....................................................................4-15
4.12.1 Top Cover Removal & Replacement................................................................................4-15
4.12.2 Bezel Removal & Replacement.........................................................................................4-16
4.12.3 Control/Display Board Removal & Replacement............................................................4-16
4.12.4 Power Board Removal & Replacement............................................................................4-17
4.12.5 Power Transistor Replacement........................................................................................4-17
4.13 Fault Codes.......................................................................................................4-18
Appx. A Schematics & BOMs .........................................................................A-1
Bill of Material: Top Assembly & Chassis......................................................................... A-1
Bill of Material: Controller PCB Assembly....................................................................... A-7
Bill of Material: Power PCB Assembly ........................................................................... A-13

Figure/Title Page
Figure 3.2 System Block Diagram......................................................................................................... 3-3
Figure 4.1 Calibration Procedure Flow Chart........................................................................................4-7
Figure 4.2 DIP Switch Positions........................................................................................................... 4-11
Figure A.1a Controller PCB (Top)....................................................................................................... A-7
Figure A.1b Controller PCB (Bottom) ................................................................................................ A-8
Figure A.2 Power PCB ...................................................................................................................... A-13

Table 4.1 Monopolar Cut Mode RF Output Power Accuracy...............................................................4-2

Table 4.2 Monopolar Coag Mode RF Output Power Accuracy.............................................................4-2
Table 4.3 Bipolar Mode RF Output Power Accuracy............................................................................4-2
Table 4.4 Allowable RF Leakage Current to Ground............................................................................4-3
Table 4.5 Allowable RF Leakage Current - Inactive Monopolar Outputs............................................4-4
Table 4.6 Allowable RF Leakage Current - Inactive Bipolar Outputs..................................................4-4
Table 4.7 Line Frequency Allowable Leakage - Inactive.......................................................................4-4
Table 4.8 Line Frequency Allowable Leakage - Active.........................................................................4-5
Table 4.9 DIP Switch Settings.............................................................................................................. 4-10
Table 4.10 DACview Channels............................................................................................................. 4-12
Table 4.11 Troubleshooting.................................................................................................................. 4-12
Table 4.12 Fault Codes............................................................................................................................ 4-18

Schematic A.1a Controller PCB - Top Sheet........................................................................................ A-1

Schematic A.1b Controller PCB - Controller Sheet.............................................................................. A-2
Schematic A.1c Controller PCB - Monitor Sheet ................................................................................. A-3
Schematic A.1d Controller PCB - FPGA Sheet.................................................................................... A-4
Schematic A.1e Controller PCB - DAC Sheet...................................................................................... A-5
Schematic A.1f Controller PCB - Display Sheet................................................................................... A-6
Schematic A.2a Power PCB - Power Amplifier .................................................................................... A-9
Schematic A.2b Power PCB - ........................................................................................................... A-10
Schematic A.2c Power PCB - ............................................................................................................ A-11
Schematic A.2d Power PCB - ........................................................................................................... A-12
 Theory of Operation
Section 3.0

System 2450™ functions and essential circuit information are provided in this section. This section begins
with a description of the key parameters for each mode. This is followed by an overview of how the
system functions and some key operational information for the modules within the system.
3.1 Mode Descriptions
The key functional parameters for each mode are presented here. Nominal mode specifications are provided
in section 1.2.11 of the System 2450 Operators Manual.
3.1.1 Cut Major Modes

Major Mode Minor Mode Nominal RF Modulation (Number of Modulation (Normal

Frequency Pulses, Nominal Time Frequency & Period)
On/Off
Cut Pure 400 KHz None None
Blend 400 KHz 11 pulses, 28µs / 12µs 25 KHz / 40µs
Hi Blend* 400 KHz 9 pulses, 23µs / 17µs 25 KHz / 40µs
*Hi Blend can be set by a Hospital Qualified Biomedical Technician – see Section 4.8.
3.1.2 Coag Major Modes

Major Mode Minor Mode Nominal RF Modulation (Number of Modulation (Normal

Frequency Pulses, Nominal Time Frequency & Period)
On/Off
Coag Standard 495 KHz Single pulse 40 KHz / 25µs
Spray 495 KHz Single pulse 20 KHz / 50µs
Standard and Spray Coag modes are fundamentally different from the Cut modes in that the resonant circuit
of the RF Amplifier and Transformer combination is excited by the energy of a single pulse, causing the reso-
nant circuit to ring until the energy is dissipated. Spray Coag provides the maximum open circuit voltage for
which the system is rated.
3.1.3 Bipolar Major Modes

Major Mode Minor Mode Nominal RF Modulation (Number of Modulation (Normal

Frequency Pulses, Nominal Time Frequency & Period)
On/Off
Bipolar Macro 400 KHz None None
Micro 400 KHz None None

3.2 System Overview

Mains power is converted to electrosurgical output power through the RF Power Supply (RFPS), the RF
Amplifier, and the Transformer and Output sections of the system.
Mains power is converted to high voltage direct current power in the RFPS to supply the RF Amplifier.
This is essentially a power transformer with a power factor corrected regulator. The power factor correction
can be enabled or disabled under software control.
Pulses generated in the RF Controller are amplified to electrosurgical power and voltage levels in the RF
Amplifier and Transformer portions of the power train. Three high-voltage bipolar transistors and a single
MOSFET make up the hybrid-cascode RF Amplifier. The hybrid-cascode amplifier is a fast, high-voltage
amplifier that can be controlled by the combination of DC voltage (VBASE_PWM) and a fixed

3
 amplitude,

3
variable pulse width signal (RFGATE). This
The RF Monitor is a Digital Signal Processor
amplifier is combined through a relay with either
(DSP) that is used to monitor the system for
the Monopolar output transformer or the Bipolar
safety problems that can result from a variety of
output transformer to generate electrosurgical
conditions.
power.
• The Monitor has independent sensors for out-
Electrosurgical power flows from the RF
put voltage and current, which it uses to
Amplifier / Transformer section to the Output sec-
cal- culate power for comparison with the
tion where the power is switched to the specific
power that the RF Controller senses and for
electrosurgical outputs. The Output section also
com- parison with the generator power
has circuitry to detect activations from accessories
setting.
and the circuitry to perform the Automatic Return
Monitor (A.R.M.) function to ensure the • To ensure that the correct outputs are acti-
integrity of the dispersive electrode connection. vated, the Monitor also independently
senses current at each of the outputs, look-
The power section also includes a number of
ing for current flow that would indicate
out- put voltage and current sensors that are
electrosurgical power at outputs other than
used by the RF Controller for control of power
the selected output.
delivery and by the Monitor to detect errant
output condi- tions. Windings on the Monopolar • The Monitor senses the audio output to ensure
output trans- former and the Bipolar output that a tone occurs whenever electrosurgical
transformer are the means for sensing output outputs are active.
voltage. Separate pri- mary-side current • The RF Amplifier drive signal is sensed by
transformers are shared by the bipolar and the Monitor to detect improper frequencies
monopolar channels for control and monitoring of or improper pulse sequences for the selected
the current. There are also separate current mode.
sensors on the monopolar outputs that are used to • The Monitor independently compares the
detect stuck output relays. activation signal with that seen by the System
The RF Controller is a Field Programmable Controller to ensure that the activation signal
Gate Array (FPGA) that generates the RFGATE is consistent.
and VBASE_PWM RF Amplifier drive signals The Monitor has the capability to independently
based upon a comparison of measured disable the electrosurgical output if a problem is
parameters detected.
and settings-based parameters. The pulse train
The System Controller provides the primary con-
sequence is a settings-based parameter that is
trol interface to the user and other outside sys-
dependent on the selected mode. Target power,
tems, including the serial interface, the activation
current limit, and voltage limit are all settings-
relay, tone generation, and displays.
based parameters derived from a load curve that
is specific to the selected mode and front panel Finally, the Display accepts all user input and pro-
power setting. The RF Controller samples vides all user feedback. The Display is controlled
electrosurgical output current and output volt- by the System Controller through a serial interface
age from sensors at a 20 Megahertz rate and uses and illuminates the LED display elements in a
these sampled values to calculate sensed current, time division multiplexed fashion; the illuminated
sensed voltage, and output power. This high sam- LED display elements are actually on less than half
ple rate allows control of the real power delivered the time. The Display also provides for user input
to the active accessory and also allows the System through the buttons on the control panel, includ-
2450 to rapidly adapt to changing loads. The ing switch de-bouncing and conditioning.
output current, output voltage, and output Figure 3.2 illustrates the key elements of the sys-
power are compared with corresponding settings tem in block diagram form.
based parameters of current limit, voltage limit,
and target power, respectively, and the RF
Controller adjusts value of VBASE_PWM in a
closed-loop fashion to control these parameters.
The RF Controller also provides fixed pulses for
RFGATE within each mode-based pulse train
sequence.

