Service Manual

English Language Version

 LIMITED WARRANTY

For a period of two years following the date of delivery,

CONMED Corporation warrants the Excalibur Plus PC™
Electrosurgical Unit 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.

This device contains components which will be damaged

by static electricity. Proper handling by a grounded person
is mandatory. CONMED will provide assistance if needed
in safeguard precautions necessary to avoid any question
of warranty responsibility

U.S. Patent Nos. 4,437,464 - 4,569,345 -

4,617,927 - 4,848,335 - 4,961,739 - 4,626,575
and other patents pending.

O 1998 CONMED Corporation

310 Broad Street
Utica, New York 13501 U.S.A.
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
Burckhardtstr 1
D - 30163 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).

Sections 1 and 2 of this manual duplicate the Excalibur

Plus PC® Operator’s Manual, Cat. No. 60-6291-ENG.

Manual Number 60-6292-ENG Rev. A

 Table of Contents
& List of Illustrations
Section Title

GENERAL INFORMATION
Cautions
Cautions For Equipment Preparation ...
Cautions For Patient Preparation
Cautions For Use
Cautions For Testing or Servicing ....
Specifications
Explanation of Symbols .
Output Characteristic Curves .
INSTALLATION & OPERATION
Initial Inspection
Installation ........
Preliminary Checks . ーー
Preliminary Functional Testing ....
Preliminary Performance Testing . . .
Controls, Displays and Connectors .
Control Panel
Output Panel
Rear Panel
Operating Instructions ... .
Preliminary Set Up....
Operation . нь
Program Mode ..........................
Storing Programs .....
Using Programs . . RR
Remote Power Control Mode ................
Changing Monopolar Power Remotely . .
User Maintenance ................. .
General Maintenance Information ......
Cleaning
Periodic Inspection
Periodic Performance Testing .
In Case of Difficulty ..........
Return Monitor Alarm . .
Single Pad Alarm ...
Dual Pad Alarm ....
ACC Faults ............
Err Faults ...............
If All Else Fails
Environmental Protection
cc e ООО
Section Title

THEORY OF OPERATION
Functional Block Diagram Description ...
Power Supplies and Distribution . .
Controller Hardware
Watchdog Timer (WDT) ....
Power On Reset . .
Controller, 1/O . . .
Memory
Base Voltage Generator
IFAIL DAC
Waveform Generator
Tone Generator
Base Voltage Monitor .
Waveform Monitor .
Tone Monitor ... . .
Controller Software . . ーー
Software Initialization and Test Function: .
Working Program Functions ................
CAL Mode Software
Calibration ..
Diagnostics . .
Last Fault Code . .
Display Hardware
Indicators
Displays and Keyboard
Power Amplifier . . . .
RF Output Section .
Aspen Return Monitor (A.R.M.) Circuitry and Software . . . 3-13
Continuity Detector . . „3-15
Footswitch Isolation . 3-16
MAINTENANCE ーー
General Maintenance Information . . 41
Assembly Breakdown & Parts Access . . 41
Display PWB A2 41
Controller Assembly A3 ...... 4-1
Power Conversion Assembly A4 42
Output Assembly A5 ーーー 42
Power Transformer and Resonating Capacitor . 42
Primary Strapping ....... 42
Replacing A9T1 and A6C1
Cleaning
Periodic Inspection .
Periodic Performance Testing ..
Chassis Ground Integrity
Displays, Alarms, Commands .... . 4-7
Output Power . 4-7
ВЕ Leakage .... .. 4-8
RF Leakage From Inactive Outputs . 4-9
Line Frequency Leakage 4-10
Aspen Return Monitor (A.R.M.) Calibration Check 4-11

a mme
 Section © Title
4.5.8 +5 Over Voltage Monitor Check .
4.6 Calibration and Adjustments .... .
i 4.6.1 CAL Mode Entry
4.6.2 CAL Mode Menu .........................
4.6.2.1 Entering a Mode and Returning to the Menu
4.6.2.2 Calibrated/Uncalibrated Status
4.6.2.3 Calibration Limits and Validity Tests
4.6.2.4 Exiting CAL Mode
| 4.6.3 Output Power Calibration Procedure .
4.6.3.1 Monopolar Power Calibration (C-C)
4.6.3.2 Bipolar Power Calibration (bP)
4.64 A.R.M. Calibration (PAd) .
1 Troubleshooting . . . =
Fault Codes ...
Checking and Clearing Last Fault Code
Pseudo Run Diagnostics (dIA 2)...........
Watchdog Timer Troubleshooting (dIA 1)
Accessing Watchdog Timer Diagnostics
dIA 1 Mode Selection
Troubleshooting with Watchdog Timer (dIA 1) . .
Base Voltage Generator Troubleshooting
Waveform Generator Troubleshooting
Aspen Return Monitor (A.R.M.) Troubleshooting . . .
RF Amplifier Troubleshooting
Power Amplifier Transistor Replacement . .
Troubleshooting Resets ......................
4.7.10 Interference with Other Equipment
4.8 Parts Ordering Information
49 Parts Lists, PWB Layouts & Schematics
Appendix A FaultCodes ............................ 0. eee

The Table of Contents for Figures, Tables and Schematics is listed on the next page.
 cl e 005g-
Figure Title Page I
11 Output Power vs. Power Setting. 1-9
12 Display vs Open Circuit Peak Voltage .. 1-9
13 Load Regulation, Monopolar Pure and Blend 1 Cut. 1-10
1.4 Load Regulation, Monopolar Blend 2 and Blend 3 Cur 1-11
1.5 Load Regulation, Monopolar Coag . . . 1-12 I
1.6 Load Regulation, Bipolar 1-13
2.1 Controls, Displays & Connectors
22 Patient Accessory Connections 212 G
23 Accessory Schematics .. 2-13
3.1 Base Voltage Generator Transfer Curve
3.2 Basic Inverting Break Point Amplifier . .
3.3 Basic Hybrid Cascode Configuration 3-12
34 Resistance vs. Bar Graph Indicator . 3-4
3.5 Power Amplifier Waveforms ......
3.6 RF Output Voltage Waveforms . I
3.7 Miscellaneous Waveforms . .
4.1 Rear Panel Screw Location .
42 Display, Controller & Footswitch Isolation PWB Locations i
4.3 Power Conversion & Output PWB Locations s
44 A2 Display PWA
45 A3 Controller PWA 1
4.6 A4 Power Conversion PWA
4.7 A5 Output PWA ー o...
4.8 A10 Footswitch Isolation PWA ........................................ - 1

Table Title

41 RF Output Power Checks .... J

4.2 RF Leakage to Ground Tests
4.3 ВЕ Leakage for Inactive Outputs Test .... =
44 Unkeyed Line Frequency Leakage Tests . 1
4.5 Keyed Line Frequency Leakage Tests . . .
4.6 Cal Mode Options .......
47 dIA 1 Modes |]
Schematics Title

4.0 Functional Block Diagram i

4.1 Interconnect and Power Supply .
42 Control Panel =
43 Display PWA м
4.4а Controller PWA, Sheet 1
4.4b Controller PWA, Sheet 2
45 Power Conversion .......
4.6 Output
4.7 Mains Voltage and Frequency Variations
4.8 Footswitch Isolation ........................
 General Information
Section 1.0

This manual provides the set up, operating * Controlled output voltage provides superior cut
instructions and servicing information for the independent of tissue impedance.
Excalibur Plus PC™. Electrosurgery can be dan-
gerous to patients, staff, and other equipment if * Dual activation in non-contact coagulation
misused, therefore, please understand and follow modes.
the warnings and cautions that are included in
this manual. Technical specifications, various * Ability to change power settings from the con-
characteristic performance curves, and user main- trol panel while the unit is activated.
tenance instructions are also included.
1.1 CAUTIONS
The Excalibur Plus PC!" provides a broad range
of capabilities in a single general purpose electro- This equipment, in conjunction with connect-
surgical generator. This rugged unit fulfills the ed accessories, is intended to produce high-
operational and safety needs of the modern oper- frequency electrical energy for the controlled
ating room by providing: destruction of tissue.

