Bone ScalpelTM System (SOP-AIC-5000808 Rev2) (BCA-UM Rev D)

BoneScalpel™ System
Instructions For Use

Instructions For Use BoneScalpel™
SOP-AIC-5000808 Rev2 Page 1 of 47

BCA-UM RevD
Table of Contents
1. General Safety Statements............................................................................................................3
1.1. EMC Statement ....................................................................................................................... 3
1.2. Electrical Safety Statement ....................................................................................................... 6
1.3. Environmental Statement ......................................................................................................... 6
1.4. Summary Of Safety Notices ...................................................................................................... 7
1.5. Trademark Information .......................................................................................................... 10
1.6. Explanation Of Symbols.......................................................................................................... 11
2. Indications And Contra Indications ............................................................................................12
2.1. Indications............................................................................................................................ 12
2.2. Contra Indications ................................................................................................................. 12
3. Adverse Effects............................................................................................................................13
4. Considerations During Clinical Use .............................................................................................14
4.1. HARD Tissue Use................................................................................................................... 15
4.2. SOFT Tissue Use ........................................................................Error! Bookmark not defined.
5. System Overview.........................................................................................................................17
5.1. Principle Of Operation ............................................................................................................ 17
5.2. Reusable System Components ................................................................................................ 18
5.3. Single-use, Sterile Components ............................................................................................... 19
6. Console ........................................................................................................................................21
6.1. Receptacles, Controls And Indicators ....................................................................................... 21
6.2. Menu Functions ..................................................................................................................... 22
6.3. Main Functions ...................................................................................................................... 24
6.4. Alerts And Alarms .................................................................................................................. 26
7. System Set-up .............................................................................................................................28
7.1. Installation ........................................................................................................................... 28
7.2. Console Set-up – Part I (Non-sterile) ....................................................................................... 29
7.3. Handpiece Assembly (Sterile).................................................................................................. 29
7.4. Console Set-up – Part II (Non-sterile) ...................................................................................... 30
7.5. Perform System Check ........................................................................................................... 32
8. Handpiece Assembly And Disassembly By Application ...............................................................33
8.1. Handpiece Assembly - HARD Tissue Use .................................................................................. 33
8.2. Handpiece Disassembly - HARD Tissue Use .............................................................................. 35
8.3. Handpiece Assembly - SOFT Tissue Use ........................................Error! Bookmark not defined.
8.4. Handpiece Disassembly - SOFT Tissue Use ....................................Error! Bookmark not defined.
9. Cleaning And Sterilization ...........................................................................................................37
9.1. Disassembly.......................................................................................................................... 37
9.2. Cleaning............................................................................................................................... 37
9.3. Sterilizing By Steam Autoclave ................................................................................................ 39
9.4. Expected Life, Reusable Components....................................................................................... 39
9.5. Deviations From Decontamination, Cleaning And Sterilization Instructions.................................... 40
10. Troubleshooting ..........................................................................................................................41
11. Specifications ..............................................................................................................................44
12. Service, Repair And Technical Correspondence ..........................................................................45
12.1. Fuse Replacement ................................................................................................................. 45
12.2. Pump Head Replacement ....................................................................................................... 46
12.3. Repair, Service and Replacement Parts .................................................................................... 46
12.4. Important Notice ................................................................................................................... 47

BCA-UM RevD
1. General Safety Statements
WARNING 1.1 The BoneScalpel system is an electro-mechanical device, which under certain circumstances could present an electrical
shock hazard to the operator and/or patient. Please read manual thoroughly and follow directions stated herein to
assure maximum safety during operation. This manual shall be kept in close proximity to the system for easy referral
when needed.
WARNING 1.2 The BoneScalpel system is intended to be used in various types of invasive, surgical procedures. There may be indirect
danger to the patient should the device fail during the procedure. It is recommended that the facility follows its back-up
equipment protocols.
CAUTION 1.1 Federal law restricts this device to sale by or on the order of a licensed healthcare practitioner
1.1. EMC Statement

The BoneScalpel system is designed and tested to comply with FCC regulations for conducted and radiated
emissions under Part 18 Subchapter J. and to comply with IEC EN60601-1-2: 2007 guidelines for EMC.
CAUTION 1.2 This device is considered medical electrical equipment. Medical electrical equipment needs special precautions regarding
electromagnetic compatibility (EMC) and needs to be installed and put into service according to the EMC information
provided in this operator’s manual.
CAUTION 1.3 Portable and mobile RF communication equipment can affect medical electrical equipment. If RF equipment is in use
monitor the Bonescalpel for proper function during procedure.
CAUTION 1.4 The use of accessories, transducers and cables other than those specified may result in increased emissions or
decreased immunity of the device. Use only Aesculap branded equipment and accessories.
CAUTION 1.5 The console should not be used adjacent to or stacked with other electrical equipment. If adjacent or stacked use is
necessary, the console should be observed to verify normal operation in the configuration in which it will be used.
Electromagnetic Compatibility Guidance (in accordance with EN/IEC 60601-1-2:2007)

Guidance And Manufacturer’s Declaration – Electromagnetic Emissions (Table 201)
The BONESCALPEL SYSTEM is intended for use in the electromagnetic environment specified below. The customer or
the user of BONESCALPEL SYSTEM should ensure that it is used in such an environment.
Emissions test Compliance Electromagnetic environment – guidance
RF emissions The BONESCALPEL SYSTEM uses RF energy only for its internal
Group 1 function. Therefore, its RF emissions are very low and are not likely
CISPR 11 to cause any interference in nearby electronic equipment.
RF emissions
Class A
CISPR 11
The BONESCALPEL SYSTEM is suitable for use in all establishments
Harmonic emissions
Class A other than domestic and those directly connected to the public low-
IEC 61000-3-2 voltage power supply network that supplies buildings used for
domestic purposes.
Voltage fluctuations/
flicker emissions Complies
IEC 61000-3-3
Table 1.1 Guidance & manufacturer’s declaration on electromagnetic emissions (EN table 201)

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Guidance And Manufacturer’s Declaration – Electromagnetic Immunity (Table 202)

the user of the BONESCALPEL SYSTEM should assure that it is used in such an environment.
IEC 60601 Electromagnetic environment –
Immunity test Compliance level
test level guidance
Electrostatic o ±6 kV contact o ±6 kV contact Floors should be wood, concrete or
discharge (ESD) o ±8 kV air o 8 kV air ceramic tile. If floors are covered with
IEC 61000-4-2 synthetic material, the relative humidity
should be at least 30%.
Electrical fast o ±2 kV for power o ±2 kV for power Mains power quality should be that of a
transient/burst supply lines supply lines typical commercial or hospital
o ±1 kV for environment.
IEC 61000-4-4 o ±1 kV for
input/output lines input/output lines
Surge o ±1 kV differential o ±1 kV differential Mains power quality should be that of a

mode mode typical commercial or hospital
IEC 61000-4-5 environment.
o ±2 kV common mode o 2 kV common mode
Voltage dips, short <5 % UT <5 % UT Mains power quality should be that of a
interruptions and (>95 % dip in UT) (>95 % dip in UT) typical commercial or hospital
voltage variations for 0,5 cycle for 0,5 cycle environment. If the user of the
on power supply 40 % UT 40 % UT BONESCALPEL SYSTEM requires
input lines continued operation during power mains
(60 % dip in UT) (60 % dip in UT)
for 5 cycles for 5 cycles interruptions, it is recommended that the
IEC 61000-4-11
powered from an uninterruptible power
70 % UT 70 % UT supply.
(30 % dip in UT) (30 % dip in UT)
for 25 cycles for 25 cycles
<5 % UT <5 % UT
(>95 % dip in UT) (>95 % dip in UT)
for 5 sec for 5 sec
Power frequency 3 A/m 3 A/m Power frequency magnetic fields should
(50/60 Hz) be at levels characteristic of a typical
magnetic field location in a typical commercial or
hospital environment.
IEC 61000-4-8
NOTE UT is the AC mains voltage prior to application of the test level.
Table 1.2 Guidance & manufacturer’s declaration on electromagnetic immunity (EN table 202)
List of Cables
Item Cable Length Type
Handpiece cable 15 ft | 4.6 m shielded 2-conductor
Power cord 10 ft | 3.0 m unshielded 3-conducter
Footswitch cable 14 ft | 4.3 m shielded 2-conductor
Table 1.3 List of cables

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Guidance And Manufacturer’s Declaration – Electromagnetic Immunity (Table 204)

the user of the BONESCALPEL SYSTEM should assure that it is used in such an environment.
IEC 60601 test Compliance
Immunity test Electromagnetic environment – guidance
level level
Portable and mobile RF communications equipment
should be used no closer to any part of the
BONESCALPEL SYSTEM, including cables, than the
recommended separation distance calculated from
the equation applicable to the frequency of the
transmitter.
Recommended separation distance
d 1.2 P
Conducted RF 3 Vrms 3V
IEC 61000-4-6 150 kHz to 80 MHz
d 1.2 P 80 MHz to 800 MHz
Radiated RF 3 V/m 3 V/m d 2.3 P 800 MHz to 2.5 GHz