3
 Indicators: Activation & Mode

Activation Request Keyboard Modes / Power

Displays

Activation Relay Connector

ACT RLY
RS232 Serial Interface Connector
SPI
AL TONE

ACT TONE
System Controller A.R.M

Patient
RF Output Relays

VARM
RLY DRV
MonoBip
RF INH

PFC EN HVEN

RF ControllerRF MP VS
RF BP VS

RF Amp

RF IS

Host Bus RFDRV

Tone Mon RFHVSup

VBPWM HV Power Supply

Monitor

HFINH

M ISN

MRF BP VSN

MRF MP VSN
MRF H1 SN
MRF HF SN

Figure 3.2 System Block Diagram

3
3.2.1 RF Power Supply (RFPS)
Controller (RFGATE). The base connections of
The RFPS is comprised a line transformer and a the three parallel bipolar transistors are also
Power Factor Control (PFC) section. The PFC driven by a signal that originates from the RF
converts Mains power from the transformer to Controller (Vbase_PWM).
approximately 95 volts D.C. using techniques The RFGATE drive pulses provide the basic
that ensure the mains current into the supply is pulse pattern that is used to form the
sinusoidal and in phase with the mains voltage. electrosurgical waveform, and have a set pulse-
By doing so, RMS current and harmonic pattern and pulse- width for each mode. A drive
distor- of several pulses
tion are reduced. Jumpers on the power board are at a frequency that closely matches the resonant
used to select input line voltage range. A graphic frequency of the amplifier characterize Cut and
on the power board and on the schematic indicate Blend modes, and the output pulses substantially
which jumpers are used for each input voltage correspond to the drive. Spray and Standard
range. Coag modes, however, are characterized by pulses
WARNING: THE RFPS VOLTAGE TAKES that occur less frequently where the amplifier is
SEVERAL SECONDS TO DECAY AFTER allowed to “ring” at its resonant frequency.
THE POWER IS SWITCHED OFF. TO Rapid regulation of the output power in this
WARN THE SERVICE TECHNICIAN, A arrangement is provided by VBASE_PWM; as
RED LED (DS1) ON THE POWER BOARD VBASE_PWM is increased, the output power
INDICATES WHEN VOLTAGE IS STILL increases. As noted in the RF Controller dis-
ON THE BOARD. cussion, the RF Controller compares the out-
The System Controller can enable or disable the put power with the desired power and adjusts
PFC section of the RFPS. The PFC is normally the VBASE_PWM to minimize the
enabled during operation to ensure a resistive load difference.
is presented to the Mains. VBASE_PWM enters the amplifier as a 312
In addition to the RFPS winding, there is also KHz Pulse-Width-Modulated (PWM) signal that
another secondary winding on the Mains trans- is fil- tered to become a variable DC base drive
former that is rectified and filtered to provide signal.
unregulated +25VDC voltage as the input for a Finally, the RF Amplifier and Transformer provide
+12V switching regulator. The +12V output is capabilities for sensing RF output current and
then used to supply input voltage to a variety voltage. The voltage sensors that are used for
of low-voltage regulators on the controller power control and power monitoring are indepen-
board. dent windings on the output transformers. The
current is also measured on the primary side of
3.2.2 RF Amplifier and Transformer the transformers. With proper characterization of
The RF Amplifier and Transformer portions use the transformer, the controller obtains an accurate
a switch-mode resonant hybrid-cascode ampli- representation of the voltage, current, and thus the
fier to convert the power from the RFPS to the output power of the system.
RF energy necessary for electrosurgery. One may 3.2.3 Electrosurgical Outputs
think of the amplifier as a high-speed switch that
pulses current through a resonant circuit, which is Relays are provided to isolate electrosurgical out-
formed by the monopolar or bipolar transformer puts and select which outputs are active. The
together with capacitors that are connected to System Controller selects the appropriate output
the transformer primary and secondary wind- relays based upon activation command inputs.
ings. The transformers are designed with a good The Monitor utilizes current sensors implemented
deal of leakage inductance in order to provide on each monopolar electrosurgical output to
inductance for resonating with the capacitors. determine whether current is flowing only to the
One Metal-Oxide-Semiconductor Field Effect correct outputs. In the event that current flows
Transistor (MOSFET) is connected in series in an output that is not selected, the Monitor
with three parallel bipolar transistors to provide can independently disable RF. The monitor uses
the switching. The pulses to drive the gate on the bipolar primary voltage to sense that the
the MOSFET in this arrangement come from bipolar relay has been activated.
the RF

3
3.2.4 Activation Command Sensing
of RF power using the VBASE_PWM and
Each of the Hand Controlled Accessory recep- RFGATE outputs. To reduce the effects on
tacles incorporate inputs that are used to sense the microprocessor circuits on the Control/
an activation command from the user. Each Display Board from RF noise at the output,
monopolar hand controlled accessory receptacle VBASE_PWM and RFGATE are both dif-
has an input for Cut and an input for Coag. ferential mode signals running between the
The bipolar receptacle incorporates a single Control/Display Board and the power section.
activation input. Each of these five inputs is The RF Controller is capable of disabling
isolated from the other electrosurgical outputs RF output power and putting the system
and from other into a safe state without any interaction from
low-level circuitry in the system. All are powered the Monitor or the System Controller. The
by a multiple output isolated power supply. The RF Controller independently monitors the
footswitch activation inputs on the back panel are RF output voltage and current for control
configured in a similar way and share one of the purposes through several scaled inputs. The
isolated power supply outputs. RF Controller is comprised of the major
por- tion of the FPGA, together with
3.2.5 Automatic Return Monitor (A.R.M.)
circuitry necessary for converting the control
The patient return connector interfaces to single signals between analog and digital form.
and dual dispersive electrodes using a two-pin • RF Monitor: A DSP that is dedicated to safety
connector. A.R.M. circuitry uses an actively driv- monitoring activities. The Monitor is capable
en impedance measurement circuit, which allows of disabling RF output power and putting
the System Controller to detect the type of the system into a safe state without any
disper- sive electrode connected and verify its interac- tion from the RF Controller or the
integrity. System Controller. To ensure that the
3.2.6 System Controllers and Monitor Monitor can correctly perform its function,
the Monitor is resistively isolated from the
Two processors and an FPGA are used for system System Controller and the RF Controller and
interface & control, RF control, and system has independent voltage regulation. The RF
moni- tor functions. The RF control section Monitor indepen- dently monitors a variety
consists of a dual-channel architecture with two of inputs to detect safety problems and has
independent channels where one is used control of disable signals for RF Amplifier
exclusively for RF out- put control and the other drive. The Monitor is comprised of a DSP,
is used for safety moni- toring. All of these together with circuitry necessary for
elements are located on the Control board, along converting the signals monitored between
with circuitry for interface with the user. analog and digital form, an FPGA to provide
• System Controller (System Microcontroller): interface logic, independent voltage
A dedicated Microcontroller that handles regulators, isolation resistors and other inter-
the entire user interface, Serial Interface, and face logic.
enables/disables the power factor control sec- 3.2.7 Low Voltage Power Monitoring
tion of the RFPS using the PFC_EN signal.
The System Controller can also disable the The low voltage power supply is monitored in
signal used to drive the RF Amplifier and hardware and resets the processors if it is out of
can terminate RF drive at any time without range. The microprocessor supervisory device on
inter- action from either the RF Controller or the Control/Display Board monitors +3.3V and
the Monitor. The System Controller is +1.8V and will reset the system should the
comprised of a standard architecture levels drop approximately 0.3V. The
microprocessor together with portions of Control/Display Board has the circuit that will
the FPGA, which provides interface logic to a reset the system should the 3.3V supply exceed
variety of signals, independent voltage 3.6V.
regulators, a processor supervisory reset
3.2.8 Operator Control Panel
circuit, and other interface logic.
• RF Controller: An FPGA implementing • Keyboard: The main operator input device
digital signal processing elements for control for choosing operating modes and settings is
the membrane keyboard panel. Tactile-feedback

3
mechanical switches allow the operator to set
modes and adjust power settings. 3.3 Optional System Configurations
• Display Panel: Consists of 7-segment displays An eight-position configuration dipswitch (S2),
and discrete dual colored LED’s that will display located on the Control/Display Board Assembly
all controls and settings. LED display elements (A4) allows a qualified service technician to
are illuminated in a time division multiplexed change some of the factory default settings. With
fashion; the illuminated LED display elements are the exception of the DACview switch, which is
actually on less than half the time. only effective in Test Mode, the configuration dip-
switch settings are only detected when power is
3.2.9 Activation Tones initialized, so any changes to the switch positions
Tone is generated for all activation requests, fault will not be detected until power is cycled. Each
detection and changes made on the Control Panel. switch is OFF in the Down position and ON in
The System Controller generates the tone signal the UP position. (The system detects changes in
(TONE_DRV), which is amplified by a driver. the DACview switch while power is on, so it is
The activation tone is adjustable and controlled by treated differently.) Relevant information for the
an output from the System Controller, but alarm configuration dipswitches appears in Section 4.8.
tones are not adjustable and are set to generate a
tone greater than 65 dB.
There is circuitry to permit the Monitor to
verify the oscillation from voltage measured
across the speaker, which provides confirmation
that the speaker is indeed generating audible
tones dur- ing activation. RF output is inhibited
should the speaker drive current be absent or
too low.
3.2.10 Activation Relay Connector
There is an Accessory Relay Connector, which
provides a relay closure (SPST switch) that may
be used for activating external accessories such as
smoke evacuation units.

3
 Maintenance
Section 4.0

This section contains information useful in the

(Windex® is a registered trademark of the S.C.
maintenance and repair of the System 2450.
Johnson Company. Formula 409® is a registered
WARNING: High voltages are present at trademark of the Clorox Company.)
the connections and within the System 2450.
Maintenance personnel should take precau- 4.4 Periodic Inspection
tions to protect themselves. Read the safety The System 2450 should be visually inspected at
summary in Section 1.1.4 of the System 2450 least every six months. This inspection should
Operators Manual before working on the include checks for the following:
ESU.
1) Damage to the power cord and plug.
4.1 General Maintenance Information 2) Proper mating and absence of damage to the
Although the System 2450 has been designed accessory connectors.
and manufactured to high industry standards, it is 3) Any obvious external or internal damage to
recommended that periodic inspection and perfor- the unit.
mance testing be performed to ensure continual 4) Any accumulation of lint or debris within the
safe and effective operation. unit or heatsink.
Ease of maintenance was a primary consideration 5) Control Panel cuts, punctures, or dents.
in the design of the System 2450. Maintenance
features of this unit include microprocessor aided 4.5 Periodic Performance Testing
troubleshooting aids and push button calibration, The System 2450 should be tested for correct
built in fault detection, circuit protection, and easy performance at least once every year. Every unit
access to circuitry while the unit is operational. is supplied with a serialized Production Test Data
These features, coupled with the warranty, local Sheet that tabulates the results of the factory tests
support, loaner equipment, factory support, toll that were performed on the unit. This data is
free phone service to the factory and available fac- supplied so that it may be used as a reference for
tory training ensure a minimal maintenance effort subsequent tests.
with extensive support available. Recommended periodic performance tests are
4.2 Maintenance Personnel listed in the following sections.