* Four monopolar cutting modes. Safe and effective electrosurgery is dependent

not only on equipment design, but also on fac-
* Two monopolar coagulation modes. tors under the control of the operator. It is
important that the instructions supplied with
* Two bipolar modes. this equipment be read, understood, and fol-
lowed in order to ensure safety and effective
* RF isolated and independent outputs. use of the equipment.

* The proven A.R.M.™ contact quality monitor- 1.1.1 CAUTIONS For Equipment Preparation
ing system.
+ Use only accessories that meet the require-
* Continuous microprocessor monitoring to pro- ments of Section 1.2 and Figure 2.3.
vide the safety required by the conscientious user.
* Reusable accessory cables should be periodi-
Convenience features include: cally function and safety tested in accordance
with the original manufacturer's instructions.
+ Remote Physician Control of power settings * Visually inspect all accessories before each
using standard hand switched pencils (PC mode). use to verify the integrity of insulation and the
absence of obvious defects. In particular, elec-
* Independent power setting for each mode. trode cables and endoscopic accessories should
be checked for damage to the insulation.
* Automatic programming restores unit to the
last settings used. * The Excalibur Plus PC™ is equipped to con-
nect three monopolar accessories at one time
+ Easy programmability to speed set up of the for the convenience of the surgical staff.
unit. Unused accessories should be stowed in a safe,
electrically insulated place such as a noncon-
ductive holster, isolated from the patient. We
recommend that accessories not be connected
unless it is known that they will be needed.
 rs ec ME
* Use only a hospital grade, 3-prong, power of pooling of flammable solutions in body
cord rated to meet the specifications in Section depressions such as the umbilicus and in body
1.2 and all of the requirements for safe cavities, such as the vagina. Any fluid pooled
grounding of the unit. The user should veri- in these areas should be removed before the
fy that the power receptacle with which this high frequency surgical equipment is used.
unit is used is properly grounded and correct- Due to the danger of ignition of endogenous
ly polarized, and of the proper frequency per gases, the bowel should be purged and filled
Section 1.2. Do not use ground cheater plugs with nonflammable gas prior to abdominal
or extension cords. surgery. To avoid the risk of tracheal fires,
never use electrosurgery to enter the trachea
* Do not place liquid containers on top of the during tracheotomy procedures.
unit. Wipe spilled liquids off the unit immedi-
ately. To preclude inadvertent entry of liquids, * Only non-flammable agents should be used
do not operate this unit except in its normal for cleaning and disinfection wherever possi-
position. ble.

* Confirm that all accessories are properly * This unit is equipped with the Aspen Return
connected to the appropriate jacks. Monitor (A.R.M.) which verifies that the
return electrode cable is unbroken and con-
* Potentially hazardous conditions may exist nected to the return electrode and to the elec-
when accessories of similar connector types are trosurgical unit when in Single Pad mode. It
combined. Be certain that accessories are DOES NOT verify that a single pad return
appropriate for the type of generator output electrode is in contact with the patient. When
used. Use only CONMED/Aspen Labs foot- in Dual Pad mode, the A.R.M. confirms that
switches. Confirm bipolar leads are connected the total resistance is in the preset safety
only to the bipolar jacks. Connecting bipolar range. Proper application and visual inspection
accessories to monopolar outputs may result of the return electrode are required for safe
in patient injury. operation.

* Do not reuse disposable (single use) acces- * The use and proper placement of a return
sories. electrode is a key element in safe and
effective electrosurgery. Follow manufacturer's
* Do not use cords as handles; damage to the directions and recommended practices for the
insulation and increased risk of burns or other preparation, placement, use, surveillance, and
injury may result. removal of any return electrode supplied for
use with this electrosurgical unit.
1.1.2 CAUTIONS For Patient Preparation
* Apply the return electrode over a well vascu-
* Electrosurgery should NEVER be per- larized muscle mass that is thoroughly clean
formed in the presence of flammable anesthet- and dry. Clean and shave site as necessary to
ics, flammable prep solutions or drapes, oxi- provide adequate electrical connection and per
dizing gases such as Nitrous Oxide (N70), or hospital policy. Avoid placement over scar tis-
in oxygen-enriched environments. The risk of sue, bony prominences or other areas where
igniting flammable gases or other materials is pressure points on small areas might develop.
inherent in electrosurgery and cannot be elim-
inated by device design. Precautions must be * Because of the risk of burns, needles should
taken to restrict flammable materials and sub- never be used as return electrodes for electro-
stances from the electrosurgical site, whether surgery. The entire area of the return electrode
they are present in the form of an anesthetic, should be placed so that the entire conductive
life support, skin preparation agent, or are area is in firm contact with an area of the
produced by natural processes within body patient’s body that has a good blood supply
cavities, or originate in surgical drapes, tra- and is as close to the operative site as is possi-
cheal tubes, or other materials. There is a risk

A©
E + +++
ble. In general, electrosurgical current paths equipment specifically designed to tolerate
should be as short as possible and should run electrosurgical interference. Cables subject to
either longitudinally or in a diagonal direction flexing should be inspected frequently for
to the body, not laterally and under no cir- shielding integrity.
cumstances lateral to the thorax.
* The patient should not be allowed to come
+ Electrodes and probes of monitoring, stimu- into contact with metal parts that are ground-
lating, and imaging devices can provide paths ed, or have an appreciable capacitance to
for high frequency currents even if they are earth. Examples of this would be operating
battery powered, insulated, or isolated at tables, supports, etc. The use of anti-static
50/60 Hz. The risk of burns can be reduced. sheeting is recommended. It is recognized
but not eliminated by placing the electrodes of that this recommendation may not be practical
probes as far away as possible from the elec- during certain procedures (e.g., those in which
trosurgical site and the return electrode. uninsulated head frames are used); however,
Protective impedances incorporated in the to maximize patient safety during the use of
monitoring leads may further reduce the risk electrosurgical devices, such practices should
of these burns. Needles should not be used as be minimized.
monitoring electrodes during electrosurgical
procedures. * Skin to skin contacts, such as between the
arm and the body of a patient, should be
* When high frequency surgical equipment avoided, by the insertion of dry gauze.
and physiological monitoring equipment is
used simultaneously on the same patient, any * The use of electrosurgery on patients with
monitoring electrodes should be placed as far cardiac pacemakers, pacemaker electrodes, or
as possible from the surgical electrodes. other active implants is potentially hazardous.
Needle monitoring electrodes are not recom- The pacemaker may be irreparably damaged
mended. In all cases, monitoring systems and/or the high frequency energy of the elec-
incorporating high frequency current limiting trosurgical output may interfere with the
devices are recommended. action of the pacemaker. Ventricular fibrilla-
tion may occur.
* The active electrode should not be used in
the vicinity of electrocardiograph electrodes. Precautions should be taken to ensure that the
patient's well-being is maintained in the event
* Heat applied by thermal blankets or other of such interference. We recommend that the
sources is cumulative with the heat produced Cardiology Department and the manufacturer
at the return electrode (caused by electrosurgi- of the pacemaker be consulted for advice
cal currents). Risk of a patient injury may be before operating on a patient with a pacemak-
minimized by choosing a dispersive electrode er. These precautions also apply to operating
site that is remote from other heat sources. room personnel with cardiac pacemakers.