IEC 61000-4-3 80 MHz to 2.5 GHz
where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter
manufacturer and d is the recommended separation
distance in meters (m).
Field strengths from fixed RF transmitters, as deter-

mined by an electromagnetic site survey,a should be
less than the compliance level in each frequency
range.b
Interference may occur in the vicinity

of equipment marked with the
following symbol:
NOTE 1 At 80 MHz and 800 MHz, the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and
reflection from structures, objects and people.
a Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless) telephones and land
mobile radios, amateur radio, AM and FM radio broadcast and TV broadcast cannot be predicted theoretically with
accuracy. To assess the electromagnetic environment due to fixed RF transmitters, an electromagnetic site survey
should be considered. If the measured field strength in the location in which the BONESCALPEL SYSTEM is used
exceeds the applicable RF compliance level above, the BONESCALPEL SYSTEM should be observed to verify
normal operation. If abnormal performance is observed, additional measures may be necessary, such as re-
orienting or relocating the BONESCALPEL SYSTEM.
b Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 3 V/m.
Table 1.4 Guidance & manufacturer’s declaration on electromagnetic immunity (EN table 204)

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Recommended Separation Distances Between Portable And Mobile RF

Communications Equipment And The BONESCALPEL SYSTEM (Table 206)
The BONESCALPEL SYSTEM is intended for use in an electromagnetic environment in which radiated RF disturbances
are controlled. The customer or the user of the BONESCALPEL SYSTEM can help prevent electromagnetic interference
by maintaining a minimum distance between portable and mobile RF communications equipment (transmitters) and
the BONESCALPEL SYSTEM below, according to the maximum output power of the communications equipment.
Separation distance according to frequency of transmitter

Rated maximum output
M
power
of transmitter 150 kHz to 80 MHz 80 MHz to 800 MHz 800 MHz to 2,5 GHz
W
d 1.2 P d 1.2 P d 2. 3 P
0.01 0.12 0.12 0.23
0.1 0.37 0.37 0.37
1 1.2 1.2 2.3
10 3.7 3.7 7.4
100 12 12 23
For transmitters rated at a maximum output power not listed above, the recommended separation distance d
in meters (m) can be estimated using the equation applicable to the frequency of the transmitter, where P is
the maximum output power rating of the transmitter in watts (W) according to the transmitter manufacturer.
NOTE 1 At 80 MHz and 800 MHz, the separation distance for the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption
and reflection from structures, objects and people.
Table 1.5 Recommended separation distances (EN table 206)
1.2. Electrical Safety Statement

The BoneScalpel System is designed and tested to comply with UL 60601-1 and EN 60601-1.
WARNING 1.3 The BoneScalpel system generates high voltages within the console itself and the connected handpiece. To avoid injury,
the console should never be operated before ensuring that its cover is properly closed and not tampered with. Do not
attempt to remove or disassemble the cover. There are no user-serviceable parts inside the console. All service should
only be performed by an authorized Aesculap USA representative.
WARNING 1.4 Proper system grounding can only be ensured when an approved, hospital-grade receptacle and matching power cord
are used. Install plug and receptacles as per local regulations before operating the unit. Power cord, plug and
receptacle should be examined to verify that they are in good working condition before connecting the console. Never
pull on the power cord to remove it from the receptacle.
WARNING 1.5 Connecting the console to a power outlet with inadequate voltage or frequency may cause the unit to malfunction or to
create a shock or fire hazard. Confirm that the voltage selector switch on the console rear panel is set to the local
voltage setting and ensure that the correct fuses are being used. Refer to section 12.1 on fuse replacement.
1.3. Environmental Statement

This equipment consists of materials that may be recycled if disassembled by a specialized company. Please
observe local and federal regulations regarding the disposal of packing materials and old equipment.

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1.4. Summary Of Safety Notices
Please read this section of the manual carefully. It contains a summary of all precaution, warning and
caution statements contained in the manual. However, the user is advised to read the entire manual and
operate the device only in accordance with all of the instructions contained herein.
Servicing of this device should only be performed by qualified technicians authorized by Aesculap USA.
There are no service controls accessible to the user.
Conventions on Warnings, Cautions and Notes

WARNING Denotes potentially dangerous situation that could result in death or serious injury to patient,
operator or staff.
CAUTION Denotes potentially dangerous situation that could result in moderate injury to patient, operator or
staff.
NOTE Indicates potential hazard that may result in product damage.
Table 1.6 Conventions on warnings, cautions and notes
List Of Warnings
WARNING 1.1 The BoneScalpel system is an electro-mechanical device, which under certain circumstances could present an electrical
shock hazard to the operator and/or patient. Please read manual thoroughly and follow directions stated herein to
assure maximum safety during operation. This manual shall be kept in close proximity to the system for easy referral
when needed.
WARNING 1.2 The BoneScalpel system is intended to be used in various types of invasive, surgical procedures. There may be indirect
danger to the patient should the device fail during the procedure. It is recommended that the facility follows its back-up
equipment protocols.
WARNING 1.3 The BoneScalpel system generates high voltages within the console itself and the connected handpiece. To avoid injury,
the console should never be operated before ensuring that its cover is properly closed and not tampered with. Do not
attempt to remove or disassemble the cover. There are no user-serviceable parts inside the console. All service should
only be performed by an authorized Aesculap USA representative.
voltage setting and ensure that the correct fuses are being used. Refer to section 12.1 on fuse replacement.
WARNING 3.1 Tip and irrigant temperatures may exceed the tissue necrosis point if insufficient irrigation flow rates are used. For
hard tissue removal , set the irrigation flowrate to a setting no less than the comparable vibration
setting. For example, if the vibration setting is 7, a minimum flow setting of 70% should be used. Additional external
irrigation, e.g. by administering sterile saline with a syringe over the distal tip portion, may be necessary for removal of
very dense, hard osseous structures.
WARNING 3.2 Tissue necrosis may result if tip is not moved relative to tissue. A continuous tip motion is recommended in
order to minimize contact duration with the ultrasonic tip and minimize heat build-up. When lateral motion is not
possible withdraw and re-insert tip frequently.
WARNING 4.1 Contact to vibrating elements like extension and ultrasonic tip may cause burns and should be avoided by all means.
The handpiece should only be held at the black housing area. A protective silicone sleeve, included with certain tips,
reduces the risk of thermal damage but does not eliminate it. Contact with the silicone sleeve should be avoided or kept
brief with minimal amount of contact pressure. Pressure and extended exposure can still result in excessive frictional

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heat and cause burns.

WARNING 4.2 Additional external irrigation, e.g. by administering sterile saline with a syringe over the distal tip portion, may be
necessary for removal of very dense, hard osseous structures of the skull, when using the BoneScalpel accessories.
WARNING 4.3 Ultrasonic tips can break under excessive use in extreme conditions, e.g. when cutting for extended duration in tight
cavities with limited lateral motion. The tip could break into two or more fragments with the main fragment remaining
attached to the handpiece. All fragments must be retrieved immediately from the surgical site. The fragments should be
checked to ensure that no further pieces are missing. It is possible that a fragment is propelled outside of the surgical
cavity. Diagnostic imaging, such as X-ray, must be used if a fragment cannot be found to confirm that the broken piece
is outside of the surgical cavity.
WARNING 4.4 Breakage of ultrasonic tips will result in sharp edges that can be harmful to soft tissue even without activation of
ultrasound. Tips can bend or deform before they actually brake. Tips showing signs of deformation or cracking should
be replaced immediately since tip breakage is otherwise imminent. Do not bend or twist the ultrasonic tips since it
reduces the structural integrity and can result in tip breakage during use. Dispose of deformed or broken tips
immediately in a sharps container.
WARNING 6.1 Immediately suspend operation if Electrical Fault appears on display and/or an Electrical Fault audible alarm sounds.
Remove ultrasonic tip from surgical site. Turn Mains Power OFF. Do not touch any metallic parts of handpiece,
extension, ultrasonic tip or generator while fault is indicated.
WARNING 7.1 Improper connection of the handpiece cable may present a shock hazard. Confirm that handpiece connector is dry prior
to plugging it in.
WARNING 7.2 Do not operate pump with pump cover in raised position. Rollers might pinch loose clothing or fingers. Personal
injuries may result. Cooling of the ultrasonic tip and irrigation at the treatment site will be inhibited.
WARNING 7.3 Tip and irrigation temperatures may exceed the tissue necrosis point with BoneScalpel accessories for hard tissue
removal if insufficient irrigation flow rates are used. Always set the irrigation flowrate for hard tissue removal
to a setting no less than the comparable vibration setting. For example, if the vibration setting is 7, a minimum
flow setting of 70% should be used.
WARNING 7.4 Heat is being generated at the tip/tissue interface. A continuous, lateral sweeping motion is recommended for general
bone/tissue removal in order to minimize contact duration with the ultrasonic tip and minimize the temperature
increase.
WARNING 8.1 Remove probe cover, ultrasonic tip and extension from the handpiece prior to cleaning and/or sterilization; otherwise
proper cleaning/sterilization may be inhibited.
WARNING 9.1 Single-use items should be discarded following each surgical procedure according to hospital protocol for disposal of
biocontaminated wastes. Do not attempt to reuse or re-sterilize any single-use items. Dispose ultrasonic tips
in a sharps container.
WARNING 9.2 All reusable handpiece parts and accessories must be properly decontaminated, cleaned and sterilized before each use
as per instructions contained in this manual. Failure to do so may lead to infections, which can ultimately cause patient
death.
WARNING 9.3 The manufacturer has validated all cleaning and sterilization cycles given in this manual. It is highly recommended that
the procedures given in this manual for cleaning and sterilizing the BoneScalpel System and related accessories be
followed. It is the responsibility of the user of this device or any accessories used with it to validate procedures for
cleaning and/or sterilization if they differ from the procedures as outlined in this manual.
WARNING 10.1 If a Mains Power fuse fails after replacement when the unit is reactivated, discontinue use of the device and contact an
authorized Aesculap USA representative.
create a shock or fire hazard. Confirm that the voltage selector switch in the console rear is set to the local voltage
setting and ensure that the correct fuses are being used. Refer to section 12 on fuse replacement
List Of Cautions
CAUTION 1.2 This device is considered medical electrical equipment. Medical electrical equipment needs special precautions regarding
electromagnetic compatibility (EMC) and needs to be installed and put into service according to the EMC information
provided in this operator’s manual.
CAUTION 1.3 Portable and mobile RF communication equipment can affect medical electrical equipment. If RF equipment is in use
monitor the Bonescalpel for proper function during procedure.
CAUTION 1.4 The use of accessories, transducers and cables other than those specified may result in increased emissions or