Only Hospital Qualified Biomedical Technicians 4.5.1 Chassis Ground Integrity

or ConMed factory technicians should perform Connect a standard ohmmeter between the
service on the System 2450. Refer all servicing earth ground prong on the power plug and
to a Hospital Qualified Biomedical Technician. the
If necessary, your CONMED sales representative Equipotential Ground Connection. Compensate
will be happy to assist you in getting your for lead resistance. Confirm less than 0.2 ohms
equip- ment serviced. resistance is measured.

4.3 Cleaning 4.5.2 Displays, Alarms and Commands

The interior of the unit may be vacuumed or Perform the Preliminary Functional Test procedure
blown out as required. The exterior of the described in section 2.3.1 of the System 2450
unit may be cleaned by wiping it with a cloth Operators Manual to verify proper operation of
that has been dampened (not dripping) with a displays, alarms and commands.
mild detergent such as Windex® or Formula
409®.

4
4.5.3 Output Power
used for checking power to obtain the
1) Equipment Requirements: best results.
a) Monopolar Footswitch 2) Use test leads to connect the ESU tester
b) Bipolar Footswitch to the unit’s return electrode output and
the footswitch controlled active output. Set
c) Commercial ESU Tester (e.g. Fluke
the Load resistance per mode as indicated
454A or equivalent) with non-inductive
in Tables 4.1 and 4.2.
50
and 300 ohm loads for bipolar modes 3) Perform the monopolar power tests indicated
and a non-inductive 500 ohm load for in Tables 4.1 and 4.2. The acceptance range
monopolar modes. is given in both Watts and Amps to
accommo- date available test equipment. It is
Note: Micro Bipolar is particularly sensitive to
not neces- sary to test for both power and
the load resistance. A 50 ohm load should be
current.

Table 4.1 Monopolar Cut Mode RF Output Power Accuracy

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)
Pure 500 20 17 23 0.184 0.214
500 100 90 110 0.424 0.469
500 300 270 330 0.735 0.812
Blend 500 20 17 23 0.184 0.214
500 100 90 110 0.424 0.469
500 200 180 220 0.600 0.663
Table 4.2 Monopolar Coag Mode RF Output Power Accuracy
Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)
Standard 500 20 17 23 0.184 0.214
500 50 45 55 0.300 0.332
500 120 108 132 0.465 0.514
Spray 500 20 17 23 0.184 0.214
500 50 45 55 0.300 0.332
500 80 72 88 0.379 0.420

4) Disconnect the ESU tester from the unit.

6) Perform the bipolar power tests indicated in
5) Use test leads to connect the ESU tester Table 4.3. This table only provides the mini-
to the Bipolar Accessory outputs. mum number of points to be tested.

Table 4.3 Bipolar Mode RF Output Power Accuracy

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)
Macro 300 20 17 23 0.238 0.277
300 50 45 55 0.387 0.428
300 70 63 77 0.458 0.507
Spray 50 20 17 23 0.583 0.678
50 50 45 55 0.949 1.049
50 70 63 77 1.122 1.241

4-
4.5.4 RF Leakage Measurement
to the patient and operating room staff through
NOTE: To ensure accuracy when making leak- unintended paths, which can cause injury. RF
age measurements, perform all leakage testing leakage occurs because the total energy in the
using methods and instruments that are com- output voltage waveform is provided with a con-
pliant with the prcedures outlined in Section ductive path through stray parasitic capacitance
19 of IEC60601-2-2 (Particular Requirements distributed within the generator and along the
for the Safety of High Frequency Surgical length of the leads.
Equipment). Table 4.4 presents the allowed RF leakage currents
RF Leakage can present a hazard in the operating to ground.
room because electrosurgical currents can flow

Table 4.4 Allowable RF Leakage Current to Ground

MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)
Dispersive Electrode Coag Combination Monopolar Standard Coag < 100
Dispersive Electrode Cut Combination Monopolar Pure Cut < 100
Dispersive Electrode Hand Controlled Standard Coag < 100
Combination Monopolar Active Coag Combination Monopolar Standard Coag < 100
Hand Controlled Active Left Hand Controlled Standard Coag < 100
Bipolar Right Bipolar Footswitch Bipolar Macro < 67
Bipolar Left Bipolar Footswitch Bipolar Macro < 67

Equipment:
WARNING: HAND CONTROL ACTIVA-
• ESU Tester with RF Leakage function -OR- TIONS SHOULD BE KEYED USING
• 0-250 is RF Ammeter with a 200 ohm 10 W 3” OR LESS WELL-INSULATED
Non-inductive Resistor JUMPER. USE OF AN INSULATING
• Patient Plate Adapter Plug ROD TO INSERT THE JUMPER IS
ADVISED TO PREVENT RF BURNS.
• 2 - Test leads, 1 m max. Length
3) One at a time, connect test setup to each RF
• 3 - Test leads, 10 cm max. Length
output terminal indicated in Table 4.4 and
• Wooden table approximately 1 m from floor. activate the unit using the corresponding
NOTE: Use a measuring device that meets IEC command. Confirm no meter readings exceed
specification for RMS measured over one second. the specified maximum. Hand controlled
Procedure: Coag activations are accomplished by con-
necting a jumper between the left jack and
1) Ensure that the unit is fully assembled and all
center jack of the desired hand switched acces-
fasteners are tight.
sory jack.
2) Place the ESU tester or meter with resistor
RF leakage should also be measured between inac-
on the table so that they are at least 0.5m
tive outputs and the Dispersive Electrode connec-
away from the unit under test and any other
tion. The procedure is as follows:
con- ductive surface.
1) Set the unit for full power for the modes
3) Set the unit for full power for the modes
noted in Table 4.5. Connect the ESU tes-
noted in the table. Connect the ESU tes-
ter according to manufacturer’s instructions
ter in accordance with the manufacturer’s
- OR- the 200-ohm non-inductive resistor in
instructions -OR- connect the 200-ohm non-
series with the 250 mA RF ammeter to the
inductive resistor in series with the 250 mA
Dispersive Electrode connection on the front
RF ammeter to the Equipotential Ground
panel. Also make sure there are no connec-
Connection on the Rear Panel. Also make
tions to any output other than the one you
sure there are no connections to any output
are measuring.
other than the one you are measuring.

4-
 2) One at a time, connect this series combination to each RF output terminal indicated in Table 4.5 and
activate the unit using the corresponding command. Confirm that no meter readings exceed the specified
maximum.
Table 4.5 Allowable RF Leakage Current - Inactive Monopolar Outputs
MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)
Combination Monopolar Active Hand Controlled Standard Coag < 50
Combination Monopolar Active Bipolar Footswitched Macro < 20
Hand Controlled Active Combination Monopolar Standard Coag < 50
Hand Controlled Active Bipolar Footswitched Macro < 20
Bipolar Left Right Hand Controlled Standard Coag < 48

Finally, RF leakage should be measured between

according to manufacturer’s instructions -OR
the inactive bipolar outputs while a monopolar
the 200-ohm non-inductive resistor in series
accessory is activated. Do the following:
with the 250 mA RF ammeter between the
1) Set the unit for full power for the bipolar two bipolar output connections.
mode noted in Table 4.6. Connect ESU
2) Activate and verify the limit in Table 4.6.
tester

Table 4.6 Allowable RF Leakage Current - Inactive Bipolar Outputs

MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)
Bipolar Right to Left Hand Controlled Standard Coag < 48

4.5.5 Line Frequency Leakage

Circuit ground and Neutral (Low Mains) must
CAUTION: To prevent RF current from destroy- be connected together for Mains leakage testing.
ing the test equipment and/or affecting leakage Equipment:
readings, set all power settings to zero. These tests are performed most conveniently using
WARNING: ELECTROCUTION HAZARD. any good quality biomedical electrical safety tester.
USE OF AN ISOLATED MAINS POWER Procedure:
SOURCE IS RECOMMENDED WHEN 1) Connect the electrical safety analyzer to make
OPENING THE MAINS GROUND the measurements indicated in Table 4.7.
DURING THE FOLLOWING SAFETY
2) Mode: Measure leakage for Bipolar to Neutral
TESTS.
and Chassis to Neutral.
Table 4.7 Line Frequency Allowable Leakage - Inactive
RF output to Neutral LINE GND LIMIT max
Equipotential Ground Normal Closed 30 µA
Equipotential Ground Reversed Closed 30 µA
Equipotential Ground Normal Open 270 µA
Equipotential Ground Reversed Open 270 µA
Dispersive Electrode Normal Closed 15 µA
Dispersive Electrode Reversed Closed 15 µA
Dispersive Electrode Normal Open 15 µA
Dispersive Electrode Reversed Open 15 µA
Bipolar Output* Normal Closed 15 µA
Bipolar Output* Reversed Closed 15 µA
Bipolar Output* Normal Open 15 µA
Bipolar Output* Reversed Open 15 µA
*Measure the Bipolar Output with Bipolar connections shorted together.