+ When using injection cannulas as electrocar- + To minimize the possibility of cardiac pace-
diograph electrodes, the metal cone must not maker interference, place the return electrode
be placed on the skin; this also applies to the such that the electrosurgical current path is as
leads to monitoring instruments. far as possible from the pacer lead.

* Electrosurgery by it's nature produces signif- 1.1.3 CAUTIONS For Use

icant levels of electromagnetic interference
(EMI) when the ESU is activated. This EMI * PLEASE NOTE: Effective November 29,
may damage or impair the function of other 1991, federal law (U.S.A.) requires that all
electronic equipment in the O.R., especially healthcare facilities must report to the manu-
that which makes contact with the patient. facturer of a medical device, any death or seri-
Adverse effects can be mitigated by use only of ous injury or illness to a patient related to the
Excel

use of a medical device. Serious injuries ог Ш- expected effect at otherwise normal settings
ness involving the use of a medical device may indicate faulty application of the return
must be reported to the manufacturer of the electrode, failure of an electrical lead, or exces-
device (or to the FDA if the manufacturer of sive accumulation of tissue on the active elec-
the device is not known) within 10 working trode. Do not increase power output before
days of the incident. Summary reports of checking for obvious defects or misapplica-
such injuries must also be submitted directly tion. Check for effective contact of the return
to the FDA twice a year. Patient deaths relat- electrode to the patient anytime that the
ed to the use of a medical device must be patient is moved after initial application of the
reported to the manufacturer and the FDA. return electrode.
For further information, please contact the
Regulatory Affairs Department of CONMED * Studies have shown that smoke generated
Corporation at 800-552-0138, 303-699-7600, during electrosurgical procedures may be
or FAX 303-699-9854. harmful to surgical personnel. These studies
recommend using a surgical mask and ade-
* A failure of the unit could result in an unin- quate ventilation of the smoke using a surgical
tended increase in output power. smoke evacuator or other means.

* Safe and effective electrosurgery is depen- * If a Dual Pad RETURN Alarm is sounded
dent not only on equipment design, but also intraoperatively, physically confirm proper
on factors under the control of the operator. return electrode attachment to the patient
It is important that the instructions supplied prior to pressing the Monitor Set key. Smooth
with this equipment be read, understood, and hand over pad surface to ensure electrode con-
followed in order to ensure safety and effec- tact to patient skin. Replace the pad, if neces-
tive use of the equipment. sary.

* Do not use monopolar electrosurgery on * Simultaneous activation can be used in both

small appendages, as in circumcision or finger Standard and Spray monopolar coagulation
surgery, as it can cause thrombosis and other modes. Caution should be used as the output
unintended injury to tissue proximal to the from either active electrode may change as a
surgical site. Please note ANSI/AAMI result of: activation of a second output, end-
Standard HF-18-1993 which currently con- ing activation of an output, or changing the
traindicates both monopolar and bipolar elec- arc length from an output. Power sharing is
trosurgery for circumcisions. unlikely to be equal because of differences in
tip to tissue distance and other factors. This
Urologic literature also contraindicates the use unequal power sharing can be enough to stop
of monopolar electrosurgery for circumcision, power delivery to one tip if the second tip is
and instead recommends the use of bipolar close to tissue, and the first tip is somewhat
electrosurgery where clinically indicated for above the tissue. The motion or deactivation
hemostasis. Physicians choosing to use bipo- of one electrode can cause the other electrode
lar electrosurgery for circumcisions should be to start delivering power when it had been too
trained in this technique and knowledgeable far away from tissue to arc before the first
of the effects of electrosurgery on tissue of electrode change. It is recommended that a
this nature. second electrosurgical generator be used as a
better alternative when it is necessary to per-
Should you decide that the bipolar electrosur- form simultaneous operation.
gical technique is acceptable for circumcision,
do not apply the bipolar electrosurgical cur- * Electrosurgical leads (active, bipolar or
rent directly to circumcision clamps. return) should not be allowed to contact the
patient, staff, or other electrical leads connect-
* Apparent low power output or failure of the ed to the patient.
electrosurgical equipment to provide the

© 때
* The output power selected should be as low * The high voltage DC power supply in the
as possible and activation times should be as Excalibur Plus PC™ is equipped with a bleed-
short as possible for the intended purpose. er resistor to dissipate the charge on the filter
capacitor. However, it takes several seconds
* When uncertain of the proper control set- after power is removed to bleed that charge
ting for the power level in a given procedure, down to a safe level; it is recommended that at
start with a low setting and increase as least thirty (30) seconds be allowed to elapse
required and/or consult the manufacturer. before touching or attempting to perform any
maintenance involving the power supply or
* Observe all caution and warning symbols power amplifier.
printed on the cover of the unit.
+ Never remove or install any parts with
* The operating room staff should never con- power on.
tact electrosurgical electrodes (either active or
dispersive) while the RF output of the unit is * Avoid contact with the output leads when
energized. the unit is activated. Periodically inspect the
test leads used for the output connections for
* The tips of recently activated accessories obvious defects.
may be hot enough to burn the patient or
ignite surgical drapes or other flammable * Although this unit will withstand momen-
material. tary short circuits on the output, prolonged
short circuits may damage the unit. Short cir-
* Do not ignore unexpected activation tones. cuiting the output should be avoided since it
Check to determine the cause of the tone, oth- is neither necessary nor desirable.
erwise injury can occur.
* Since the clinical use of electrosurgical units
* Temporarily unused active electrodes should is intermittent in nature with duty cycles on
be stored in an electrically insulated container. the order of 10%, this unit is not designed to
The unused active electrode should never be operate for extended periods of continuous
placed on the patient. This is especially impor- output. When testing, it is recommended that
tant for laparoscopic procedures. duty cycles be limited to 50% with maximum
activation times of 30 seconds.
1.1.4 CAUTIONS For Testing or Servicing
* Life of the equipment will be extended by
* Service should not be attempted without minimizing operating temperature and
reference to sections 3 and 4 of this manual. extreme thermal cycles.

* This electrosurgical unit should be tested by * The heat dissipation capability of the heat
qualified maintenance personnel on a periodic sink is impaired by activating the Excalibur
basis to ensure proper and safe operation. It is Plus PC™ in other than its normal operating
recommended that examination of the unit be position.
performed at least yearly.
¢ Ensure that the two top cover screws are
* Refer all servicing to qualified personnel. tightened, and always perform a power-up
Your CONMED representative will be happy check to confirm a normal power-up sequence
to assist you in getting your equipment ser- before returning the unit to service.
viced.

* High voltages are developed within the unit

that are accessible when the top cover is
removed. These voltages are potentially dan-
gerous and should be treated with extreme
caution.

a
Exec MI rr
1.2 SPECIFICATIONS
INPUT POWER: 700 W max.
Mains Voltage Max Mains Current Mains Circuit
VRMS ARMS Breaker Rating

Catalog Freq. Nom. Min. Max. Nominal Max.