BCA-UM RevD
decreased immunity of the device. Use only Aesculap branded equipment and accessories.
CAUTION 1.5 The console should not be used adjacent to or stacked with other electrical equipment. If adjacent or stacked use is
necessary, the console should be observed to verify normal operation in the configuration in which it will be used.
CAUTION 3.1 The BoneScalpel system and its accessories may emit harmful acoustic pressure if exposure exceeds recommended
limits.
CAUTION 4.1 Ultrasonic energy is inhibited if excessive physical force is applied to the ultrasonic tip; use only enough force to guide
the tip to the surgical site and to advance it through the tissue. Do not force the tip; allow the ultrasonic action to do
the work.
CAUTION 4.2 Insufficient irrigation and high tip pressure (loading) under extended exposure, e.g. in tight cavities, are to be avoided
in BoneScalpel hard tissue removal. It is recommended to withdraw and re-insert the ultrasonic tip repeatedly to re-
establish adequate cooling and lubrication.
CAUTION 7.1 All reusable system components like handpiece, probe covers, counter wrench, and T-wrench are supplied industrially
cleaned, but NON-STERILE. All items intended for use in the sterile field must be cleaned and sterilized as per the
indicated instructions before first clinical use and before every subsequent clinical use.
CAUTION 7.2 All items intended for use in the sterile field must be cleaned and sterilized as per indicated instructions before each
clinical use.
CAUTION 7.3 The disposable items are intended for one procedure only (single use). Do not attempt to reuse or re-sterilize.
CAUTION 7.4 Do not place the soft silicone tube behind or in front of the rollers (latch removed in illustrations)
CAUTION 7.5 Do not pinch the soft silicone tube when the latch is locked.
CAUTION 7.6 Do not pinch barb fittings when closing the latch.
CAUTION 7.7 Prime the irrigation tubing prior to use. At all times ensure that the irrigant flows towards the handpiece when
footswitch is depressed. If no irrigant is flowing, cease use until flow is restored.
CAUTION 7.8 The system check should always be done in advance of preparing patient for surgery to minimize risk to patient in case
of system malfunction.
CAUTION 8.1 Ensure all connections and mating surfaces of handpiece, extension and ultrasonic tip are clean and dry before
assembly.
CAUTION 9.1 Use manual cleaning techniques only. Do not use ultrasonic cleaners or automated washers to clean the handpiece as
both methods could damage handpiece.
CAUTION 9.2 Be certain to clear debris from all internal passages by brushing. Failure to do so may hinder sterilization of units
during autoclaving.
CAUTION 9.3 Do not immerse ultrasonic console, handpiece, irrigation pump, remote footswitch or electric cables. These items are
not sealed against liquids and damage to equipment will result.
CAUTION 12.1 Use only genuine replacement parts from Aesculap. Use of parts furnished by other sources may result in patient or
operator injury or system malfunction and will void any applicable warranty.
CAUTION 12.2 Before using loose packing materials, such as foam pellets, shredded paper or similar, be sure to wrap the
component(s) separately in plastic bags, film or other protective wrapping.
List Of Notes
NOTE 4.1 After extended periods of operation, the bottom of the console housing may become warm to the touch. This is normal.
Do not touch the bottom of the console housing while in operation or shortly after operation.
NOTE 4.2 Loose tip/tissue contact upon an initial bone incision can cause a thin tip to resonate not only longitudinally but also
transversely. This can cause a thin tip to break. It is necessary to engage bone actively and with a minimal tip pressure
greater than zero in order to prevent the shattering.
NOTE 4.3 Contact of the ultrasonic tip or the exposed extension with metal, surgical instruments or other objects during
ultrasound use must be avoided. Such contact can damage the ultrasonic components very easily and may result in
compromised performance, including failure. Discard any extensions or tips that show signs of damages like gouges,
nicks or fractures. External aspiration may be used but it is recommended that a plastic suction tip should be used
when in proximity with the probe tip.
NOTE 7.1 Adequate air circulation is needed to cool electronic components inside of the unit. Do not block the cooling fan at the
console rear or the air vents on the console bottom. Do not place the unit on a towel, foam or other soft surface since
the material may block the air vents. Blocking these vents may cause unit to overheat and malfunction or create a
shock hazard. A clear drape can be used to protect the console front panel but do not cover the pump housing or other
console portions.

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NOTE 8.1 The handpiece must be placed into the counter wrench. Do not attempt to tighten or loosen handpiece components by
holding the handpiece case or endcap. Always use the T-wrench wrench when tightening or un-tightening the tip or an
extension. Never apply a pipe or strap wrench to the handpiece case. Do not over-tighten the tip or the extension.
NOTE 8.2 Always tighten or un-tighten the probe cover by hand and without using any wrenches. Do not over-tighten the probe
cover.
NOTE 8.3 Always hold the handpiece at its metallic endcap when tightening or un-tightening the irrigation tubing. Always tighten
or un-tighten the irrigation tubing by hand and without using any wrenches. Do not over-tighten the tubing connector.
NOTE 9.1 Allow reusable, autoclavable items to gradually return to room temperature after steam sterilization and prior to usage.
NOTE 9.2 The reuse life given takes into account wear and tear due to cleaning and sterilization only. Damage or wear caused by
actual use in treatments will affect life of components.
1.5. Trademark Information

Aesculap® is a registered trademark of Aesculap, Inc.
Misonix® is a registered trademarks of Misonix, Inc., Farmingdale, NY
BoneScalpel™ is a pending trademark of Misonix, Inc., Farmingdale, NY
ASP Enzol® and Prolystica® are registered trademarks of STERIS Corporation, Mentor, OH

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1.6. Explanation Of Symbols
Console Related Symbols
Symbol Description Symbol Description Symbol Description
Enable / Standby Caution:

Mains Power ON
Ultrasound Dangerous voltage
Scroll through Caution:

Consult accompanying Mains Power OFF
menu pages documents
Caution: Protective
Amplitude setting
Pinch hazard earth ground
Consult Equipotentiality
Pulse setting
Instructions for Use connection
Disposal to be
compliant with
Flow setting Type B equipment
EN 50419 (WEEE
directive)
2
Restricted to sale
Sterilized using
Do not reuse STERILE EO Rx ONLY by or on the order
Ethylene Oxide
of a physician only
Do not use
Sterilized using Authorized
if packaging STERILE R Gamma Irradiation EC REP representative
is damaged
Contents are
LATEX
latex-free
Use by date indicated REF Catalog number
~
°C Max Do not expose to
temperatures
LOT Lot or batch code AC Voltage
greater than
indicated
Must use hospital

grade power cord Fuse Manufacturer
only
Contains DEHP Footswitch

Classified by UL
and/or Phthalates connector
Table 1.7 Explanation of symbols

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2. Indications And Contra Indications

2.1. Indications
The BoneScalpel system is indicated for use in the fragmentation and aspiration of both soft and hard (e.g.:
bone) tissue as used in the following surgical specialties:
Orthopedic Surgery
Plastic and Reconstructive Surgery
Thoracic Surgery
NeuroSurgery
General Surgery
2.2. Contra Indications

The BoneScalpel system is contra indicated for cardiac surgery and any procedure in the proximity of the heart.
The irrigation pump is contra indicated for the administration of parenteral fluids, infusion of drugs or for any
life sustaining purposes

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3. Adverse Effects
CAUTION 3.1 The BoneScalpel system and its accessories may emit harmful acoustic pressure if exposure exceeds recommended
limits.
Limits For Airborn Acoustic Exposure

Minimum Operating Distance Maximum Exposure Period
From operator’s or patient’s ear Within a 24hour period
3” - 12” 8 cm – 30 cm Not to exceed 30 minutes
12” - 24” 30 cm – 60 cm Not to exceed 90 minutes
> 24” 60 cm Not to exceed 240 minutes
WARNING 3.1 Tip and irrigant temperatures may exceed the tissue necrosis point if insufficient irrigation flow rates are used. For
hard tissue removal , set the irrigation flowrate to a setting no less than the comparable vibration
setting. For example, if the vibration setting is 7, a minimum flow setting of 70% should be used. Additional external
irrigation, e.g. by administering sterile saline with a syringe over the distal tip portion, may be necessary for removal of
very dense, hard osseous structures.
WARNING 3.2 Tissue necrosis may result if tip is not moved relative to tissue. A continuous tip motion is recommended in
order to minimize contact duration with the ultrasonic tip and minimize heat build-up. When lateral motion is not
possible withdraw and re-insert tip frequently.