4
 5) Since the System 2450 monopolar active out-
see Table 4.8; while that output is activated
puts are disconnected by relays when the unit
in Cut by the appropriate footswitch or
is not activated, active-to-neutral leakage tests
hand control jumper. Hand control cut
must be performed with the unit activated in
activations are accomplished by connecting
order to be valid.
a jumper between the two outer jacks of
6) With all power controls set to zero, measure where the handcontrolled accessory is
the leakage current as in step 1 from each plugged into the unit.
of the three active output terminals to
neutral;
Table 4.8 Line Frequency Allowable Leakage - Active
RF output to Neutral LINE GND ACTIVATION LIMIT max
Combination Monopolar Active Normal Closed Combination Monopolar Cut 15 µA
Combination Monopolar Active Reversed Closed Combination Monopolar Cut 15 µA
Combination Monopolar Active Normal Open Combination Monopolar Cut 15 µA
Combination Monopolar Active Reversed Open Combination Monopolar Cut 15 µA
Hand Controlled Active Normal Closed Hand Controlled Cut 15 µA
Hand Controlled Active Reversed Closed Hand Controlled Cut 15 µA
Hand Controlled Active Normal Open Hand Controlled Cut 15 µA
Hand Controlled Active Reversed Open Hand Controlled Cut 15 µA

4.5.6 Automatic Return Monitor (A.R.M.)

3) Dual Electrode Lower Limit: Set the DRB
Check
to 15 Ohms and verify the Dual
A.R.M. has two specific ranges that will be tested Dispersive Electrode Status/Alarm
initially and then the circuit will be tested to verify Indicator is Green.
that the circuit measures dispersive electrode resis- 4) Single Electrode Upper Limit: Set the DRB
tance correctly. For this testing, only a Decade to 7 Ohms, then reset A.R.M. and verify the
Resistance Box (DRB) and a dispersive electrode Single Dispersive Electrode Status/Alarm
cable adapter are required. Connect the DRB to Indicator is Green.
the Dispersive Electrode Receptacle using the dis-
persive electrode cable adapter. 4.5.7 Output Coupling Capacitor Check
A.R.M. may be reset by disconnecting the dis- WARNING: ENSURE ALL POWER
persive electrode connector or adjusting the DRB SETTINGS ARE AT 0 WATTS BEFORE
above 10K Ohms until the Single and Dual CONDUCTING THIS TEST TO PREVENT
Dispersive Electrode Status/Alarm Indicators flash INJURY TO PERSONNEL AND DAMAGE
red in alternating fashion. Allow approximately TO TEST EQUIPMENT.
two seconds after the DRB is changed before NOTE: Not all capacitance meters will read
pro- ceeding to the next step in the procedure. prop- erly for this test. The test frequency
A.R.M. indicators not mentioned in the procedure should be at or below 1 kHz for best accuracy.
must be off for each test. The following meters have been tried
1) Dual Electrode Alarm Limit: Set the DRB to successfully: Fluke 189, Extech 285, Sencor
158 Ohms, then connect it to the Dispersive LC75 and HP4284A (1 kHz setting or below).
Electrode Receptacle and verify that the 1) Connect shorting plug to banana adapter to
Single and Dual Dispersive Electrode Status/ the two pin Dispersive Electrode Receptacle.
Alarm Indicators flash red in alternating fash- Use 6” or shorter test leads to connect a
ion. capacitance meter between the shorting plug
2) Dual Electrode Upper Limit: Set DRB to adapter and the footswitched ReadiPlug
140 Ohms and verify that the Dual Universal Accessory Receptacle.
Dispersive Electrode Status/Alarm Indicator 2) Measure capacitance and confirm it is less
is Green. than 0.2 nF.

4-
 3) Confirm cut power is set to 0, then
positions will not affect this. See Section 4.8
activate and confirm capacitance is
for system configuration DIP switch details.
between 0.6 and
0.9 nF. With this configuration set, turn on power while
pressing and holding both Bipolar Mode Select
4) Do not activate for this bipolar test. Move
Keys. Release these Keys when CAL appears in
test leads to Bipolar Output Accessory
the Monopolar Cut Power Digital Display and
Receptacles. Confirm capacitance is between
the software revision appears in the Monopolar
2.2 and 2.5 nF.
Coag Power Digital Display. CAL and the soft-
4.6 System Calibration ware revision may persist in the displays for a few
seconds after the Bipolar Mode Select Keys are
The System 2450 is calibrated during manufacture released. The display will then provide an indica-
using equipment traceable to National Institute tion of the calibration status:
of Standards & Technology (NIST) standards
and should retain its accuracy for a long period of • “ LL” will appear in the Monopolar Cut
time. Recalibrate the generator after repair or if it Power Digital Display if the calibration mem-
performs out of specification. Check the calibra- ory is empty.
tion in normal operating mode and only perform • “nEr” will appear in the Monopolar Cut
calibration if errors are identified. Power Digital Display, where “n” indicates
The System 2450 stores its calibration in nonvola- how many major modes require calibration,
tile semiconductor memory, so the calibration will will be displayed if only particular modes
be retained without any action on the part of the require calibration. All of the minor mode
user or maintenance staff. Calibration should be indicators will be illuminated and the minor
checked in normal operating mode during annual modes needing calibration will flash.
preventative maintenance to ensure there is no • “ U”, “ ”, “bP”, or “P d” will appear in
change. the Monopolar Cut Power Digital Display
Calibration is required when: to indicate the major mode when only
minor
• “Err 1 8”, “Err 1 ”, or “Err 1 ” occurs: modes under that major mode require calibra-
An error is detected with the stored calibra- tion. All of the minor mode indicators will
tion values. be illuminated and the minor modes needing
• “Err 1 ” or “Err 21” occurs: One or more calibration will flash.
modes require calibration. • “ U” will appear in the Monopolar Cut
• “Err 1 5” occurs: An error is detected with Power Digital Display with the Pure Cut
stored ARM calibration values. Mode Indicator illuminated if all modes are
• Either the Control/Display Board assembly cali- brated.
(Conmed P/N 61-6991) or the Power Board For all except the last of these, a single Press and
assembly (Conmed P/N 61-6981) is replaced. release of the Tone Loudness Adjustment Down
• Calibration differences are found during pre- Key is required to proceed past this point on the
ventative maintenance. menu. After pressing this key, “ U” will appear in
Refer to Figure 4.1 for calibration process flow. the Monopolar Cut Power Digital Display with
the Pure Cut Mode Indicator illuminated.
4.6.1 Calibration Preliminaries
4.6.2 Selecting the Mode to Calibrate
System 2450 calibration occurs in Calibration
Operating Mode, which is entered by setting Press the Monopolar Cut Power Adjustment
the system configuration DIP switches on the Keys to select the major mode to calibrate as
Control/Display Board. Set the Calibration sys- displayed in the Monopolar Cut Power Digital
tem configuration DIP switch (Control/Display Display. The selections are “ U” for Cut, “ ”
Board SW2.2) to the ON (UP) position and the for Coag, “Bp” for Bipolar, or “P d” for the
Test system configuration DIP switch (Control/ Dispersive Electrode
Display Board SW2.1) to the OFF (DOWN) A.R.M. connection. If any of the minor modes
position. Other configuration DIP switch settings under these major modes are not calibrated, the
displayed major mode will flash.
Select the monopolar minor mode by pressing the

4
appropriate Mode Select Key.

4-
 Calibration

Set the Calibration System Configuration Dipswitch on the Controller to the ON position

Turn main power switch on while pressing both Bipolar Mode Select Keys.

Release Bipolar Mode Select Keys when the Monopolar Cut Power Digital Display indicates “L”

L rxx

LL 2Er Er u bP Pd

Press Tone Loudness Adjustment Down Key

Press Monopolar Cut Power Adjustment Keys to select u,, bP and P d.

u bP

Press Cut Minor Mode Select Key for Pure or Blend.

Do NOT select Pulsed Press Tone Loudness Adjustment Down Key

Connect 10 ohm load Two-Pin Dispersive Electrode Receptacle

Connect indicated load with meter to output
Press Tone Loudness Adjustment Down Key Activate when target level displayed.
Press Bipolar Power Adjustment Key

Press Up Arrow Key

PAd Target.
Press Monopolar Coag Power Adjustment keys to match power/current to Calibration 150

Connect 150 ohm load Two-Pin Dispersive Electrode Receptacle.

Minimum activation 2 seconds, release.
Press Bipolar Power Adjustment Key.
Press Tone Loudness Adjustment Down Key.

Power off

Set the Calibration System Configuration Dipswitch on the Controller to the OFF position

End

Figure 4.1 Calibration Procedure Flow Chart

4
4.6.3 Calibrating a Monopolar Mode
After a minor mode has been calibrated, the
This section applies to the Pure Cut, associated minor mode indicator will quit flash-
Blend, Standard Coag, and Spray Coag ing. When all of the minor modes within a
modes. major mode have been calibrated, the major
Calibration may be performed by measuring cur- mode indicated in the Monopolar Cut Power
rent or by measuring power. To select between Digital Display will quit flashing.
calibration using measured current and measured 4.6.4 Calibrating Bipolar Modes
power, press the Bipolar Power Adjustment Keys
to set the calibration units to either “A” for current The Bipolar modes are calibrated using a method
or “P” for power. that is very similar to the Monopolar modes.
The resistance to be used for calibration will Calibration may be performed by measuring cur-
appear in the Monopolar Coag Power Digital rent or by measuring power. To select between
Display. Connect a resistor of this value between calibration using measured current and measured
the output connection that is being used for cali- power, press the Bipolar Power Adjustment Keys
bration and both pins on the Two-Pin Dispersive to set the calibration units to either “A” for current
Electrode Receptacle. or “P” for power.
Press and release the Tone Loudness Adjustment The resistance to be used for calibration will
Down Key to begin calibration. After this key is appear in the Monopolar Coag Power Digital
pressed, the target level appears in the Monopolar Display. Connect a resistor of this value between
Coag Power Digital Display. the two active connections in the Bipolar
Accessory Receptacle.
Activate using the appropriate Handswitch or
Footswitch. Power will now flow to the resis- Press and release the Tone Loudness Adjustment
tor. While monitoring either the current or the Down Key to begin calibration. After this key is
power, adjust the power up or down using the pressed, the target level appears in the Monopolar
Monopolar Coag Power Adjustment Keys until Coag Power Digital Display.
the measured value is as close to the target level Activate using the Bipolar Footswitch. Power
as possible. The activation must be maintained will now flow to the resistor. While monitoring
for a minimum of 2 seconds to ensure the calibra- either the current or the power, adjust the power
tion is valid. After the power is properly adjusted, up or down using the Monopolar Coag Power
release the activation. Press and release the Tone Adjustment Keys until the measured value is as
Loudness Adjustment Down Key to complete the close to the target level as possible. The activation
calibration sequence for the selected minor mode. must be maintained for a minimum of 2 seconds
*Blend mode only: Both the default Lo Blend to ensure the calibration is valid. After the power
mode and the optional Hi Blend mode must be is properly adjusted, release the activation. Press
calibrated. After Lo Blend is calibrated, the sys- and release the Tone Loudness Adjustment Down
tem will return to the step where the target Key to complete the calibration sequence for the
power is displayed for Hi Blend calibration. bipolar mode.
Note that the target value for Hi Blend is After a Bipolar minor mode has been calibrated,
different from the associated Bipolar minor mode indicator will
the target value for Lo Blend. To complete the quit flashing. When all of the Bipolar minor
Hi Blend calibration, activate again using the modes have been calibrated, the major mode
appropriate Handswitch or Footswitch. Power indicated in the Monopolar Cut Power Digital
will now flow to the resistor. While monitoring Display will quit flashing.
either the current or the power, adjust the power
4.6.5 Calibrating A.R.M.
up or down using the Monopolar Coag Power
Adjustment Keys until the measured value is as A.R.M. is calibrated against a pair of known resis-
close to the target level as possible. The activa- tances.
tion must be maintained for a minimum of 2 sec- Press and release the Tone Loudness Adjustment
onds to ensure the calibration is valid. After the Down Key to begin calibration. The resistance
power is properly adjusted, release the activation. to be used for calibration will appear in the
Press and release the Tone Loudness Adjustment Monopolar Coag Power Digital Display. Connect
Down Key to complete the Hi Blend calibration
sequence.