Number $ Hz Mains
Mains Freq. (+1 Hz) Idle

160-6290-120 60 120 104 127 0.8 7.0 10A/120V

60-6290-226 60 220 198 242 0.5 3.8 5A/240V

60-6290-230 50 220-230 198 253 0.5 3.8 5A/240V

|60-6290-240 50 240 216 264 0.4 3.5 5A/240V

60-6290-100 50-60 100 90 110 10 84 10A/120V

MAINS OVERCURRENT PROTECTION: POWER DISPLAY ACCURACY: The greater of

Combined 2-pole circuit breaker/power switch +/- 10% of display or +/-3 watts at rated load.
MAINS FREQUENCY LEAKAGE: LINE REGULATION: Power change < 1%/V
(Per IEC 601-1) for VLINE = Min to Max Voltage
Patient Connections to Neutral: Less than 10 yA
Chassis to Neutral: Less than 25 wA (120 V) Duty Cycle: 15s on, 30s idle
Less than 45 A (240 V)
ENVIRONMENTAL
TEC Class I, Type CE, Defibrillator Proof 4 v ト Operating Conditions: 10°C to 30°C,
95% RH Non-Condensing maximum

Non-Ionizing Radiation VW MOUNTING RESTRICTION: 2 inch (5cm)

clearance required on each side and above unit for
cooling.
REGULATORY CERTIFICATION
COOLING: Natural convection, conduction and
radiation. No fan.
UL Listed, Medical and Dental Eguipment
(E68077) Storage Conditions: -40°C to 70°C, altitude -60
to +4500 m MSL when sealed in original poly-
ISO 9002:1994 Registered Facility bag, packing material and shipping carton.

Prior to shipment or storage, the unit should be

C € 0123 enclosed and sealed in a polyethylene bag and
placed in original carton using original packaging
materials.

a€ ή
RF Leakage: POWER CORD: All units are supplied with an
<100 mA per IEC 60601-2-2 TEC-320 250V 10A 65° C mains inlet connector.
The power cord must be ordered separately from
PAD MONITOR: CONMED Corp. The appropriate power cord
SINGLE PAD MODE: Two wire continuity must be rated at a minimum of 250V, LOA,
detector, typical threshold = 10 ohms. 1.5mm’ (#18AWG) Cu.
DUAL PAD MODE: Two wire resistance moni-
tor, typical acceptance range 10 to 150 ohms, trip WEIGHT: 40 Ib. 12 oz. (18.5 Kg) 60 Hz Units;
threshold typically 20% higher than last MONI- 19.5 Kg (43 lbs.) 50 Hz Units
TOR SET POINT activation, visual indication of
patient resistance. HEIGHT: 6.25 inches (15.9 cm)
WIDTH: 15.9 inches (40.4 cm)
AUDIO SPECIFICATIONS: DEPTH: 22.75 inches (57.8 cm)
Cut = 520 Hz
Coag = 400 Hz SPECIFICATIONS SUBJECT TO
Operator Error = 1710 Hz, pulsating CHANGE WITHOUT NOTICE
Plate Alarm = 1000 Hz (65 dbA minimum)
Machine Fault = 1000 Hz
(45 dba min. except Alarms are 65 dba min.)

OPERATING MODES and

NOMINAL OUTPUT PARAMETERS:

MAX RATED | TYPICAL MAXIMUM CARRIER | PULSE

POWER | LOAD | CREST OPEN CIRCUIT | FREQ. REPETITION
¡MODE (watts) (ohms) | FACTOR VOLTAGE (P-P) | (KHz) FREQ. (KHz)

IMonopolar
Pure Cut 300 300 1.7-1.9 1650 416.7 Continuous
Blend 1 Cut | 180 300 2.3-2.5 1800 416.7 20.0
Blend 2 Cut | 120 300 2.9-3.2 1900 416.7 20.0
Blend 3 Cut | 80 300 3.6-4.0 2000 416.7 20.0
Std. Coag 120 300 6.2-6.5 6500 540 40.0
Spray Coag | 80 500 8.0-9.0 10000 540 20.0
Bipolar
Cut 50 50 1.6-1.8 350 1000 Continuous
Coag 50 50 1.5-12.0 350 1050 20.0
(Bipolar Coag
crest factor
decreases with
power setting.)
 MI rrrr_r_r_—__r_._._.._.._
1.3 EXPLANATION OF SYMBOLS

CONTROL PANEL OUTPUT PANEL

+ Pure Cut waveform with minimum

thermal damage and hemostasis
Blend 1-Cut waveform with moderate
Handswitched Output - Connection for
handswitched monopolar accessories
hemostasis Footswitched Output - Connection for
footswitched monopolar accessories
| Blend 2-Cut waveform with heavy

Pasai- |
hemostasis High Voltage Outputs
Blend 3-Cut waveform with maximum
hemostasis Bipolar Output - Connection for bipolar
Standard Monopolar Coagulation accessories
トキ

Spray Monopolar Coagulation Handswitched Bipolar Output

Return Fault Alarm - Monopolar output Footswitched Bipolar Output
is disabled Type CF - Patient connections are isolated
Return Electrode Monitor set from earth and resist the effects of difibrilla-
tor discharge
vr hg

Resis nce - In Dual Pad mode, indicates rel- Return Electrode - Connection for monopo-
ative resistance of return electrode lar dispersive electrode
contact with the patient
RF Isolated - Patient connections are isolat-
Single Pad - Used with electrodes that do ed from earth at high frequency
not monitor contact quality
Consult accompanying documents prior to
Dual Pad - Sets monitor to use electrodes placing equipment in service
that do monitor contact quality
TOP COVER
Bipolar Coagulation Consult accompanying documents prior to
Bipolar Cut placing equipment in service
DP

CAUTION - High Voltage Inside - Refer

Sede

Program servicing to qualified personnel

Program Store Explosion risk if used with flammable anes-
thetics

Remote Power Control This equipment intentionally supplies non-

ionizing RF energy for physiological effect
INTERIOR Enclosure resists entry of vertically falling
IPX1
Replace Fuse only with type and rating water
as shown
REAR PANEL
OD

Protective Earth (Inlet Connector)

Equipotential Ground Stud
High Voltage Circuitry
Footswitch Connector
 [re
1.4 OUTPUT CHARACTERISTIC CURVES
Figure 1.1 illustrates output power delivered to rated load for all available modes. Figure 1.2 illustrates the
maximum peak voltage available at a given power setting and output mode. Section 1.2 specified rated loads
and maximum power for each mode, while Figures 1.3 - 1.6 illustrate output power delivered to a range of
load resistances for each mode.

350

300
SPECIFICATION
WATTS TO RATED LOAD

250 LIMITS >

POWER OUTPUT

200

150

100

50

04
0 100 200 300
POWER DISPLAY
Figure 1.1 Output Power vs. Power Setting

6000

5000

4000
VOLTS (PEAK)

3000

2000

и
na

100 150 200 250 300

POWER SETTING

Figure 1.2 Display vs Open Circuit Peak Voltage

di] I
Figure 1.3 Load Regulation, Monopolar Pure and Blend 1 Cut a

Pure Cut |
350

300 300 I

3
< 250
'
Us 20 150 ||
2 | Tİ I
E 15

E o 7| = a
35
° || I
0
O 200 400 600 800 1000 1200 1400 1600 1800 2000 ||
LOAD RESISTANCE (OHMS)

Blend 1 Cut I

> 180 i
= i
== |
| 90 I
8 100 |

Е
上
I
5o 50 /| 35
DA E = I

O 200 400 600 800 1000 1200 1400 1600 1800 2000 ㅣ
LOAD RESISTANCE (OHMS) i

1-10 ra) |
 re it PC
Figure 1.4 Load Regulation, Monopolar Blend 2 and Blend 3 Cut

| 2 Cut
Blend
' 140

tm PS 120
_ 1

= | |
5 © 60
è는
a в
ιτ
в | AS
53 ο / 35 == Y
20

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000

LOAD RESISTANCE (OHMS)