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4. Considerations During Clinical Use

4.1. Hand position
Recommended Hand Positions
The following illustrations demonstrate safe positions for holding the handpiece.
Figure 4.1 Correct hand position
Holding the handpiece at the silicone sleeve should be avoided or kept brief with minimal amount of contact
pressure.
Figure 4.2 Incorrect hand position
WARNING 4.1 Contact to vibrating elements like extension and ultrasonic tip may cause burns and should be avoided by all means.
The handpiece should only be held at the black housing area. A protective silicone sleeve, included with certain tips,
reduces the risk of thermal damage but does not eliminate it. Contact with the silicone sleeve should be avoided or kept

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brief with minimal amount of contact pressure. Pressure and extended exposure can still result in excessive frictional
heat and cause burns.
NOTE 4.1 After extended periods of operation, the bottom of the console housing may become warm to the touch. This is normal.
Do not touch the bottom of the console housing while in operation or shortly after operation.
4.2. HARD Tissue Use

Recommended Settings For Hard Tissue Use
The following settings are general guidelines and should be adjusted based on indication, anatomy, pathology
and surgeon’s preference.
Amplitude Pulse Flow

Highest 10 100% 100%
Very High 9 100% 90%
High 8 100% 80%
Standard (Default) 7 100% 70%
Moderate 6 100% 60%
Low 5 100% 50%
Table 4.1 Recommended settings for hard tissue removal
A high amplitude setting results in more aggressive tissue removal, a low setting in less aggressive tissue
removal.
A higher amplitude setting in combination with lower irrigation could result in increased tissue necrosis. A
lower amplitude setting in combination with higher irrigation would minimize or eliminate tissue necrosis.
Bone shaving tips tend to require a lower amplitude than cutting blades.
WARNING 3.1 Tip and irrigant temperatures may exceed the tissue necrosis point if insufficient irrigation flow rates are used. For hard
tissue removal , set the irrigation flowrate to a setting no less than the comparable vibration setting. For example, if the
vibration setting is 7, a minimum flow setting of 70% should be used. Additional external irrigation, e.g. by
administering sterile saline with a syringe over the distal tip portion, may be necessary for removal of very dense, hard
osseous structures.
WARNING 3.2 Tissue necrosis may result if tip is not moved relative to tissue. A continuous tip motion is recommended in order to
minimize contact duration with the ultrasonic tip and minimize heat build-up. When lateral motion is not possible
withdraw and re-insert tip frequently.
WARNING 4.2 Additional external irrigation, e.g. by administering sterile saline with a syringe over the distal tip portion, may be
necessary for removal of very dense, hard osseous structures of the skull, when using the BoneScalpel accessories.
CAUTION 4.1 Ultrasonic energy is inhibited if excessive physical force is applied to the ultrasonic tip; use only enough force to guide
the tip to the surgical site and to advance it through the tissue. Do not force the tip; allow the ultrasonic action to do
the work.

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Tip Limitations During Bone Removal

Both the ultrasonic tip and the extension are vibrating at high frequency and are thus exposed to extreme
mechanical stresses, especially when cutting bone.
WARNING 4.3 Ultrasonic tips can break under excessive use in extreme conditions, e.g. when cutting for extended duration in tight
cavities with limited lateral motion. The tip could break into two or more fragments with the main fragment remaining
attached to the handpiece. All fragments must be retrieved immediately from the surgical site. The fragments should be
checked to ensure that no further pieces are missing. It is possible that a fragment is propelled outside of the surgical
cavity. Diagnostic imaging, such as X-ray, must be used if a fragment cannot be found to confirm that the broken piece
is outside of the surgical cavity.
WARNING 4.4 Breakage of ultrasonic tips will result in sharp edges that can be harmful to soft tissue even without activation of
ultrasound. Tips can bend or deform before they actually brake. Tips showing signs of deformation or cracking should
be replaced immediately since tip breakage is otherwise imminent. Do not bend or twist the ultrasonic tips since it
reduces the structural integrity and can result in tip breakage during use. Dispose of deformed or broken tips
immediately in a sharps container.
CAUTION 4.2 Insufficient irrigation and high tip pressure (loading) under extended exposure, e.g. in tight cavities, are to be avoided
in BoneScalpel hard tissue removal. It is recommended to withdraw and re-insert the ultrasonic tip repeatedly to re-
establish adequate cooling and lubrication.
NOTE 4.2 Loose tip/tissue contact upon an initial bone incision can cause a thin tip to resonate not only longitudinally but also
transversely. This can cause a thin tip to break. It is necessary to engage bone actively and with a minimal tip pressure
greater than zero in order to prevent the shattering.
NOTE 4.3 Contact of the ultrasonic tip or the exposed extension with metal, surgical instruments or other objects during
ultrasound use must be avoided. Such contact can damage the ultrasonic components very easily and may result in
compromised performance, including failure. Discard any extensions or tips that show signs of damages like gouges,
nicks or fractures. External aspiration may be used but it is recommended that a plastic suction tip should be used
when in proximity with the probe tip.

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5. System Overview
5.1. Principle Of Operation
The BoneScalpel system is designed to ultrasonically dissect and fragment hard (osseous) tissues. The system
consists of an ultrasonic console with handpiece and accessories. The console features an integrated irrigation
pump.
Figure 5.1 BoneScalpel Console
Figure 5.2 BoneScalpel Handpiece
The console produces an electrical signal that is fed into the handpiece and its piezoelectric transducer. The
transducer converts the electrical signal into mechanical vibrations. The vibratory motion is amplified all the way
down to the tip’s distal end. Various tip shapes and sizes are available to achieve desired tissue effects.
Hard Tissue Applications: Specialized hard tissue tips are utilized to cut hard, osseous structures.
o BoneScalpel blades, typically used for performing osteotomies, are usually flat and have a blunt
active edge. A compression cut is achieved through repetitive impacts on the bone at an
ultrasonic frequency.
o Bone shaving tips are used for sculpting bone. They have an abrasive surface for bone removal
through abrasion under ultrasonic oscillation.
o BoneScalpel multi-function tips can have a combination of blunt and abrasive cutting surfaces.
A peristaltic pump, integrated into the BoneScalpel console, provides irrigant to the operative site during use.

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5.2. Reusable System Components

The following system components represent the minimum requirements for performing hard tissue procedures.
They can be ordered as a system or individually.
Required System Components
MC634 BoneScalpel console 1 ea.
Includes IV pole, power cord, footswitch, peristaltic pump and instructions for use
MC632 BoneScalpel handpiece 1 ea.
MC637 Counter wrench Compatible with 1 ea.

MC632
MC628 T-Wrench Compatible with 1 ea.

MC922
MC923
MC925
MC926
MC927
MC631 Probe cover Compatible with 1 ea.

MC922
MC923
MC925
MC926
MC927
Table 5.1 Required system components
Components and quantities included with the system may change over time, please check with your Aesculap
USA representative for the most current configuration.

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5.3. Single-use, Sterile Components

At least one irrigation tubeset must be available for each surgical procedure.
Irrigation Tubeset
MC924 Irrigation Tubeset 1 ea.
Table 5.2 Irrigation tubeset
Ultrasonic tips are supplied sterile and are for single use only. At least one of the following tips must be
available for each surgical procedure.
Hard Tissue Tips

All tips requires MC631 probe cover
MC922 Bone Scalpel – 10mm, Blunt 1 ea.
Includes blade, short extension, and silicone sleeve
MC923 Bone Scalpel – 20mm, Blunt 1 ea.
Includes blade, short extension, and silicone sleeve
MC928 BoneScalpel –20mm, serrated blade 1 ea.
Includes blade, short extension,

and silicone sleeve
MC925 Bone Shaver – Micro Hook 1 ea.
Includes shaver tip, short extension and silicone sleeve
MC927 Bone Scalpel – 10mm, Blunt, Long Straight 1 ea.
Includes blade, long curved extension, and silicone sleeve
MC926 Bone Scalpel – 10mm, Blunt, Long Curved 1 ea.
Includes blade, long curved extension, and silicone sleeve

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MC929 Bone Scalpel – 20mm, Blunt, Long Curved Requires

BCM-SS
probe cover
Includes blade, long curved extension and silicone sleeve
Table 5.3 Tips

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6. Console
6.1. Receptacles, Controls And Indicators
The rear of the console features receptacles for the power cord, fuses, footswitch cable and IV-pole as well as a
switch for mains power.
1 IV-pole receptacle
2 Mains power on/off
3 Power cord receptacle with
fuse block
4 Voltage selector switch
5 Cooling fan
6 Equipotentiality connection
7 Footswitch receptacle
Figure 6.1 Console rear
The front of the console features a receptacle for the handpiece cable and an irrigation pump head, in which
the irrigation tubing is inserted. A large color LCD screen provides information on system status and set points
for ultrasound amplitude, pulse rate and irrigant flow rate with respective controls on the panel below.
Additional controls for ultrasound enable/standby and menu access are provided on the left of the display panel.
An ultrasound timer indicates the elapsed time, in which the ultrasound was on.
1 Amplitude setting
2 Pulse setting
3 Flow setting
4 Enable/standby button
5 Ultrasound timer
6 Menu button
7 Handpiece cable receptacle
8 Indicator for flow direction
9 Irrigation pump head
A-F Custom buttons
Figure 6.2 Console front
Buttons A-F perform various functions, depending on the information displayed on the screen. The display
screen shown is the Main Screen used for all major control functions.
The handpiece receptacle is keyed in order to facilitate connection. The red dot on top of the receptacle must
be in line with the corresponding red dot on the handpiece cable.