4-
 a resistor of this value ±1% between the two
a few seconds after the Bipolar Mode Select
active connections in the Two-Pin Dispersive
Keys are released. This action will place the
Electrode Receptacle.
system in the Last Fault Code Mode (LFC).
Calibrate the particular value connected by press- Electrosurgical outputs cannot be activated
ing one of the Bipolar Power Adjustment Keys. while the system is in LFC.
When the value is accepted, a two-tone sequence
2) If any errors are stored in memory, the Cut
will sound and the resistance in the Monopolar
Window will next display “Err”; the Coag
Coag Power Digital Display will quit flashing.
window will display the error code (a numeric
Now scroll to the other of the pair of known value); and the Bipolar Window will display
resistances using the Monopolar Coag Power the storage location of that error code.
Adjustment Keys. The resistance to be used for
Last Fault display example:
calibration will appear in the Monopolar Coag
Power Digital Display. Connect a resistor of this
value ±1% between the two active connections
Err 81 1
in the Two-Pin Dispersive Electrode Receptacle. 3) Scroll through the stored error codes using
the Bipolar Power Adjustment Keys. The
Calibrate the particular value connected by again
error codes are stored Last in, First out. A
pressing one of the Bipolar Power Adjustment
“1” in the Bipolar Display shows the last
Keys. When the value is accepted, a two-tone
error that occurred. Press the Bipolar Up
sequence will sound and the resistance in the
key and
Monopolar Coag Power Digital Display will
a “2” will be displayed if more than one
quit flashing.
error occurred.
Press and release the Tone Loudness Adjustment
4) To retrieve the settings when the error
Down Key to complete A.R.M. calibration.
occurred, it is necessary to have a
After A.R.M. has been calibrated, the major Handcontrol accessory connected. Press both
mode “P d” indicated in the Monopolar Cut Cut and Coag activation switches and the
Power Digital Display will quit flashing. Display Panel will show the system settings
4.6.6 Completing Calibration when the error occurred.

Turn power off and set the Calibration system 4.7.2 Clearing Last Fault Codes
configuration DIP switch (Control/Display As errors occur, fault codes from earlier errors are
Board SW2.2) to the OFF (DOWN) position. erased in a last-in-first-out fashion. While it is not
See Section 4.8 Displaying Optional System absolutely necessary to clear the older codes, clear-
Configuration for system configuration DIP ing the codes may be desirable in some situations.
switch details. The ESU will be ready for
• Pressing the Monopolar Cut Power
normal operation the next time the power is
Adjustment down Key followed by the
turned on.
Tone Loudness Adjustment Down Key
4.7 Last Fault Code Retrieval & Clear will clear the entire fault code memory. The
cut window will display “ Lr” when codes
Up to 50 error (Err) and accessory ( ) codes are cleared.
can be stored in memory for retrieval. When
retrieving the error codes, it is also possible • Pressing the Tone Loudness Adjustment Down
to retrieve the system settings when the error Key again will display the optional system
occurred. configuration settings.

4.7.1 Last Fault Code Retrieval 4.8 Displaying Optional System

Configuration
1) Turn on power while pressing and holding
both Bipolar Mode Select Keys. Release these The optional system configuration DIP switch
Keys when L appears in the Monopolar settings can be checked without removing the top
Cut Power Digital Display and the software cover.
revision appears in the Monopolar Coag • Access Last Fault Code retrieval as described in
Power Digital Display. L and the soft- the preceding section.
ware revision may persist in the displays for

4
 • Press the Tone Loudness Adjustment Down
switch is only read during Power on Self Test
Key again and the configuration DIP switch
(POST) or when the system is powered on, so
settings will be displayed. “0” is for OFF
any changes to the switch positions should be
and a “1” is for ON.
made with the main power off. Each switch is
The eight-position configuration DIP switch OFF in the down position and ON in the up
(S2), located on the Control/Display Board position. Relevant information for each switch is
Assembly allows a qualified service technician to described in Table 4.9 and the positions are illus-
change some of the factory default settings. The trated in Figure 4.2.
default

Table 4.9 DIP Switch Settings

Config. Title / Display Default Description for Description for On
Switch Element Off
Position
1 TEST / Cut 100’s Off Run Mode. Activates Test Mode, which inhibits most
Required position of the system level monitoring for trouble-
for surgery. shooting purposes. When this switch is
ON, both Bipolar Mode Select Keys on
the Display Panel must be pressed until
888 appears in the Monopolar Cut Power
Digital Display and the software revision
appears in the Monopolar Coag Power
Digital Display. 888 and the software revi-
sion may persist in the displays for a few
seconds after the Bipolar Mode Select Keys
are released. If both Bipolar Mode Select
Keys are not pressed, and Err 1 is dis-
played and the power must be cycled.
2 CAL/ Cut 10’s Off Run Mode. Required for calibration of output power
Required position and A.R.M. When this switch is ON,
for surgery. both Bipolar Mode Select Keys on the
Display Panel must be pressed until L
appears in the Monopolar Cut Power
Digital Display and the software revision
appears in the Monopolar Coag Power
Digital Display. L and the software revi-
sion may persist in the displays for a few
seconds after the Bipolar Mode Select Keys
are released. If both Bipolar Mode Select
Keys are not pressed, and Err 1 is dis-
played and the power must be cycled.
3 SCOAG / Cut 1’s On Allows activation Allows simultaneous activation of two
of only one acces- accessories for Coagulation modes.
sory at a time
in Coagulation
modes.
4 DCUT / Coag Off Allows activation Allows simultaneous activation of two
100’s of only one acces- accessories for Cut modes.
sory at a time in
Cut modes.

4-
 Config. Title / Display Default Description for Description for On
Switch Element Off
Position
5 LAST / Coag 10’s On Defaults to Pure Defaults all modes and power levels to the
Cut, Standard last activated settings from the last time the
Coag, and Micro system was powered down.
Bipolar and sets
all power levels to
zero (0W) each
time the system is
initialized.
6 Not used / Coag Off Not used. Not used.
1’s
7 Blend Mode Off Lo Blend is select- Hi Blend is selected when the Blend
Selection / Bipolar ed when the Blend Mode Select Key is pressed.
10’s Mode Select Key
is pressed.
8 DACview / Bipolar NA DACview - See DACview - See below.
1’s below.

Figure 4.2 DIP Switch Positions

4
4.9 DACview 4) Move the DACview switch
DACview is a troubleshooting aid that allows (Control/Display Board S2 position 8 – the
access to internal readings. The feature allows change is recog- nized, not whether the
output voltage, current and power that the system switch is on or off).
reads to be output to a DVM or oscilloscope. 5) The Monopolar Cut Power Digital Display
To use DACview, the system must be in the is used to display the selected DACview
Test Mode. chan- nel. Since power was just initialized,
1) Set the system for operation in Test Mode as the Monopolar Cut Power Digital Display
described in the preceding section. will display “0” at this point. Select the
2) Connect a DVM to the Control/Display desired channel using the Monopolar Cut
Board test point labeled TP60 – DACV Power Adjustment Keys.
and any GND test point (e.g. TP61). 6) Move the DACview switch (again, the
3) Turn on power while pressing and holding change is recognized, not whether the switch
both Bipolar Mode Select Keys. Release these is on or off). The cut power setting will be
Keys when 888 appears in the Monopolar displayed.
Cut Power Digital Display and the software 7) To select a different location to monitor with
revision appears in the Monopolar Coag a DVM, simply move the DACview switch
Power Digital Display. 888 and the software and the memory locations will be displayed
revision may persist in the displays for a few instead of the cut power. Select the desired
seconds after the Bipolar Mode Select Keys selection and then move the DACview
are released. switch again.

Table 4.10 DACview Channels

Channel Source Function Scaling
0 No channel selected
1 Monitor RF RMS Power (300mS running average) 0.01 V / 1 W

4.10 Troubleshooting Error codes are stored as Last Fault Codes (See
Listed in Table 4.11 are potential errors that Last Fault Codes).
may occur and problem solving ideas for each. CAUTION: Activation of unit with the collector
All error codes (Err xxx) can only be cleared fuses (F2,6, & 7 on power board) removed and
by cycling power. the base fuses (F1,4, & 5) in place can result in
When an error code is displayed, reset the sys- damage to U3 on power board. Activation with
tem to determine if the error can be cleared with base fuses removed and collector fuses in place is
a System Reset or if further service is required. acceptable.

Table 4.11 Troubleshooting

Problem Possible Cause
Display Panel Blank when System Verify the power cord is fully seated in the power receptacle on the back of the
is Powered on System.
With the power cord disconnected, verify fuses are good and are installed properly
in the receptacles on the back panel of the generator.
Remove the top cover and verify that the Control/Display Board and all harnesses
are properly seated.
Check that power appears on the Control/Display Board by measuring +12 V
at TP66 and +5V at TP54. Check other power supply test points as necessary
to characterize the problem.
Check that J17 and J8 on power board are connected. Check fuses F3 and F11
on power board.