3 Cut
Blend
90
80
80

= 60 MN
EUs oil 40
o | (| 一
Π40
5로 e „l
3 „l OA
=
10 /
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
LOAD RESISTANCE (OHMS)

re 111
Ecos ec NS i
Figure 1.5 Load Regulation, Monopolar Coag a

Standard 1
140 T
120
120 トー ゴ i
TT
OA

s
_ 10
i
ğ 80

8
È 60 |
| ==" | I
a. | 一 一一
5 4ο 35 i
o PAL]

°0 I
0 200 400 600 800 1000 1200 1400 1600 1800 2000 a
LOAD RESISTANCE (OHMS)

Spray
90 | 1
во 80
РЕ |
то / + ーー I

E al I
Set
6 40|-一|
sа
a 40

30
| EL | I
è3 » al A
10
oO I
200 400 600 800 1000 1200 1400 1600 1800 2000
LOAD RESISTANCE (OHMS) i

1-12 ¡e I
 -ee
Figure 1.6 Load Regulation, Bipolar

Bipolar Coag
| 55
|
45
_ 40
Es
|| E 30
$a 2
E
2 2
E
8 6
10
5
0
0 100 200 300 400 500 600 700 800 900 1000
LOAD RESISTANCE (OHMS)

Bipolar Cut
55
50
45
_ ©
Ècc ss
z 90
o
@ 25
E
а 2
는
o 15
10
5
0
0 100 200 300 400 500 600 700 800 900 1000
LOAD RESISTANCE (OHMS)

re) 1-13
Ecer. с ОИ

This page intentionally left blank.

 Installation © Operation
Section 2.0

This section contains initial installation, prelimi- 2.3.1 Preliminary Functional Testing
nary checks and operating instructions for the
Excalibur Plus PC". The following checks are recommended upon ini-
tial installation of the equipment and prior to
2.1 INITIAL INSPECTION each use of the instrument to avoid unnecessary
delays in surgery. See Figure 2.1 for location of
Unpack the unit upon receipt and physically controls and connectors.
inspect it for any obvious damage that may have
occurred during shipment. This inspection should 1. Ensure that the Power Switch is OFF and no
be performed by a qualified biomedical engineer accessories are connected.
or other person thoroughly familiar with electro-
surgical devices. If the unit is found to be dam- 2. Connect the power cable to a properly ground-
aged, notify the carrier and your CONMED rep- ed and polarized mating power receptacle of the
resentative immediately. proper voltage and frequency.
2.2 INSTALLATION
3. Connect a two-treadle monopolar foot switch
The unit may be mounted on a matching cart or and a single treadle bipolar foot switch to their
any stable cart or table. mating connectors at the rear of the unit. Note:
Use only CONMED/Aspen Labs footwitches.
WARNING Although other types may fit, they may not be
THE POWER CORD OF THE UNIT compatible.
SHOULD BE CONNECTED TO A PROP-
ERLY POLARIZED AND GROUNDED 4. Make no connection to the Return Electrode
POWER SOURCE WHOSE VOLTAGE jacks at this time.
AND FREQUENCY CHARACTERISTICS
ARE COMPATIBLE WITH THOSE LIST- 5. Set the Power Switch to the ON position. The
ED ON THE NAMEPLATE OF THIS green lamp in the power switch shall illuminate.
UNIT. As the unit goes through it's internal self-diagnos-
tics, the machine should respond by:
CAUTION: Since the unit depends on natural
convection of air for cooling, it should not be a) Sounding a tone test.
installed in a cabinet or similar enclosure. If
mounted on a shelf, or otherwise near a wall, b) During the tone test, displaying a total of nine
allow a two inch clearance around and above "8"s on the four digital displays.
the unit to permit free circulation of air at.the c) Illuminating all three mode indicators, all
sides of the unit. twelve key indicators, Return Fault indicator, and
2.3 PRELIMINARY CHECKS all of the ASSIST Resistance indicator bars.

Prior to initial installation and use of this unit, it d) After the display test, the unit will show
is recommended that the performance of the SLF dIA (for self-diagnostics) nn X, where nn is
device be tested in this manual. Results of that the last 2 digits of the software part number, and
testing should be compared to the results tabulat- X is the software revision level. The unit is con-
ed on the factory Test Data Sheet that is supplied ducting a power-on self test during this interval.
with each unit. This data should be retained for
future reference and comparison.
6. Depress the Cut treadle of the monopolar foot operator error tone shall sound. Release the Cut
switch. The Return Alarm tone should sound treadle, continue to press the Coag treadle and
and Return Fault should continue to glow. While confirm that the tone changes to the coag activa-
holding the Cut treadle, rotate the volume control tion tone, and the blue Coag Mode indicator is
over its full range and verify there is no signifi- illuminated until the Coag treadle is also released.
cant change in sound level. Release the Cut foot
switch and the tone should stop. 12. Connect a handswitching active electrode to
the Monopolar Accessory Jack #1. Activate, one
7. Verify that each of the following modes can be at a time, the Cut and Coag hand switch controls
selected and adjusted up and down, and that no verifying that each control causes the correct indi-
other displays are affected: cator and tone to sound. Move the handswitch-
*Pure Cut ing active electrode to the Monopolar Accessory
*Blend 1 Cut Jack #2 and repeat.
*Blend 2 Cut
*Blend 3 Cut 13. Remove the two wire, single pad return elec-
*Standard Coag trode, and confirm that the Excalibur Plus PC™
*Spray Coag beeps twice, and the Return Fault indicator illu-
*Bipolar Coag minates.
«Bipolar Cut
2.3.2 Preliminary Performance Testing
Return all power settings to desired setting.
After the unit passes the Preliminary Functional
8. Select Bipolar Coag and depress the bipolar Tests of Paragraph 2.3.1, preliminary performance
foot switch. Confirm that the Bipolar Mode indi- testing may be conducted. Such testing is best
cator illuminates, and a coag activation tone is carried out by use of an electrosurgical generator
sounded, While still depressing the bipolar foot tester, as described in this manual. Note that the
switch, rotate the Sound Volume Control over it's power display of the tester will be most accurate
full range to verify the function of that control when a noninductive resistor of the rated genera-
and that sound is audible at all positions. This tor output impedance for the selected mode is
control may be left at any desired position. used.
Confirm that releasing the bipolar foot switch
returns the Excalibur Plus PC™ to its idle state. If no tester is convenient, the availability of thera-
Verify that the bipolar hand switch control is peutic current may be ascertained subjectively by
functional by use of the appropriate forceps or by attempting to cut and coagulate on surrogate tis-
connecting a jumper between the center and bot- sue such as a piece of meat or fresh fruit, a wet
tom Bipolar Output jack on the Output Panel. bar of soap, or a sponge moistened in saline.
The effect will be identical to depressing the
Bipolar foot switch. 2.4 CONTROLS, DISPLAYS AND
CONNECTORS
9. Press the Single Pad Select key to select Single
Pad mode and confirm that no ASSIST The numbers preceding the following paragraphs
Resistance indicator bars are lit, and the Return correspond to the numbered items in Figure 2.1.
Fault indicator remains lit. Connect a single pad 2.4.1 Control Panel
Return electrode to the Return electrode jack.
Confirm the Return Fault indicator goes out. All controls except for the sound volume control
and the power circuit breaker are located on the
10. Depress the Cut treadle of the Monopolar control panel. Refer to the CONTROL PANEL
foot switch. The yellow Cut Mode indicator shall portion of Fig. 2.1.
light and the cut activation tone shall sound.