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6.2. Menu Functions

The standard screen is the Main Screen. Additional screens are the Options and the Help Screen. Both the
Options and Help screens can be accessed by pressing the menu button to toggle through the three main
screens; Main Menu, Options and Help.
Main Screen
The Main Screen allows control of the main system functions such as Amplitude, Pulse, and Flow .
1 Menu Button
A-E Custom Buttons
Figure 6.3 Main screen
Amplitude Control
The amplitude can be set between 0 and 10. Press A to increase and B to decrease the amplitude. The
default setting for amplitude is 7. Refer to section 6.3 for further details on the Amplitude feature.
Pulse Control
The pulse can be set between 50% and 100%. Press C to increase and D to decrease the pulse. The
default setting for pulse is 100%. Refer to section 6.3 for further details on the Pulse feature.
Flow Control
The flow can be set between 20% and 100%. Press E to increase and F to decrease the flow. The
default setting is 70%. Refer to section 6.3 for further details on the Flow feature.
Ultrasound Timer
The ultrasound timer records the elapsed time, in which the ultrasound was activated with the
footswitch. The timer can be re-set to zero via the secondary screen.
In the event of error, such as a Mechanical Limit or an Electrical Fault, the main screen is replaced by alert
screens. Refer to section 6.4 for a description of these warnings.

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Options Screen
The Options Screen allows the user to do the following; re-set the elapsed ultrasound time, save and choose
presets and adjust the display contrast.
1 Menu Button
A-E Custom Buttons
Figure 6.4 Options screen
Ultrasound timer
The elapsed ultrasound time can be re-set to 00:00 by pressing either A or B.
Presets
Preferred settings for amplitude, pulse and flow can be saved as two presets. A third preset features
the default settings, which can not be customized. A sub-screen for presets 1, 2 and 3 can be accessed
by pressing either C or D.
Contrast
The display contrast can be adjusted. Press E to increase and F to decrease contrast.
Pressing the menu button toggles from the options to the help screen.

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Help Screen
The Help Screen provides access to a quick guide on system operation and troubleshooting.
1 Menu Button
A-E Custom Buttons
Figure 6.5 Help screen
System Operation
Press A to access the quick reference guide on system operation.
Troubleshooting
Press B to access the quick reference guide on troubleshooting.
Pressing the menu button toggles from the help to the main screen.
6.3. Main Functions

Amplitude
The ultrasonic tip engages the target area in linear strokes at a rate of approximately 22,500 cycles per second.
During each cycle the tip elongates from resting to maximum position, contracts back over resting and to
minimum position and elongates back to its resting point. The peak-to-peak amplitude or stroke distance can be
adjusted by changing the Amplitude from setting 1-10. This is the main parameter to control the rate of tissue
removal. A high amplitude setting results in more aggressive tissue removal, a low setting in less aggressive
tissue removal. Amplitude and thus removal rate may alter with size and geometry of the ultrasonic tip.
Pulse
The ultrasonic energy output over time can be reduced by using the pulse mode, in which a resting period is
inserted within the duty cycle. This results in an active period, followed by a resting period during each duty
cycle. The total period is a ¼ second (250ms). The pulse can be set between 50% and 100%.
Pulse Setting 100% [Continuous]

The default setting is 100% or continuous, which refers to 100% energy output or zero resting period. This is
the recommended setting for hard tissue applications.
Pulse Setting 50-90% [Pulsed]

The Pulse function minimizes exposure to ultrasound over time.

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The Pulse setting corresponds to the duration of the active period of the ultrasound output. For example, a
Pulse setting of 60% corresponds to an active period of 60% of ¼ second (150ms). The resulting resting period
is 40% of ¼ second (100ms). The ultrasonic energy output over time is reduced by 40% with this setting. Note
that the ultrasound timer will only advance during the active period and not during the resting period. For most
applications, the recommended pulse setting is 100%.
Figure 6.6 Illustration of pulse setting
Irrigation
Proper irrigation with sterile saline ensures:
1) Cooling of handpiece and vibrating elements
2) Cooling and lavage of the surgical site
3) Lubrication of bone/tip interface for BoneScalpel hard tissue removal
The active ultrasonic probe remains cold when not in contact with tissue. However, when a tip contacts tissue
heat is generated. The heat increases with applied tip pressure or amplitude. Irrigant needs to be applied at the
tip/tissue interface to mitigate this temperature rise.
Most ultrasonic tips and probes feature an integrated irrigation channel. The irrigant is expelled through a jet
nozzle at the tip. Active tip surfaces are being cooled directly.

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Enable/Standby
The Enable/Standby button on the console’s front panel can be used to block accidental ultrasound activation
during longer periods of inactivity following set-up or during surgery.
Standby Mode Enable Mode
Amplitude setting is GREY and HOLLOW Amplitude setting is GREEN and SOLID
Footswitch activates Footswitch activates
Irrigation only. Irrigation can be used for Ultrasound output and irrigation. A bell chime is
lavage or priming. emitted briefly.
Table 6.1 Enable/standby function
6.4. Alerts And Alarms

Mechanical Limit Alert
The console monitors the ultrasonic output at all times and alerts in cases of overload or malfunction of the
vibrating elements (handpiece, extension and ultrasonic tip).
A “Limit” alert is displayed together with a pulsed audible alarm as long as the footswitch is depressed.
Ultrasound and Irrigation are deactivated temporarily.

Alert Type Alert Screen Alert Action
Mechanical Limit Displays “LIMIT” alert located above amplitude setting

display.
Triggers a pulsed, audible alarm upon footswitch activation.
Temporarily deactivates ultrasound and irrigation functions.
Possible Cause Corrective Action
1. Tip overload Release footswitch.

Reduce tip pressure and/or use higher amplitude setting as required.
Continue procedure.
2. Loose or Release footswitch.
damaged component Set ultrasound to STANDBY.
Remove silicone sleeve (if applicable) and probe cover.
Inspect extension probe and ultrasonic tip for damage. Replace if necessary.
Otherwise re-tighten extension probe and tip using the correct wrenches.
Set ultrasound to ENABLE.
Continue procedure.
3. Defective Handpiece If corrective action steps above are followed and alert continues, the handpiece may need
to be replaced.
Table 6.2 Mechanical limit alert and recommended corrective actions

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Tip overload can occur during hard tissue removal when applying excessive tip pressure or facing strong tissue
resistance, e.g. from thick cortical bone. This can lead to stalling of the ultrasonic tip. A pulsed audible signal
alerts of the stalling and the ultrasound is deactivated. Release the footswitch briefly and reduce the tip
pressure, e.g. by retrieving the ultrasonic tip. Depress the footswitch again and continue with reduced tip
pressure. Consider using higher amplitude setting or reduced loading if stalling persists.
Electrical Fault Alert

The console monitors the electrical output at all times and alerts in cases where the handpiece is not properly
connected to the console, when an output short or open circuit is detected or electrical safety is compromised.
An Electrical Fault Screen is displayed together with a steady audible alarm. Ultrasound and Irrigation are
deactivated. Requires recycling of mains power switch to re-set.

Electrical Fault Displays Electrical Fault Screen.
Triggers steady audible alarm.
Permanently deactivates ultrasound and irrigation. Requires

recycling of mains power switch to re-set.
1. Handpiece not Turn mains power OFF.

connected Check handpiece cable connection.
Restart console.
2. Defective Turn mains power OFF.

Handpiece Replace handpiece and restart console.
If problem persists replace console.
3. Defective console Turn mains power OFF.