4-
Problem Possible Cause
Display Panel Blank when System Confirm Jumpers JP1-5 are configured correctly for line voltage. Refer to
is Powered on (continued) power board schematic for details.
Unplug J8 and J17, and check continuity of transformer windings. Refer
to power board schematic for details.
Display: xxx Accessory error – Faulty accessory is connected, a hand controlled accessory
is erroneously actuated, or a footswitch is erroneously actuated. Ensure that
footswitches are not stacked on top one another. r and L indi-
cate problems with the accessories connected to the Hand Controlled and
Combination Monopolar Accessory Receptacles, respectively. S indicates
a problem with the footswitch connected to either of the Monopolar or
Bipolar
Footswitch Connectors.
Display: p xx Control Panel error – Check for a faulty push button on the front control panel,
a control panel push button that has been pushed while the unit is being turned on,
or a faulty cable connection between the front panel and the display board.
Display: L C xxx Last Fault Codes – the Tone Loudness Adjustment Down Key was pressed while
power was initialized. The generator must be reset to clear this condition. See
section 4.7.
Display: L The system is in the Calibration Mode. Calibration Mode is selected when the
configuration DIP switch in the second position on the Control/Display Board
is in the ON (Up) position and the Tone Loudness Adjustment Down Key is
pressed and held while power is turned on. See section 4.8.
Display: Err xxx Refer to Table 4.12 for list of Err codes and possible causes. If an Err code
appears, try cycling power. If it reappears, the unit should be taken out of service
until a qualified biomedical engineer can diagnose the problem.
Single and Dual Dispersive A Dispersive Electrode is not connected to the system.
Electrode Status / Alarm Indicators A Dual Dispersive Electrode is connected but is not properly applied to patient.
flash alternating red.
A Dispersive Electrode is connected but is not properly seated. Ensure the con-
nector is fully seated in the Two-Pin Dispersive Electrode Receptacle.
Flashing Decimal Points on the The system is in the Test Mode. Test Mode is selected when the configuration
Display DIP switch in the first position on the Control/Display Board is in the ON (Up)
position and the Tone Loudness Adjustment Down Key is pressed and held while
power is turned on. Note: When the Test Mode is active, most of the internal
safety monitoring is inhibited. See section 4.8.
No output power One or more connections inside the system are bad. Check:
• J5, Control/Display Board
• J12, Power board
• Faulty accessory – blade not seated fully
• Output board jacks not making contact
Low voltage power supplied to the Control/Display Board is bad. Check +12V
and +5V on the Control/Display Board.
Shorted RF Amplifier power MOSFET Q5.
(Note: A better indication of the problem will be provided by cycling
power, which will allow the generator to find a fault during POST.)
• Remove F1, F2, F4, F5, F6, and F7 on the Power board
• Using an ohmmeter measure between drain and ground on Q2, Q3, and Q4
for low resistance.
• Using an ohmmeter measure between gate and ground on Q2, Q3, and Q4
for low resistance.
• If either exhibit low resistance, either replace the faulty MOSFET or replace
the Power board.

4-
 Problem Possible Cause
No output power (continued) HVPS output too low.
• Configure system for test mode operation.
• Set the system for Pure cut at 1 watt.
• Activate and confirm RFSUP at TP8 is approximately 95Vdc.
Improper gate drive.
• Configure system for test mode operation.
• Verify that RFGATE (TP11) and BGATE (TP5) are correct.
Improper VBASE_PWM.
• Check VB_PWM for 312 Khz signal
• Check VBASE_PWM (TP9) for dc voltage corresponding to duty cycle of
VB_PWM. VBASE_PWM is approximately linear with the percentage duty cycle
between 0.6 volts and 10 volts.
Incorrect monopolar output Bad calibration – Recalibrate
Ensure the load resistor is correct when checking output power.Bad voltage or
current feedback. Check:
• C_MVSNS, monopolar voltage sense
• C_ISNS, monopolar current sense
• These signals should match the Monitor voltage and current sense, M_MVSNS
and M_ISNS, respectively.
Incorrect bipolar output Bad calibration – Recalibrate Ensure the load resistor is correct when checking
output power.
Bad voltage or current feedback. Check:
• C_BVSNS, bipolar voltage sense
• C_ISNS, bipolar current sense
• These signals should match the Monitor voltage and current sense, M_BVSNS
and M_BISNS, respectively.

4.10.1 HVPS Troubleshooting Hints • At low output current, the PFC will cycle on
WARNING: LOSS OF POWER SUPPLY and off. This is normal.
ISOLATION CAN CAUSE • When replacing a MOSFET, check all the gate
ELECTRICAL SHOCK. WHEN drive components.
SERVICING THE HIGH VOLTAGE
POWER SUPPLY, ASSUME INTERNAL 4.11 Parts Ordering Information
ISOLATION IS COMPROMISED To obtain replacement parts or additional infor-
UNTIL VERIFIED OTHERWISE. mation regarding your unit, write or telephone
WARNING: MAKE SURE THE LED FOR according to the contact information as listed on
THE CIRCUIT YOU’RE WORKING ON the inside front cover of this manual, or contact
IS OFF WHEN MAKING CONNECTIONS your CONMED distributor. To ensure prompt
OR TOUCHING CIRCUITRY. service, please provide the following information:
• The PFC LED should always be on when • Model Number
power is on. It will become momentarily and • Serial Number
slightly brighter during POST. • Reference Designator and Description of Part
• If fuse F3 is blown, Q1 is probably shorted. • CONMED Part Number (if known)
Also check surrounding components for failure if
Q1 is found to be bad. • Quantity Desired
• Check the clock frequency and reference volt- • Mailing or Shipping Address
age on the PFC controller integrated circuit. • Preferred Shipping Means (if any)
The PFC clock must have PFC enabled to • Purchase Order Number (if applicable)
function correctly. • Your Name

4-
When returning a unit, obtain a Return
Authorization (R.A.) Number from CONMED
Technical Services. Please mark the R.A. number
on the outside of the carton for prompt service.
Please enclose a brief note with the unit describing
all of the symptoms found.
4.12 Assembly Breakdown/Parts Access
CAUTION: This device contains components
that can be damaged by static electricity. Proper
handling by grounding of personnel during servic-
ing is mandatory.
Following are instructions for unit disassembly
and reassembly instructions.
4.12.1 Top Cover Removal & Replacement
Top Removal:
1) Remove the two screws located on rear
of unit as shown.

4) To completely remove the top, disconnect the

ribbon cable at its Power Board connection
point.
Top Replacement:
1) Reconnect the ribbon cable to its
Power Board connection point.
2) Place top approximately ¾” from front bezel
on top of unit.
3) Press forward, aligning lip of front bezel with
groove in top.
4) Re-install screws.

2) Pull back and up to disengage the top.

3) Open the top by lifting the front edge. A
bracket is provided at the back edge of the
top to support the top in its service position
as shown.

4-
4.12.2 Bezel Removal & Replacement
Bezel Replacement:
Bezel Removal: 1) Connect power switch connectors as shown,
1) Remove Top. if required.
2) Remove two flat-head screws on side of bezel
and two pan-head screws on bottom of
bezel as shown. White Blue Black Brown

2) Connect dispersive electrode connector.

3) Align bezel between chassis flanges and center
slot. Slide bezel into unit as shown in figure.
4) Replace and tighten screws.
4.12.3 Control/Display Board Removal &
Replacement
Control/Display Board Removal:
1) Remove Top.
2) Remove the six screws and remove sheet
metal shield.
3) Disconnect the ribbon cable.
3) Unlatch dispersive electrode connector.
4) Remove the one aluminum and five plastic
4) In most situations, it is not necessary to hex standoffs, noting location of aluminum
remove the four power switch connectors. standoff. Lift board off the threaded stand-
The bezel can be rotated off to the right offs.
side for power board removal. To fully
remove the bezel, these connectors must be
discon- nected.

Power Switch Connectors

This standoff must be aluminum

4-
 5) Disconnect display flex connector, being care-
Power Board Replacement:
ful not to damage it.
1) Reverse board removal operation.
Control/Display Board Replacement:
NOTE: Install the noted two, smaller
1) Connect display flex connector and place
screws first, to assure Power Board
board back onto threaded standoffs.
alignment in chassis.
2) Replace aluminum standoff in its previous
location and tighten all hex standoffs. 4.12.5 Power Transistor Replacement
NOTE: The aluminum standoff provides a CAUTION: This device contains components
ground and must be located as shown below. that can be damaged by static electricity. Proper
3) Connect ribbon cable. handling by grounding of personnel during servic-
ing is mandatory.
4) Replace sheet metal shield and tighten six
screws into hex standoffs. All Power Board components mounted to the
heat sink may be replaced. Use only components
4.12.4 Power Board Removal & Replacement sup- plied by CONMED.
Power Board Removal: Follow these instructions for replacement:
1) Remove Top. 1) No thermal compound is necessary, but the
2) Remove Bezel. mating surfaces of the transistor, insulator
pad and surface of heat sink should be clean.
3) Remove the five screws mounted to the
Always replace the insulator pad associated
heat sink in the rear, bottom and side of
with the transistor. Always fasten or clamp
chassis.
the part to the heat sink surface prior to
4) Remove the five screws mounted to the chas- sol- dering it to the board. This will assure
sis standoffs. Do not remove the screws good thermal contact is maintained.
that secure the angle bracket between the
2) In order to maintain alignment with the heat
Power PWB and the heat sink.
sink surface, the leads of these parts have been
Reinstall these two screws first
bent to the proper shape. They should be
purchased from CONMED with bent leads.
3) When installing these parts, be sure to orient
the Bellville washer as shown, with the convex
surface next to the head of the screw. Tighten
screws to 5-7 inch pounds.