11. While continuing to press the Cut treadle of

the foot switch, depress the Coag treadle. An
1. MONOPOLAR CUT MODE INDICATOR: the ASSIST Resistance indicator (28) to stop
This yellow lamp lights when the unit is keyed in flashing if the patient's resistance is within the
a monopolar cut mode. acceptable range (see ASSIST Resistance indica-
tor).
2. MONOPOLAR CUT POWER DIGITAL
DISPLAY: Indicates the cutting power level 12. BIPOLAR MODE INDICATOR: This lamp
selected in the currently selected monopolar cut lights when the unit is keyed in either of the
mode. bipolar modes.

3,4. MONOPOLAR CUT POWER ADJUST- 13. BIPOLAR POWER DIGITAL DISPLAY:
MENT KEYS: Adjusts the output power level of Indicates the bipolar power level set via the
the selected cut mode. Bipolar Power Level Controls in the currently
selected Bipolar modes.
5. MONOPOLAR COAG MODE INDICA-
TOR: This blue lamp lights when the unit is 14,15. BIPOLAR POWER ADJUSTMENT
keyed in a monopolar coagulation mode. KEYS: Adjusts the output power level of the
selected Bipolar mode.
6. MONOPOLAR COAG POWER DIGITAL
DISPLAY: Indicates the power level set in the 16. PROGRAM LOCATION INDICATOR:
currently selected monopolar coagulation mode. Shows "P" for previous, "0" for zero power set-
tings, or 1-9 for user programmable settings.
7,8. MONOPOLAR COAGULATION POWER
ADJUSTMENT KEYS: Adjusts the output 17,18. PROGRAM LOCATION SELECTION
power level of the selected Coag mode. KEYS: Press these keys to scroll to desired pro-
gram location.
9. RETURN FAULT INDICATOR: Illuminates
when the unit detects a problem in the return 19. STORE KEY: Pressing this key will store the
electrode circuit. In Dual Pad mode, the indica- present settings at the program location indicated,
tor will illuminate when the Monitor Set Point except for the "P" or "0" indicators.
has not been set, or a return electrode cable is
open or shorted, or the type of return electrode 20. BIPOLAR COAGULATION MODE INDI-
used does not match the type selected, or when CATOR: Illuminates when Bipolar Coagulation
patient resistance is out of range. In Single Pad mode has been selected.
mode, it will illuminate if either of the return
electrode cables is open. In addition, a return 21. BIPOLAR COAG SELECT KEY: Selects
fault tone will sound when a Return fault is Bipolar Coagulation mode.
detected for either type of electrode and a
monopolar activation is attempted. The unit will 22. BIPOLAR CUT MODE INDICATOR:
not produce monopolar energy when this indica- Illuminates when Bipolar Cut mode has been
tor is illuminated. selected.

10. MONITOR SET INDICATOR: Flashes 23. BIPOLAR CUT SELECT KEY: Selects
when Dual Pad is selected and A.R.M. is in Bipolar Cut mode.
range, but Monitor Set is not pressed yet. After
Monitor Set is pressed, light goes out. 24. DUAL PAD SELECT: Is pressed to select
Dual Pad return electrode mode.
11. MONITOR SET POINT KEY: Push when
in the Dual Pad mode after a dual pad electrode 25. DUAL PAD MODE INDICATOR:
has been properly applied to the patient and con- Illuminates when the DUAL pad return electrode
nected to the unit. Pressing this key notifies the mode has been selected.
unit that the present return circuit resistance rep-
resents safe return electrode placement and causes
seen |
26. SINGLE PAD SELECT KEY: Pressing this 38. BLEND 2 CUT INDICATOR: Illuminates
key will select the Single Pad return electrode when Blend 2 is selected.
mode.
39. PURE CUT SELECT KEY: Pressing this
27. SINGLE PAD INDICATOR: Illuminates key will select the Pure cut mode.
when the SINGLE pad electrode mode is select-
ed. 40. MONOPOLAR PURE CUT MODE INDI-
CATOR: Illuminates when Pure mode has been
28. ASSIST RESISTANCE INDICATOR: This selected.
green LED bar graph is a visual indicator of
patient resistance measured between the contacts 41. REMOTE POWER SELECT KEY: Pressing
of the return electrode. The number of green bars this key will select the Remote Power Mode if not
illuminated increases with increasing resistance selected and will deselect the Remote Power
and may be used as an aid in detecting high risk Mode if selected.
patients. The ASSIST Resistance indicator will
flash if the Excalibur Plus PC™ is in Dual pad 42. REMOTE POWER SELECT INDICATOR:
mode and the Monitor Set Point (11) has not Illuminates when the Remote Power Mode is
been properly established (see Monitor Set Point selected.
Key). The ASSIST Resistance indicator will light
2 to 8 bars when the patient's return electrode 2.4.2 Output Panel
resistance is within range.
The output panel contains the power circuit
29. STANDARD COAG SELECT KEY: breaker and the required patient connection jacks
Pressing this key will select Standard Coag mode. for electrosurgery. Refer to the OUTPUT
PANEL portion of Fig. 2.1.
30. STANDARD COAGULATION MODE
INDICATOR: IIluminates when Monopolar 1. CIRCUIT BREAKER: Primary power switch
STANDARD Coagulation mode has been select- for the unit; turns unit on and off. Also provides
ed. double-pole power line overload protection.

31. SPRAY COAG SELECT KEY: Pressing this 2 & 3. HAND SWITCHABLE MONOPOLAR
key will select Spray Coag mode. ACCESSORY JACKS: Two independent sets of
color coded banana jacks are provided for the
32. SPRAY COAGULATION MODE INDICA- connection of hand switched monopolar acces-
TOR: Illuminates when Monopolar SPRAY sories. Hand switchable monopolar coagulating
Coagulation mode has been selected. forceps may be used by connecting to the red and
lower black jacks. These jacks may be activated
33. BLEND 1 CUT SELECT KEY: Pressing this only by the accessories connected to them.
key will select the Blend 1 cut mode
4. FOOT SWITCH CONTROLLED
34. BLEND 1 CUT INDICATOR: Illuminates MONOPOLAR ACCESSORY JACK: This jack
when Blend 1 is selected. accepts accessory cables or adapters eguipped
with standard active (Bovie #12) plugs. This
35. BLEND 3 CUT SELECT KEY: Pressing this jack can be activated only by the monopolar foot
key will select the Blend 3 cut mode. switch.

36. BLEND 3 CUT INDICATOR: Illuminates 5. TWO-PIN RETURN ELECTRODE JACK:

when Blend 3 is selected. This jack accepts a standard two-pin return elec-
trode plug.
37. BLEND 2 CUT SELECT KEY: Pressing this
key will select the Blend 2 cut mode.
 US RG

6 & 7. BIPOLAR ACCESSORY JACKS: Bipolar 3. BIPOLAR FOOT SWITCH CONNECTOR:

output, activated by the bipolar foot switch or by A 3-pin threaded connector designed to accept
hand switchable bipolar accessories. any CONMED/Aspen Labs single-treadle bipolar
foot switch.
8. BIPOLAR SWITCH JACK: Hand switchable
bipolar accessories must be connected such that 4. SOUND VOLUME CONTROL: Controls
the hand switch contacts are connected between the volume of the sound tones produced during
this black miniature banana Bipolar Switch Jack normal activation of the unit. Clockwise rotation
and the lower blue Bipolar Accessory Jack (6). increases the volume. It does not affect volume
of alarm tones.
2.4.3 Rear Panel
5. EQUIPOTENTIAL GROUND CONNEC-
The rear panel contains the foot switch connec- TION: Chassis ground connection suitable for
tors, power cord connector, volume control and attachment of standard auxiliary grounding cable
carrying handle/cord wrap. Refer to the REAR when required for additional protection against
PANEL portion of Fig. 2.1. low frequency risk current.