Replace console.
Table 6.3 Electrical fault alert and recommended corrective actions

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7. System Set-up
7.1. Installation
Upon delivery perform a visual inspection of the shipping containers and all system components for obvious
shipping damage. Retain the shipping container and immediately notify the shipping carrier of any damages
found.
CAUTION 7.1 All reusable system components like handpiece, probe covers, counter wrench, and T-wrench are supplied industrially
cleaned, but NON-STERILE. All items intended for use in the sterile field must be cleaned and sterilized as per the
indicated instructions before first clinical use and before every subsequent clinical use.
The BoneScalpel system is designed and tested to comply with IEC EN60601-1-2: 2001 guidelines for EMC. See
section 1 for general safety statements.
voltage setting and ensure that the correct fuses are being used. Refer to section 12.1 on fuse replacement.See section
12.1 for instructions on adjusting to local electrical requirements.
Care should be taken to stay within the general operating conditions.
Operating Conditions
Operating conditions Temperature 55-95 F (13-35 C)

Relative humidity 20-90% (non condensing)
Standard atmospheric pressure
Table 7.1 Operating conditions
The console can be placed on an appropriate table or cart outside of the sterile field. Ensure that the pump
head on the console right is installed. Refer to section 12.2 if the pump head is not yet installed.
The console features air vents on the bottom. When installing the unit, ensure that these vents are not blocked
in a way that would prevent the circulation of air around the unit.
1 Air vents
Figure 7.1 Underside view of console with air vents

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NOTE 7.1 Adequate air circulation is needed to cool electronic components inside of the unit. Do not block the cooling fan at the
console rear or the air vents on the console bottom. Do not place the unit on a towel, foam or other soft surface since
the material may block the air vents. Blocking these vents may cause unit to overheat and malfunction or create a
shock hazard. A clear drape can be used to protect the console front panel but do not cover the pump housing or other
console portions.
7.2. Console Set-up – Part I (Non-sterile)
Console Set-up | Part I
Switch Mains Power OFF Set Mains Power switch on console rear to OFF.
Connect IV-pole Connect IV-pole to receptacle in console rear.
Hang container with sterile irrigant into IV-pole hook.
Irrigation tubing features IV-spike and is compatible with rigid bottles or flexible bags.
Connect Electrical Power Connect power cord to receptacle on console rear and to wall outlet.
Connect Footswitch Connect footswitch cable to receptacle on console rear.
Footswitch connector and receptacle are keyed to ensure proper connection. Turn cable
connector until keys match. Insert connector fully into receptacle. Turn outer connector
ring clockwise to lock into position.
Footswitch may be covered with clear drape during clinical use.
Switch Mains Power ON Set Mains Power switch on console rear to ON.
Front panel will display Main Screen upon completion of system start.
Table 7.2 Console set-up - part I
7.3. Handpiece Assembly (Sterile)

Handpiece assembly in the sterile field should be performed by trained and authorized OR staff only.
Please refer to section 8.0 for specifics on the handpiece assembly and disassembly for both hard tissue
applications.
Once the handpiece has been assembled, continue with part II of the Console Set Up.
clinical use.

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7.4. Console Set-up – Part II (Non-sterile)

Console Set-up | Part II
Connect Handpiece cable Attach cable connector receptacle on console front panel.
Align red dot on cable connector with red dot on front panel receptacle. Push cable
connector into place.
Open pump cover Open the latch of the irrigation pump
The arrow on the pump housing indicates the direction of flow.
Insert tubing Insert the soft silicone section by placing it over the pump rollers.
Verify that the tubing enters the pump from fluid container and exits to handpiece and
in direction of arrow on pump housing.
Secure tubing in V-notches Place and hold the tubing’s silicone section in the V-notches on both pump sides.
Apply slight pressure to ensure that tubing rests within both V-notches.
Close pump cover Close the latch of the irrigation pump until it locks.
Adjust the grip of the V-notches Evenly adjust the V-notches to their fully opened position by turning the adjustment
wheel underneath the front and back of the pump assembly. Allow for tight grip to
prevent the tubing from slipping but without pinching the tubing, which would obstruct
the irrigation flow.
Connect Tubing to Fluid Container Connect IV-Spike to fluid container following standard sterility protocol.
Irrigation tubing features vented IV-spike and is compatible with rigid bottles and
flexible bags.
Prime Tubing Check that ultrasound is in Standby Mode. Set Flow rate to 10.
Depress footswitch until fluid discharges at ultrasonic tip.
Table 7.3 Console set-up - part II

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to plugging it in.
CAUTION 7.4 Do not place the soft silicone tube behind or in front of the rollers (latch removed in illustrations)
CAUTION 7.5 Do not pinch the soft silicone tube when the latch is locked.
CAUTION 7.6 Do not pinch barb fittings when closing the latch.
CAUTION 7.7 Prime the irrigation tubing prior to use. At all times ensure that the irrigant flows towards the handpiece when
footswitch is depressed. If no irrigant is flowing, cease use until flow is restored.
WARNING 7.3 Tip and irrigation temperatures may exceed the tissue necrosis point with BoneScalpel accessories for hard tissue
removal if insufficient irrigation flow rates are used. Always set the irrigation flowrate for hard tissue removal
to a setting no less than the comparable vibration setting. For example, if the vibration setting is 7, a minimum
flow setting of 70% should be used.
WARNING 7.4 Heat is being generated at the tip/tissue interface. A continuous, lateral sweeping motion is recommended for general
bone/tissue removal in order to minimize contact duration with the ultrasonic tip and minimize the temperature
increase.
The BoneScalpel System is now ready for the system check.

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7.5. Perform System Check
System Check
Enable Ultrasound Switch to Enable Mode using enable/standby button. Confirm that Amplitude setting is
FILLED GREEN.
Depress footswitch Direct ultrasonic tip toward suitable reservoir to collect irrigant. Depress footswitch.
Confirm Function Console emits a bell chime.
Irrigant will be pumped from console towards handpiece.
Ultrasonic tip emits buzzing sound and irrigant exits tip as fine spray.
Ultrasound timer counts up in 1-second increments.
Release footswitch Release footswitch.
Ultrasound and Flow output stop.
Ultrasound timer freezes at last reading.
Function Confirmed Reset ultrasound timer as desired.
System is now ready for use.
Function NOT confirmed Console alerts of Mechanical Limit or Electrical Fault or does not respond as expected.
Refer to troubleshooting section for next steps.
Table 7.4 System check
CAUTION 7.8 The system check should always be done in advance of preparing patient for surgery to minimize risk to patient in case
of system malfunction.
The BoneScalpel System is now ready for use. Refer to section 1.0 for general safety statements, indications
and adverse affects and section 4.0 for use of main system functions.

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8. Handpiece Assembly And Disassembly

The BoneScalpel Ultrasonic Surgical System can accommodate different tip configurations to perform hard
tissue applications.
8.1. Handpiece Assembly

Perform an inspection of handpiece and all components prior assembly.
Handpiece Inspection
Inspect Inspect the black handpiece housing for any visual cracks. Inspect the front metallic portion
Handpiece probe for surface damage like nicks, gouges and cracks. Replace if damaged.
Inspect Inspect mating face of handpiece to verify that it is clean and dry.
Mating Surface
Table 8.1 Handpiece inspection
CAUTION 8.1 Ensure all connections and mating surfaces of handpiece, extension and ultrasonic tip are clean and dry before
assembly.
clinical use.
cover.
Handpiece Assembly
Mount
Handpiece Wrench
Align wrench flats
Mount
Extension
Turn clockwise

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Tighten
Extension
Tighten clockwise
Mount
Ultrasonic Tip
Turn clockwise
Mount
Tip Wrench
Align wrench flats
Tighten
Ultrasonic Tip
Tighten clockwise Match alignment marks
Mount
Probe Cover
Turn clockwise
Mount Push sleeve over probe cover

Sleeve (if applicable)
Connect
Irrigation Tubing
Turn clockwise
Table 8.2 Handpiece assembly
The handpiece is now ready for use and can be connected to the BoneScalpel System. Please refer to Section
7.0 for details.

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Figure 8.1 Fully assembled handpiece
If desired, mount suitable sterile cable clips or sterile adhesive tape strips to attach irrigation tubing to
handpiece cable.
8.2. Handpiece Disassembly
cover.
Handpiece Disassembly
Disconnect
Irrigation Tubing
Turn counter-clockwise
Remove
Sheath
Pull sheath from probe cover

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Remove
Probe Cover
Turn counter-clockwise
Mount
Handpiece Wrench
Align wrench flats
Mount
Tip Wrench
Remove
Ultrasonic Tip
Table 8.3 Handpiece disassembly

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9. Cleaning And Sterilization

9.1. Disassembly
Console Tear-down
Disable Ultrasound Switch to Standby Mode using enable/standby button. Confirm that Amplitude setting is
HOLLOW GREY.
Switch Console OFF Set Mains Power switch on console rear to OFF.
Remove Handpiece Pull cable connector from receptacle on console front.
Cable
Remove Tubing Open pump cover. Remove tubing from pump compartment.
Disconnect tubing from irrigant container.
Wipe Down Console Wipe down the console.
Table 9.1 Console tear-down
Handpiece Disassembly
Disassemble all handpiece components in reverse order of assembly. Please refer to Section 8.2 for
disassembly.
Dispose Of Single-Use Items

The following items are considered single use items and must not be reused. Reuse of these items could result
in severe patient injury or death.
Irrigation tubeset
Tips with extensions
Silicon sleeves
Once used, dispose of above items in accordance with standard hospital procedures for disposal of
biocontaminated wastes.
WARNING 9.1 Single-use items should be discarded following each surgical procedure according to hospital protocol for disposal of
biocontaminated wastes. Do not attempt to reuse or re-sterilize any single-use items. Dispose ultrasonic tips
in a sharps container.
9.2. Cleaning
Follow Standards For Decontamination, Cleaning And Sterilization
Follow ANSI/AAMI ST35, Good Hospital Practice: Handling and Biological Contamination of Reusable Medical
Devices (1991), or other such guidelines as may be directed by Hospital or Clinic GHP’s.
WARNING 9.2 All reusable handpiece parts and accessories must be properly decontaminated, cleaned and sterilized before each use