5) Disconnect all cable connectors –

Transformer, speaker, footswitch, AC power,
and 3.5mm jack.
6) Pull board slightly forward to remove it
from the chassis.

4-
4.13 Fault Codes
This section of the manual contains a table of fault codes. Each numeric fault code is listed along with a
description of the fault, possible causes and things to check, and corrective actions.
Table 4.12 Fault Codes
Err Description Possible Cause Things to check Correction
Code
100 Test or CAL When either of these DIP Cycle system power while press- Replace the Control/
mode dip switch switches are ON, both Bipolar ing both Bipolar Mode Select Display Board.
without both Mode Select Keys on the Keys and determine if this error
Bipolar Mode Display Panel must be pressed is repeated.
Select Keys until the Blend mode appears in
pressed when the Monopolar Power Digital
power is turned Displays – i.e. either “BL L”
on. or “BL XI”. The Blend mode
may persist in the displays for
a few seconds after the Bipolar
Mode Select Keys are released.
101 Controller/ The System Controller and the Cycle system power and deter- Replace the Control/
Monitor DIP Monitor do not detect the same mine if this error is repeated. Display Board.
switch mismatch settings for the Configuration
Dipswitches.
102 Corrupted The data transmitted from Cycle system power and deter- Replace the Control/
communica- the System Controller to mine if this error is repeated. Display Board.
tions between the
the System Monitor through the HPI port
Controller and is faulty. This could be caused
Monitor by damage to components asso-
ciated with the HPI bus on the
Controller, permitting electro-
magnetic interference to upset
one of the processors.
103 Corrupted The data transmitted from the Cycle system power and deter- Replace the Control/
communica- System Controller to the RF mine if this error is repeated. Display Board.
tions between Controller through the HPI
the System port is faulty. This could be
Controller and caused by damage to compo-
RF Controller nents associated with the HPI
bus on the Controller, permit-
ting electromagnetic interfer-
ence to upset one of the
proces- sors.
104 Monitor The data transmitted from Cycle system power and deter- Replace the Control/
TOKEN not the System Controller to mine if this error is repeated. Display Board.
incremented, the
monitor pro- Monitor through the HPI port
gram corrupted is faulty. This could be caused
by damage to components asso-
ciated with the HPI bus on the
Controller, permitting electro-
magnetic interference to upset
one of the processors.
105 Controller failed The System Controller memory Cycle system power and deter- Replace the Control/
RAM test errors have been detected dur- mine if this error is repeated. Display Board.
ing POST.

4-
Err Description Possible Cause Things to check Correction
Code
107 Monitor boot- The program transmitted from Cycle system power and deter- Replace the Control/
load program the System Controller to the mine if this error is repeated. Display Board.
does not match Monitor through the HPI
controller ROM port at startup is faulty. This
table could be caused by damage to
components associated with
the HPI bus on the Controller,
permitting electromagnetic
interference to upset one of the
processors.
108 RF TOKEN not The program transmitted from Cycle system power and deter- Replace the Control/
incremented, RF the System Controller to the mine if this error is repeated. Display Board.
controller pro- RF Controller through the HPI
gram corrupted port at startup is faulty or has
been corrupted after initializa-
tion. This could be caused by
damage to components associ-
ated with the HPI bus on the
Controller, permitting electro-
magnetic interference to upset
one of the processors.
109 Communications Communications through Cycle system power and deter- Replace the Control/
lost during the HPI port are faulty. mine if this error is repeated. Display Board.
POST tests This
could be caused by damage to
components associated with
the HPI bus on the Controller,
permitting electromagnetic
interference to upset one of the
processors.
112 Pre-activation The activation signals detected Cycle system power and deter- Replace the Control/
handshake, by the System Controller and mine if this error is repeated. Display Board.
monitor does the Monitor do not match.
not read an acti-
vation signal
113 Pre-activation Prior to enabling electrosurgical Increase the tone volume by Replace the Control/
handshake, output power, the Monitor adjusting the Volume Control Display Board.
monitor does ensures that an activation tone on the back panel of the Replace the Power
not read a is present. This error occurs if generator. Cycle system power Board.
tone signal the activation tone is not pres- and deter- mine if this error is
ent when the Monitor checks repeated.
prior to enabling electrosurgical Configure system for test mode
output power. operation. Check the tone drive
signal from the Control/Display
Board while the unit is activated.
Lack of a signal indicates a prob-
lem with the Control/Display
Board. Check for a proper
TONE_ MON signal to the con-
troller. Lack of a signal indicates
a problem with the Power Board.

4-
Err Description Possible Cause Things to check Correction
Code
114 Display or Communication between the Cycle system power and deter- Replace the cable
keyboard SPI Control/Display Board and the mine if this error is repeated. between the Display
communication Display assembly over the SPI Check SPI_SCK, SPI_MOSI, and the Controller.
failure bus is faulty. and SPI_MISO to see signals Replace the Control/
toggle. Display Board.
Replace the Display
assembly.
122 System The self-check CRC for the Cycle system power and deter- Replace the Control/
Controller flash System Controller is not inter- mine if this error is repeated. Display Board.
program CRC nally consistent, indicating an
does not match error in the stored software.
the calculated
CRC
135 A.R.M. calibra- The CRC for the calibration Recalibrate the A.R.M. system. Check J1 connector
tion (10/150 coefficient memory is not self See section 4.6. on the Power
Ohm) EPROM consistent, indicating an error Board. Repair ARM
CRC failed in the stored calibration coef- circuit- ry on Power
ficients. Board or replace
Power Board if
necessary. Replace
the Control/ Display
Board if
the system will not
calibrate.
136 A.R.M. circuit The A.R.M. circuit on the Verify proper voltage on Repair or replace
dropped below Output assembly or the A.R.M. the VARM signal entering the Power Board if
.4V (circuit sensing circuit on the Control/ the Control/Display Board. VARM entering the
failed) Display Board has failed. Controller is faulty.
Replace the Control/
Display Board if
VARM appears cor-
rect.
138 Monitor calibra- The CRC for the calibration Recalibrate the entire system. Replace the Control/
tion EEPROM coefficient memory is not self Display Board if
CRC failed consistent, indicating an error the system will not
in the stored calibration coef- calibrate.
ficients.
139 During calibra- The calibration was not com- Recalibrate any uncalibrated Replace the Control/
tion, not all pleted in the correct manner. modes. See Section 4.6. Display Board if
points were the system will not
entered for the calibrate.
mode
140 A calibration The CRC for the calibration Recalibrate any un-calibrated Replace the Control/
EEPROM CRC coefficient memory is not self modes. See Section 4.6. Display Board if
failed (POST consistent, indicating an error the system will not
ERROR) in the stored calibration coef- calibrate.
ficients.
141 Test and cal dip The Calibration and Test Change the Calibration and Test Replace the Control/
switches are both Configuration Dipswitches are Configuration Dipswitches to the Display Board.
turned on both in the ON position. At desired state, cycle system power,
least one of these must be in and determine if this error is
the OFF position. repeated.

4-
Err Description Possible Cause Things to check Correction
Code
143 The unit or a The system or a mode was Calibrate any modes that need Replace the Control/
mode was never never calibrated. The Controller calibration. Display Board if
calibrated was replaced but not calibrated. the system will not
calibrate.
144 RF controller The Monitor and RF Use DACView to troubleshoot Replace the Control/
and Monitor Controller and constantly the Monitor. Verify that the Display Board.
power levels do checking to ensure they see the output power is consistent with Troubleshoot the
not match same electrosurgical output displayed power setting. Check RF voltage (Vsense)
power during activation. This voltage and current sensing chan- and current (Isense)
error occurs if the power they nels for both the RF Controller feedback circuits for
sense does not match. This and the Monitor. the activated mode.
typically results from
differences between the
independent Monitor and RF
Controller sensing circuits.
145 Inter-processor The data transmitted from the Cycle system power and deter- Replace the Control/
communications System Controller through mine if this error is repeated. Display Board.
error the HPI port is faulty. This
could be caused by damage to
components associated with
the HPI bus on the Controller,
permitting electromagnetic
interference to upset one of the
processors.
150 2.5 volt too low 2.5-volt power on the Check for proper connection If +12V is out of
Control/ Display Board is too of the ribbon cable.Check the limits, replace or
low. +12V entering Control/Display repair the Power
Board (TP66). Check the +2.5V Board. If either
power on the Control/Display +2.5V or the ADC
Board (TP36). Verify that the reference is out of
System Controller ADC refer- limits, replace the
ence voltage (C_2.5V) on the Control/Display
Control/Display Board is 2.5 Board.
volts.
151 2.5 volt too high 2.5-volt power in the system is Check for proper connection If +12V is out of
too high. of the ribbon cable. limits, replace or
Check the +12V entering repair the Power
Control/Display Board (TP66). Board. If either
Check the +2.5V power on the +2.5V or the ADC
Control/Display Board (TP36). reference is out of
Verify that the System Controller limits, replace the
ADC reference voltage (C_2.5V) Control/Display
on the Control/Display Board is Board.
2.5 volts.
152 1.2 volt too low 1.2-volt power on the Check for proper connection If +12V is out of
Control/ Display Board is too of the ribbon cable. limits, replace or
low. Check the +12V entering repair the Power
Control/Display Board (TP66). Board. If either
Check the +1.2V power on the +1.8V or the ADC
Control/Display Board (TP15). reference is out of
Verify that the System Controller limits, replace the
ADC reference voltage (C_2.5V) Control/Display
on the Control/Display Board is Board.
2.5 volts.