1. CARRYING HANDLE 6. POWER INLET: Supplies ac mains power to

the unit. It only should be connected to a source
2. MONOPOLAR FOOT SWITCH CONNEC- of power corresponding to that listed on the
TOR: This 4-pin threaded connector is designed nameplate.
to accept plugs attached to any two treadle
monopolar foot switch available from 7. NAMEPLATE: Specifies model name, serial
CONMED/Aspen Labs. Use only CONMED/ number, nominal line voltage, frequency, current,
Aspen footswitches. Other manufacturer’s power consumption and rated duty cycle.
footswitches may not be compatible.
Figure 2.1 Controls, Displays & Connectors

1234 587 8 9 10 11 12 13 14 15 16 17

sea TE ou wrİLE gr E

A
3005) 120] |= 9 50| ak
—
елей. E, RBL,
ο G

v) [+ 7
Ea EA | pm fre La
39 a) ABE ode), HE tb [Control
/ : +

37 Day] / / | | \ \ \ M
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20
CONTROL PANEL
1 2 3 4 5 67 8
\ \ λ IL /
OHIO iz cree,
>=! Ш | ОНО К) ==
A| 回 oj ol 三 + = 2
HAND CONTROL FOOT CONTROL BIPOLAR

OUTPUT PANEL

VOLUME Econ

G
„© © \ ;

7 ] \ 7 / \
2 3 4 7 1 5 6
REAR PANEL
κ«ὃ«ουὐληνῑἒκϊκῑϊξὲ.ς.Σ.ὲ.ὲ:ὺέὲέ«Ὄ«τνα,..
υπ κ
2.5 OPERATING INSTRUCTIONS 4. Connect the foot switches, as required, to the
rear of the unit (not required if only hand switch-
2.5.1 Preliminary Set Up able accessories are to be used). Use only
CONMED/Aspen Labs footswitches.
1. Ensure the Power Switch is OFE, then connect
the power cable to a properly grounded and 5. Inspect, then connect the plug of the disper-
polarized mating power receptacle. Do not con- sive electrode cable to the return electrode jack or
nect a Return electrode at this time. to an appropriate adapter. Refer to Figure 2.2. A
dispersive electrode need not be connected if only
2. Set the Power Switch to the ON position. The Bipolar operation is required.
green lamp in the Power Switch shall illuminate.
As the unit goes through it's internal self-diagnos- NOTE: This electrosurgical unit incorporates the
tics, confirm the machine responds by: Aspen Return Monitor. The monitor will inhibit
monopolar operation of the unit if its require-
a) Sounding a tone test. ments for the return electrode have not been sat-
isfied (see instruction 7).
b) During the tone test, displaying a total of nine
"8's on the four digital displays. 6. Select and prepare the patient return electrode
site and apply the return electrode in full contact
c) Illuminating all three mode indicators, all with the patient, and in accordance with the man-
twelve key indicators, Return Fault indicator, and ufacturer's instructions. If no instructions are
all of the ASSIST Resistance indicator bars. After given, observe the guidelines provided in Section
the display test, the unit will show SLF dIA (for 1 of this manual.
self-diagnostics) in the cut and coag power win-
dows. The bipolar power window will show the 7. Generally, the return pad type will already be
software part number and the program window set to the proper mode, since the unit automati-
will show the software revision level. cally retains the last pad setting. If it is incorrect,
select Dual Pad or Single Pad Mode. Confirm
d) After the power-on self-tests are complete, the that the ASSIST Resistance indicator and the
unit should beep the “test completed” tones. Return Fault Indicator are blank if Single Pad
mode is selected. If Dual Pad mode is selected,
After the power-on self-tests, the unit is ready for press the Monitor Set Point key only after visually
use. If the unit sounds a continuous high tone, confirming full dual pad electrode contact with
displays a fault code, or otherwise fails to respond patient. Confirm the Return Fault indicator is
as above, the unit has failed one of its internal blank, and the ASSIST Resistance indicator stops
tests and is not suitable for use. Before turning flashing and displays 2 to 8 green bars. The
the power off, note the "Err" or "ACC" code dis- number of green bars indicates the patient's resis-
played in the Power Displays to assist in the diag- tance and can be used as an indicator of patient
nosis by a biomedical technician. ACC codes can risk.
often be corrected by Operating Room staff, see
WARNING
Section 2.7.2. Contact your Biomedical depart-
DO NOT DEPEND SOLELY ON THE
ment for repair if an “Err” code appears.
ASSIST RESISTANCE INDICATOR FOR
CONFIRMATION OF GOOD RETURN
3. Inspect, then connect the desired monopolar
ELECTRODE APPLICATION.
accessories to connectors. Refer to Figure 2.2 for
QUALIFIED PERSONNEL SHOULD
typical monopolar accessory connections.
MAKE THE FINAL DECISION ON
PROPER ELECTRODE PLACEMENT.
WARNING
ALWAYS STOW UNUSED ACCESSORIES
8. The machine may already be setup to desired
IN A SAFE, INSULATED LOCATION
settings, since it powers up to the last settings at
SUCH AS A HOLSTER.
the time the unit was powered down. If not, but
the desired settings have been programmed, use
Excalibyrius,

the Program select keys to scroll to the desired The size and geometry of monopolar electrodes
program location. Refer to Section 2.5.3 for are significant in that a large electrode, absent of
details on programming. At this point, the unit is sharp features (e.g., a ball electrode) will have no
ready for operation. Otherwise, continue setup tendency to cut, regardless of the waveform
instructions below. power level. Conversely, a small, sharp electrode,
such as a needle or wire loop, will be likely to cut
CAUTION: Confirm the Program settings are simply from mechanical pressure.
correct before using.
The activation mode is selected by the user via
9. Set the Monopolar Cut Mode to Pure for cut- hand or foot switch and the setting of the active
ting or one of three Blend modes for desired cut- Mode Select switch.
ting with hemostasis.
The Bipolar Coagulation waveform is designed to
10. Set the Monopolar Coag Mode to STAN- minimize tissue sticking and popping by limiting
DARD to provide pinpoint hemostasis or to the output voltage regardless of power setting.
SPRAY to provide fulguration. Bipolar hemostasis is more localized than in
monopolar, since only the tissue grasped betwe
11. Select the desired Bipolar mode. the forceps tips is affected. This is particularly
desirable in vascular surgery, where monopolar
12. Adjust the CUT, COAG, and BIPOLAR current may concentrate in the affected vessel and
power level controls to the desired levels. If result in undesired tissue effects. This easily con-
unsure of the proper settings, use low power set- trolled localization is also of benefit in plastic
tings initially and make adjustments intraopera- surgery and neurosurgery.
tively according to the surgeon's requests. Use of
program mode or a written record of each sur- The Bipolar Cut waveform is essentially identical
geon's preferred power setting for various pro to that for monopolar Pure cut, but is delivered at
dures will expedite subsequent pre-op setup. a lower voltage and higher frequency.