BCA-UM RevD
as per instructions contained in this manual. Failure to do so may lead to infections, which can ultimately cause patient
death.
WARNING 9.3 The manufacturer has validated all cleaning and sterilization cycles given in this manual. It is highly recommended that
the procedures given in this manual for cleaning and sterilizing the BoneScalpel System and related accessories be
followed. It is the responsibility of the user of this device or any accessories used with it to validate procedures for
cleaning and/or sterilization if they differ from the procedures as outlined in this manual.
Clean And Disinfect/Sterilize Reusable Items

The following items are considered reusable items and should be cleaned as recommended:
Handpiece
Counter wrench
T-wrench
Probe cover
Probe Cover and Wrenches
Wash & Brush Wash items with hot water mixed with an enzymatic detergent such as ASP Enzol ® or Steris
Prolystica® according to standard hospital protocol. Follow manufacturer’s directions for
preparing solutions.
Probe cover and wrenches may be fully immersed.
Brush all passages at least four (4) times from FRONT to REAR, rotating the brushes during
insertion and inserting the brushes fully. This ensures clearing of debris from the internal
passages.
Item’s exterior surface can be cleaned using a standard soft bristle cleaning brush.
Rinse Rinse item under warm running water for a minimum of 1 minute to clear soap residue.
Dry Dry item fully with absorbent towel or paper. Dispose of cloth or paper in accordance with
Hospital or Clinic practices for contaminated wastes.
Table 9.2 Cleaning of probe cover and wrenches
Handpiece
Wipe Cable Wipe cable with cloth or absorbent paper moistened with an enzymatic detergent such as
ASP Enzol or Steris Prolystica. Follow manufacturer’s directions for preparing solutions.
Clean all surfaces of bloodstains and obvious signs of decontamination.
Wash & Brush Wash and brush handpiece item with hot water mixed with an enzymatic detergent such as
ASP Enzol or Steris Prolystica. Follow manufacturer’s directions for preparing solutions.
The handpiece cannot be immersed.
Brush all passages at least four (4) times from FRONT to REAR, rotating the brushes during
insertion and inserting the brushes fully. This insures clearing of debris from the internal
passages.
The item’s exterior surface can be cleaned using a standard soft bristle cleaning brush.
Rinse Rinse item under warm running water for a minimum of 1 minute to clear soap residue.
Dry Dry item fully with absorbent towel or paper. Dispose of cloth or paper in accordance with
Hospital or Clinic practices for contaminated wastes.
Inspect Inspect handpiece and cable and remove any item which shows signs of damages (cracks,
gouges, fractures etc.). Mark damaged items clearly to prevent future use before disposal.
Table 9.3 Cleaning of handpiece
CAUTION 9.1 Use manual cleaning techniques only. Do not use ultrasonic cleaners or automated washers to clean the handpiece as
both methods could damage handpiece.

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CAUTION 9.2 Be certain to clear debris from all internal passages by brushing. Failure to do so may hinder sterilization of units
during autoclaving.
CAUTION 9.3 Do not immerse ultrasonic console, handpiece, irrigation pump, remote footswitch or electric cables. These items are
not sealed against liquids and damage to equipment will result.
Console and Footswitch
Wipe Surfaces Wipe footswitch and console, including irrigation unit, with cloth or absorbent paper
moistened with an enzymatic detergent such as ASP Enzol ® or Steris Prolystica®. Follow
manufacturer’s directions for preparing solutions. Clean all surfaces of bloodstains and
obvious signs of decontamination.
Dispose of cloth or paper with contaminated waste.
Table 9.4 Cleaning of console and footswitch
9.3. Sterilizing By Steam Autoclave
Reusable, autoclavable Components
MC632 Handpiece
MC628 T-Wrench
MC637 Handpiece/Counter Wrench
MC631 Probe Cover for hard tissue applications
MC638 Brush Set, Small

MC639 Brush Set, Large
Table 9.5 Autoclavable components
Validated Steam Sterilization Cycles
Sterilizer Type Pre-Vacuum at 132 °C | 270 °F Gravity at 134 °C | 273 °F
Preconditioning pulses 3 None
Minimum Temperature 132 °C | 270 °F 134 °C | 273 °F
Full Cycle Time 8 min 20 min
Minimum Dry Time 5 min 5 min
Cooling Time Allow items to cool gradually to room temperature prior use.
Sample configuration Wrapped Wrapped
Table 9.6 Steam sterilization cycles
9.4. Expected Life, Reusable Components

All handpiece components need to examined regularly, prior each use and be replaced if damaged.

BCA-UM RevD
The estimated sterilization life of handpiece components is listed below. All sterilization life estimates are
approximate and may be affected by rough handling, damage, wear due to vigorous cleaning, etc.
Estimated Sterilization Life
Item Number Of Steam

Sterilization Cycles
Handpiece with attached cable > 200 cycles
Probe cover > 300 cycles
Wrenches: > 300 cycles

Handpiece/counter wrench and T-wrench
Table 9.7 Estimated re-use life
NOTE 9.2 The reuse life given takes into account wear and tear due to cleaning and sterilization only. Damage or wear caused by
actual use in treatments will affect life of components.
9.5. Deviations From Decontamination, Cleaning And Sterilization Instructions

The manufacturer has validated all cleaning, disinfection and sterilization cycles given in this manual. It is highly
recommended that the procedures given in this manual for cleaning and sterilizing the BoneScalpel System and
related accessories be followed. It is the responsibility of the user of this device or any accessories used with it
to validate procedures for cleaning and/or sterilization if they differ from the procedures as outlined in this
manual.
Technical Assistance
Should the user wish further information or instructions regarding any aspect of cleaning or sterilizing
procedures, please contact Aesculap USA or an Authorized Representative.

BCA-UM RevD
10. Troubleshooting
The BoneScalpel system provides both visual and audible alert signals when the system is not functioning
properly.

Mechanical Limit Displays “LIMIT” alert located above amplitude setting

display.
Triggers a pulsed, audible alarm upon footswitch activation.
Temporarily deactivates ultrasound and irrigation functions.
1. Tip overload Release footswitch.

Reduce tip pressure and/or use higher amplitude setting as required.
Continue procedure.
2. Loose or Release footswitch.

damaged component Set ultrasound to STANDBY.
Remove silicone sleeve (if applicable) and probe cover.
Inspect extension probe and ultrasonic tip for damage. Replace if necessary.
Otherwise re-tighten extension probe and tip using the correct wrenches.
Set ultrasound to ENABLE.
Continue procedure.
3. Defective Handpiece If corrective action steps above are followed and alert continues, the handpiece may need
to be replaced.
Table 6.2 Mechanical limit alert and recommended corrective actions
Tip overload can occur during hard tissue removal when applying excessive tip pressure or facing strong tissue
resistance, e.g. from thick cortical bone. This can lead to stalling of the ultrasonic tip. A pulsed audible signal
alerts of the stalling and the ultrasound is deactivated. Release the footswitch briefly and reduce the tip
pressure, e.g. by retrieving the ultrasonic tip. Depress the footswitch again and continue with reduced tip
pressure. Consider using higher amplitude setting or reduced loading if stalling persists.

BCA-UM RevD

Electrical Fault Displays Electrical Fault Screen.
Triggers steady audible alarm.
Permanently deactivates ultrasound and irrigation. Requires

recycling of mains power switch to re-set.
1. Handpiece not Turn console OFF.

connected Check handpiece cable connection.
Restart console.
2. Defective Turn console OFF.

Handpiece Replace handpiece and restart console.
If problem persists replace console.
3. Defective console Turn console OFF.

Replace console.
Table 6.3 Electrical fault alert and recommended corrective actions
WARNING 10.1 If a Mains Power fuse fails after replacement when the unit is reactivated, discontinue use of the device and contact an
authorized Aesculap USA representative.

BCA-UM RevD
Lack of Irrigant
Symptons
No spray from tip when ultrasound is engaged
No flush fluid available
Unexpected temperature rise at operative site
Unexpected temperature rise of handpiece
None None None
Possible Cause Ultrasound Mode Corrective Action
1. Closed or Set ultrasound to STANDBY. Check fluid bag and tubing clamp. Replace fluid bag if
empty fluid bag necessary.
2. Tubing not Set ultrasound to STANDBY. Check tubing connections.

connected Check mounting in pump head. Close pump cover until
locked.
3. Tubing Set ultrasound to STANDBY. Check tubing for kinking, restrictions or leaks. Replace tubing
obstructed or if necessary.
defective Check mounting in pump head. Close pump cover until
locked.
4. Tubing installed Set ultrasound to STANDBY. Open pump cover. Reposition the tubing in direction of flow.
in reverse Close pump cover until locked.
5. Tubing slides Set ultrasound to STANDBY. Open pump cover. Adjust the grip of the tubing by turning
through pump the adjustment wheel underneath the front and back of the
pump assembly.
6. Pump defect Set ultrasound to STANDBY. Open pump cover. Check if pump rollers are rotating when
depressing footswitch. Replace console if they don’t.
Table 10.1 Troubleshooting – Insufficient Irrigation
WARNING 3.1 Tip and irrigant temperatures may exceed the tissue necrosis point if insufficient irrigation flow rates are used. For hard
tissue removal , set the irrigation flowrate to a setting no less than the comparable vibration setting. For example, if the
vibration setting is 7, a minimum flow setting of 70% should be used.
to plugging it in.
For all other malfunctions please contact Aesculap USA or an Aesculap USA authorized representative for service.