4-
Err Description Possible Cause Things to check Correction
Code
153 1.2 volt too high 1.2-volt power in the system Check for proper connection If +12V is out of
is too high. of the ribbon cable. limits, replace or
Check the +12V entering repair the Power
Control/Display Board (TP66). Board. If either
Check the +1.2V power on the +1.8V or the ADC
Control/Display Board (TP15). reference is out of
Verify that the System Controller limits, replace the
ADC reference voltage (C_2.5V) Control/Display
on the Control/Display Board is Board.
2.5 volts.
154 1.8 volt too low 1.8-volt power on the Check for proper connection If +12V is out of
Control/ Display Board is too of the ribbon cable. limits, replace or
low. Check the +12V entering repair the Power
Control/Display Board (TP66). Board. If either
Check the +1.8V power on the +1.8V or the ADC
Control/Display Board (TP39). reference is out of
Verify that the System Controller limits, replace the
ADC reference voltage (C_2.5V) Control/Display
on the Control/Display Board is Board.
2.5 volts.
155 1.8 volt too high 1.8-volt power in the system Check for proper connection If +12V is out of
is too high. of the ribbon cable. limits, replace or
Check the +12V entering repair the Power
Control/Display Board (TP66). Board. If either
Check the +1.8V power on the +1.8V or the ADC
Control/Display Board (TP39). reference is out of
Verify that the System Controller limits, replace the
ADC reference voltage (C_2.5V) Control/Display
on the Control/Display Board is Board.
2.5 volts.
160 POST has deter- RF Controller voltage sense Cycle system power and deter- Replace the Control/
mined that the is open or shorted. This mine if this error is repeated. Display Board.
RF Controller can Verify that all internal connectors Replace the Power
voltage sense is result from a disconnected wire are properly seated. Check for Board.
faulty. terminal or bad A/D converter. loose wires on Power board T3.
170 Controller The Monitor has detected that Cycle system power and deter- Replace the Control/
waveform the System Controller cannot mine if this error is repeated. Display Board.
inhibit failed disable the RF Drive signal dur-
(will not dis- ing POST.
able RF) (POST
ERROR)
311 POST Monitor Errors found in Monitor Cycle system power and deter- Replace the Control/
memory failure. microprocessor memory during mine if this error is repeated. Display Board.
power initialization.
314 POST Monitor Monitor or RF Controller clock Check for 10 MHz clock fre- Replace the Control/
or RF Controller oscillator failure detected during quency input to Monitor proces- Display Board.
clock failure POST. sor and or RF Controller.
315 POST Monitor The states of the activation Check for active high activation Replace the Control/
activation cir- request signals detected by request on lines running to the Display Board.
cuitry failure the Monitor do not match Monitor.
the states detected by the
System Controller.

4-
Err Description Possible Cause Things to check Correction
Code
320 Monitor failed Errors found in software Cycle system power and deter- Replace the Control/
program CRC downloaded from the System mine if this error is repeated. Display Board.
test Controller to the Monitor
dur- ing initialization.
321 Monitor failed Monitor calibration data is cor- Recalibrate all system modes. Replace the Control/
calibration data rupted. Display Board.
CRC test
322 Monitor or RF Activation continues after acti- Cycle system power and deter- Replace the Control/
controller did vation command ceases. mine if this error is repeated. Display Board.
not return to
IDLE state
330 POST RF AC Monitor senses electrosurgical Configure the system for Replace the Control/
voltage cut feed- voltage output too low during Calibration mode operation and Display Board or
back too low POST, indicating insufficient initialize power. Configure the the Power Board
voltage from HVPS, insufficient system for test mode operation depending on the
drive from the RF Controller, and cycle power. Measure specific cause of the
failed RF Amplifier, or a failed HVPS output, RF Amplifier failure.
voltage sensing channel. The drive, RF Amplifier output, and
limits for this comparison are voltage sensing channel.
set when the system enters cali-
bration mode.
331 POST RF AC Monitor senses electrosurgical See 330 above. Confirm proper
voltage cut feed- voltage output too low during connection of J3 on
back too high POST test, indicating insuf- the Power Board.See
ficient voltage from HVPS, above.
insufficient drive from the RF
Controller, failed RF Amplifier,
or a failed voltage sensing chan-
nel. The limits for this com-
parison are set when the system
enters calibration mode.
340 Monitor Timer0 One of the timers internal Cycle system power and deter- Replace the Control/
interrupt failed to the Monitor is failed. mine if this error is repeated. Display Board.
341 Monitor Timer0 Failure of one of the timers Cycle system power and deter- Replace the Control/
interrupt failed internal to the Monitor detected mine if this error is repeated. Display Board.
POST during POST.
342 Monitor Timer1 Failure of one of the timers Cycle system power and deter- Replace the Control/
interrupt failed internal to the Monitor detected mine if this error is repeated. Display Board.
POST during POST.
343 Monitor has lost Reset machine and if error Cycle system power and deter- Replace the Control/
communica- repeats, then replace Control/ mine if this error is repeated. Display Board.
tions - controller Display Board.
TOKENS not
incremented

4-
Err Description Possible Cause Things to check Correction
Code
350 Monitor output Current detected through the Configure the system for test Repair or Replace
channel current output channel current sensor mode operation and cycle power. the Power board.
sensor failure that is used to detect a stuck Use DACview to compare the Replace the Control/
output relay does not match output channel current with the Display Board.
the current sensed by the output current while activating at
power monitoring sensor. This constant power into a fixed load.
typically indicates that there is a
problem with the output chan-
nel current sensing circuit.
351 Monitor sensed Over power at the Configure the system for test Repair or Replace
over power electrosurgical output has per- mode operation and cycle power. the Power board.
condition for sisted for more than 300 ms. Measure the actual power into Replace the Control/
300mS running a fixed load. If power is cor- Display Board.
average rect, verify proper operation of
the Monitor voltage and cur-
rent sensing circuits. If power is
correct, verify proper operation
of the RF Controller voltage
and current sensing circuits, the
HVPS, and the RF Amplifier.
357 Monitor sensed The Monitor has sensed Recalibrate the system. Configure Repair or Replace
power @ 0W electrosurgical output power the system for test mode opera- the Power board.
dial power set- during activation while the tion and cycle power. Measure Replace the Control/
ting power is set to zero. the actual power into a fixed Display Board.
load. If power is correct, verify
proper operation of the Monitor
voltage and current sensing
circuits. If power is correct,
verify proper operation of the
RF Controller voltage and
current sensing circuits, the
HVPS, and
the RF Amplifier.
358 Monitor sensed The Monitor has detected a Cycle system power and deter- Replace the Control/
gate drive in drive signal while the system is mine if this error is repeated. Display Board.
idle @ 0W dial not activated.
power setting
360 Monitor pro- Monitor processor anomaly. Cycle system power and deter- Replace the Control/
gram counter mine if this error is repeated. Display Board.
landed on an
unused interrupt
vector
371 Monitor will POST has determined that the Cycle system power and deter- Replace the Control/
not disable RF Monitor cannot disable the RF mine if this error is repeated. Display Board.
waveform on the waveform.
Control/Display
Board during
POST
375 Monitor activa- POST has determined that acti- Cycle system power and deter- Replace the Control/
tion I/O failed vation commands sensed by the mine if this error is repeated. Display Board.
POST System Controller do not match
the activation commands sensed
by the Monitor.

4-
Err Description Possible Cause Things to check Correction
Code
379 RF calibration System calibration required on Recalibrate the system. Configure Replace the Control/
failed POST one or more modes. the system for test mode opera- Display Board if
tion and cycle power. Measure the system will not
the actual power into a fixed calibrate.
load. If power is correct, verify
proper operation of the Monitor
voltage and current sensing
circuits. If power is correct,
verify proper operation of the
RF Controller voltage and
current sensing circuits, the
HVPS, and
the RF Amplifier.
381 No tone feed- The Monitor did not detect Listen for tones during POST. Replace the Control/
back during tones during POST. This Verify that all internal cables are Display Board.
POST typically occurs because of a properly connected. Increase Repair or replace the
problem in the tone generation the tone volume by adjusting Back Panel assembly.
circuitry. the Volume Control on the
con- trol panel. Cycle system
power and determine if this
error is repeated. Configure
system for test mode
operation. Check
the tone drive signal from the
Control/Display Board while the
unit is activated. Lack of a signal
indicates a problem with the
Control/Display Board. Check
for a proper TONE_ MON sig-
nal to the controller. Lack of a
signal indicates a problem with
the Power Board assembly.
382 Activation with- The Monitor did not detect a Listen for a tone during acti- Replace the Control/
out a tone tone during activation. This vation. Verify that all internal Display Board.
typically occurs because of a cables are properly connected. Repair or replace
problem in the tone generation Increase the tone volume by the Power
circuitry. adjusting the Volume Control Board.
on the control panel. Cycle
system power and determine if
this error is repeated. Configure
system
for test mode operation. Check
the tone drive signal from the
Control/Display Board while the
unit is activated. Lack of a signal
indicates a problem with the
Control/Display Board. Check
for a proper TONE_ MON sig-
nal to the controller. Lack of a
signal indicates a problem with
the Power Board.
383 RF Current The Monitor has sensed cur- Arrange the system with fixed Replace or repair the
sensed at an rent flowing at an output that loads connected to all outputs. Output assembly.
unselected out- has not been selected. This may Activate each output in turn Replace the Control/
put. indicate a faulty or stuck output while monitoring all outputs for Display Board.
relay. current.

4-
Err Description Probable Cause Things to check Correction
Code
388 POST monitor Reset machine and if error Cycle system power and deter- Replace the Control/
timed out- did repeats, then replace Control/ mine if this error is repeated. Display Board.
not respond to a Display Board
POST command
389 Dial setting over The front panel power setting Cycle system power and deter- Replace the Control/
maximum limit exceeds the limit for the selected mine if this error is repeated. Display Board.
mode.
391 Monitor detect- The Monitor has detected an Cycle system power and deter- Replace the Control/
ed the wrong RF improper RF Amplifier drive mine if this error is repeated. Display Board.
waveform waveform or frequency for the
selected mode.
395 Maximum peak Disconnected wire terminal or Check for loose wires on the Replace the Control/
voltage was bad A/D converter. Power board T3.Cycle system Display Board.
exceeded for a power. Test each mode open Replace the Power
given mode. circuit at maximum power and Board.
determine if this error is repeat-
ed.
396 The monopolar- TBD
bipolar selection
relay is stuck in
the bipolar posi-
tion.

4-