BCA-UM RevD
11. Specifications
Console Specifications
Power input 120VAC, 4 Amps, 60Hz

220 VAC, 2.5 Amps, 50/60Hz
230/240VAC, 2.5 Amps, 50Hz
Operating frequency 22.5 kHz
Ground leakage current 300 µA (max.)
Output power 130 Watts (max.)
Mode of Operation Continuous Wave

Pulse Wave
Controls Mains Power on/off switch (rear panel)

Footswitch control for ultrasonic and irrigation on/off
Ultrasound enable/standby button
Amplitude control
Pulse control
Flow control
Ultrasonic timer with reset
Menu button
Six screen-specific buttons
Irrigation pump Peristaltic pump
Pump flow rate Max flow > 67 ml/min.
Irrigation tubing Dedicated tubeset, sterile, single-use

Vented IV-spike, compatible with fluid bags and bottles
Dedicated handpiece connection
Handpiece cable 15 ft | 4.6m
Footswitch cable 14 ft | 4.3m
Power cord 10 ft | 3.0m
Operating conditions Temperature 55-95 F (13-35 C)

Relative humidity 20-90% (non condensing)
Standard atmospheric pressure
Shipping/storage conditions Temperature: 35-120 F (2-49 C)

Relative humidity: 10-95% (non condensing)
Ambient pressure extremes: 40,000 ft | 14,125m
Dimensions 7” H x 16” W x 19” D | 180mm H x 410 mm W x 485mm D
Weight 25.6 Lb. | 11.6 kg
Table 11.1 Console specifications

12. Service, Repair And Technical Correspondence
12.1. Fuse Replacement
create a shock or fire hazard. Confirm that the voltage selector switch in the console rear is set to the local voltage
setting and ensure that the correct fuses are being used. Refer to section 12 on fuse replacement
Fuse Specifications
Line Voltage Manufacturer Manufacturer Rating Description

P/N
120 VAC, 60 Hz Cooper/Bussman GDB-4 250V @4 A Fast Acting, Low Breaking
220/230/240 VAC, 50/60 Hz Littlefuse 021702.5 250V @ 2.5A Fast Acting
Table 12.1 Console fuse specifications
Fuse Replacement (The fuse holder is located on the console rear)
Disable Ultrasound Switch to Standby Mode using enable/standby button. Confirm that Amplitude setting
is HOLLOW GREY.
Switch Console OFF Switch console OFF and disconnect power cord.
Remove Fuse Holder
Pinch tab on fuse holder. Pull fuse holder out.
Replace Fuses
Replace both fuses as specified above.
Mount Fuse Holder Push fuse holder back into receptacle.
Switch Console ON Connect power cord and switch console ON
Check Function Confirm that console powers up and that Main Settings respond to activation of
buttons A-F.
Table 12.2 Fuse replacement

BCA-UM RevD
12.2. Pump Head Replacement

The pump head may not be connected to the unit for shipping purposes.
Mount Pump Head
Shaft recess and bayonet fitting on pump Pump drive shaft on console front
head rear
Position Pump Head Align drive shaft on console front and

shaft recess on pump head rear. Drive
shaft and recess must engage easily.
Rotate pump head slightly back and forth
to check engagement.
Turn pump head 45°clockwise.
Lock pump head in place Turn pump head clockwise until it locks in place. Arrow should be in the vertical
position pointing down.
Table 12.3 Assembly of pump head
Remove Pump Head
Disable Ultrasound Switch to Standby Mode using enable/standby button. Confirm that Amplitude setting
is HOLLOW GREY.
Switch Console OFF Switch console OFF and disconnect power cord.
Remove Tubing Open pump cover. Remove tubing. Close pump cover.
Release Pump Head
Press and hold lock lever

on pump head bottom.
Turn pump head 45° counter clockwise.
Remove pump head Pull pump head away from console until pump drive shaft clears. Release lock lever.
Table 12.4 Disassembly of pump head
12.3. Repair, Service and Replacement Parts

All requests for repairs and replacement parts should be directed to Aesculap USA or an authorized Aesculap
USA representative. Always provide model and serial number of malfunctioning items.
When returning items include model, serial and RMA number as well as purchase order number on all
documents. Always prepay return shipping and specify method of shipment.

BCA-UM RevD
CAUTION 12.1 Use only genuine replacement parts from Aesculap. Use of parts furnished by other sources may result in patient or
operator injury or system malfunction and will void any applicable warranty.
CAUTION 12.2 Before using loose packing materials, such as foam pellets, shredded paper or similar, be sure to wrap the
component(s) separately in plastic bags, film or other protective wrapping.
12.4. Important Notice
Please contact Aesculap USA with any questions regarding the specifications, use, sterilization, limitations or
maintenance of the BoneScalpel System:
Aesculap, Inc.
Web www.aesculapusa.com
Email [email protected]
Phone +1-800-258-1946
Customer Service: 1-800-282-9000
Technical Service: 1-800-214-3392
Address 3773 Corporate Parkway
Center Valley, PA 18034
U.S.A.
By returning any material to Aesculap USA the customer or the customer's agent must certify that
any and all materials so returned are or have been rendered free of any hazardous or noxious
matter or radioactive contamination and are safe for handling under normal repair shop conditions.
Do not return any material for which such certification cannot be made without prior approval from
Aesculap USA.
The correct return address should read as follows:
Aesculap, Inc.
615 Lambert Pointe
RMA#: ___________
Hazelwood, MO 63042
Phone: 1-800-258-1946
U.S.A.
Distributed in the U.S.A. by: Aesculap, Inc.

3773 Corporate Parkway
Center Valley, PA 18034
Phone: 1-800-258-1946
Manufactured by: Misonix, Inc.

1938 New Highway
Farmingdale, NY 11735
Phone: 1-800-694-9612
SOP-AIC-5000808 Rev2 Effective- 07/12/12 Page 47 of 47

BCA-UM RevD

BCA-UM RevD
Customer Service: 1.800.282.9000, Technical Service: 1.800.214.3392

3773 Corporate Parkway, Center Valley, PA 18034, U.S.A.

BCA-UM RevD

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BoneScalpel™ System

Instructions For Use

SOP-AIC-5000808 Rev2 Page 1 of 47

SOP-AIC-5000808 Rev2 Page 2 of 47

1. General Safety Statements

1.1. EMC Statement

Electromagnetic Compatibility Guidance (in accordance with EN/IEC 60601-1-2:2007)

SOP-AIC-5000808 Rev2 Page 3 of 47

Guidance And Manufacturer’s Declaration – Electromagnetic Immunity (Table 202)

Surge o ±1 kV differential o ±1 kV differential Mains power quality should be that of a

Table 1.3 List of cables

SOP-AIC-5000808 Rev2 Page 4 of 47

Guidance And Manufacturer’s Declaration – Electromagnetic Immunity (Table 204)

Radiated RF 3 V/m 3 V/m d 2.3 P 800 MHz to 2.5 GHz

Field strengths from fixed RF transmitters, as deter-

Interference may occur in the vicinity

SOP-AIC-5000808 Rev2 Page 5 of 47

Recommended Separation Distances Between Portable And Mobile RF

Separation distance according to frequency of transmitter

Table 1.5 Recommended separation distances (EN table 206)

1.2. Electrical Safety Statement

1.3. Environmental Statement

SOP-AIC-5000808 Rev2 Page 6 of 47

1.4. Summary Of Safety Notices

Conventions on Warnings, Cautions and Notes

NOTE Indicates potential hazard that may result in product damage.

Table 1.6 Conventions on warnings, cautions and notes

SOP-AIC-5000808 Rev2 Page 7 of 47

heat and cause burns.

SOP-AIC-5000808 Rev2 Page 8 of 47

SOP-AIC-5000808 Rev2 Page 9 of 47

1.5. Trademark Information

SOP-AIC-5000808 Rev2 Page 10 of 47

1.6. Explanation Of Symbols

Console Related Symbols

Symbol Description Symbol Description Symbol Description

Enable / Standby Caution:

Scroll through Caution:

Must use hospital

Contains DEHP Footswitch

Table 1.7 Explanation of symbols

SOP-AIC-5000808 Rev2 Page 11 of 47

2. Indications And Contra Indications

2.2. Contra Indications

SOP-AIC-5000808 Rev2 Page 12 of 47

Limits For Airborn Acoustic Exposure

SOP-AIC-5000808 Rev2 Page 13 of 47

4. Considerations During Clinical Use

Figure 4.1 Correct hand position

Figure 4.2 Incorrect hand position

SOP-AIC-5000808 Rev2 Page 14 of 47

4.2. HARD Tissue Use

Amplitude Pulse Flow

SOP-AIC-5000808 Rev2 Page 15 of 47

Tip Limitations During Bone Removal

SOP-AIC-5000808 Rev2 Page 16 of 47

Figure 5.1 BoneScalpel Console

Figure 5.2 BoneScalpel Handpiece

SOP-AIC-5000808 Rev2 Page 17 of 47

5.2. Reusable System Components