2.5.2 Operation 2.5.3 Program Mode

Activate the electrosurgical unit in the desired Up to 9 complete mode and power settings can
operating mode by depressing the appropriate be easily stored and recalled at any time.
treadle of the foot switch or switch of a hand Additionally, there are two settings that the unit
switching accessory. Adjust the corresponding automatically sets, "P" and "0" (zero).
power level until the desired surgical effects are
obtained. Remember that power setting changes The unit automatically stores the most recent set-
are limited when the unit is keyed. The available tings at power down and will restore thos set-
power in watts will be displayed on the digital tings when the unit is turned ON. A "P" (for
display corresponding to activation mode. Previous) will be displayed in the Program
Noting this wattage may be useful in attempting Location Indicator. Note that if a power loss
to derive similar surgical effects from several occurs during activation, the values stored in the
machines of different manufacturers. The surgical "P" location will be those just prior to the activa-
effects obtained are dependent on a number of tion.
factors including waveform, electrode size, elec-
trode geometry, power level and surgical tech- The "0" (zero) location sets all power settings to
nique. zero, and the activation modes to Pure Cut,
Standard Coag and Bipolar Coag. The pad mode
will remain at the last setting. The settings 1-9
contain user stored settings.
 2.5.3.1 Storing Programs 4. The Power Indicator for the associated power
adjustment selected will flash.
1. Select the desired storage location BEFORE
setting the desired modes and power settings. As 5. Only the Remote Power Select Key on the
each location is shown, the displays will indicate front panel will be functional.
the contents of that location.
6. Depress CUT to increase power or depress
2. Set the modes, power and pad settings as COAG to decrease power. An audible tone will
desired. Note that non-displayed mode settings sound for each power increment change.
are also stored at this time.
7. The first activation for a power increase will
sound an intermediate tone to a higher tone.
3. Press the STORE key. If a correction is need-
ed, simply set the machine as desired and press 8. The first activation for a power decrease will
STORE again. sound an intermediate tone to a lower tone.
9. Between 0 and 20 watts, a short up or down
2.5.3.2 Using Programs tone will sound with cach one watt step.
Select the stored setting location by using the 10. At greater than 20 watts, a short up or down
PROGRAM SELECTION keys. Confirm the tone will sound with each five watt step. Should
program settings are correct before using. the switch be held for more than 4 successive five
watt steps, the power adjustment will be acceler-
2.5.4 Remote Power Control Mode ated and a continuous up or down tone will
sound. Releasing the switch and pressing will

| CAUTION: The Remote Power Control feature

should be enabled only if the surgeon is familiar
with its operation and requires its capabilities.
once again start the five watt step. Note that the
5 watt increment will be calculated on the power
display when the switch is not depressed.

|
The power displays should be monitored for 11. The associated Power Indicator will not flash
expected effect while Remote Power Control
during the period of adjustment.
adjustments are being performed until normal

|
operation is restored.
12. To end power adjust:
The Remote Power Control may only be activat- a. Double click either CUT or COAG.
ed when the Remote Power Select Indicator is -OR-

| on. This mode may be selected or deselected with

the Remote Power Select Switch, and the status
of the Remote Power Control Mode may be
b. Turn off Remote Power Control Mode.
-OR-
c. Do not press CUT or COAG buttons for 6

|
stored as per Section 2.5.3 Program mode. The seconds for time out.
Remote Power Control Mode will always be off
after power up (i.e., “P” will be displayed in the 13. A loud acceptance tone will sound, returning
Program Location Indicator). control for normal operation. See Section 2.5.2

| 2.5.4.1 Changing Monopolar Power Remotely

Operation.

| 1. Select Remote Power Control.

2. Double click CUT button on the pencil to

|
adjust the cut power or double click COAG but-
ton to adjust the coag power.

3. A loud acceptance tone will sound, allowing

|
power adjustments only from the pencil that the
double click was detected.

|
|
2-9
2.6 USER MAINTENANCE 2.7 IN CASE OF DIFFICULTY

2.6.1 General Maintenance Information 2.7.1 Return Monitor Alarm

This section contains information for ordinary Trouble with the Return Pad is signalled by illu-
upkeep of the Excalibur Plus PC™. While the mination of the Return Fault Indicator.
unit has been designed and manufactured to high Activation attempts will result in an audible fault
industry standards, it is recommended that peri- alarm. Replace Pad if any patient contact has
odic inspection and performance testing be per- been lost, and press the Monitor Set key to store
formed by a qualified biomedical technician to the new resistance for Dual Pad mode.
ensure continued safe and effective operation.
2.7.1.1 Single Pad Alarm
2.6.2 Cleaning
If a Single Pad Alarm condition exists, confirm
The exterior of the unit may be cleaned by wiping that a single pad is attached to the unit. Check all
it with a cloth that has been dampened (not drip- Return Pad cable connections and replace pad or
ping) with a mild detergent such as Windex® or cable if necessary.
Formula 409® . Windex® is the registered
trademark of the Drackett Products Company. 2.7.1.2 Dual Pad Alarm
Formula 409® is the registered trademark of the
Clorox Company. If a Dual Pad alarm exists, check the ASSIST bar
graph for clues to the problem.
2.6.3 Periodic Inspection
A. All of the bars are flashing, the resistance is
The Excalibur Plus PC™ should be visually too high. This can be caused by inappropriate
inspected at least every year. This inspection pad site, a broken cable, or poor connections to
should include checks for: the unit.

* Damage to the power cord. B. More bars are flashing than originally were
* Damage to the power plug. when Monitor Set was pressed. Check to see if
* Tightness of the power plug. the pad has peeled from the patient or if the unit
* Tightness of the volume control knob. has a poor connection.
*Ргорег mating, cleanliness and absence of
damage to the patient connectors. C. No bars are on. Check to see if a single pad
* Obvious external or internal damage to the unit. has been connected instead ofa dual pad.
* Accumulation of lint or debris within the unit Confirm a dual pad is not connected to some-
or heatsink. thing highly conductive or folded over on itself.

2.6.4 Periodic Performance Testing

The Excalibur Plus PC™ should be performance

tested at least every year. Each unit is supplied
with a serialized Product Test Data Sheet which
tabulates the results of the factory tests that were
performed on the unit. This data may be used as
a reference for subsequent tests and should be
made available to the biomedical technician con-
ducting the tests.

2-10 [=
 ec
2.7.2 ACC Faults 2.7.4 If All Else Fails

ACC Codes are most often caused by faults in Contact CONMED Corporation Technical
accessories attached to the unit. Often the fault Services at the phone or fax numbers listed on the
can be corrected in the operating room without a inside front cover of this manual. Please have the
service call. The following list gives the meaning model and serial numbers from the rear panel
of each code, and what to check. For each code, nameplate along with a description of the prob-
check to see that the switch, panel or accessory is lem, including power settings, accessories in use,
not being pressed while the unit is powering up. and fault code.
Turn unit off, unplug accessory, then turn unit
back on. If the code still shows, call service. 2.8 ENVIRONMENTAL PROTECTION

ACC The shipping container and packing material

Code What to check should be retained in the event the unit must be
returned for factory service. At the end of the
FS Monopolar Foot Switch shorted equipment’s life, it should be disposed of in
(Ensure Foot Switch treadle is not accordance with your local regulations.
depressed.) Component materials are:
LH Left Hand monopolar accessory shorted
tH right Hand monopolar accessory shorted * Aluminum enclosure and heatsinks.
bP biPolar accessory shorted + Unit front handle is steel.
*CPxx Control Panel key stuck * Thermoset printed wiring boards containing
miscellaneous electronic components.
*Note: “xx” displayed in the bipolar window cor- * Power transformer made of steel and copper.
responds to the stuck key using figure 2.1 as a * Mains cord made of thermoplastic and copper.
reference. Multiple keys show as “88”. * Shipping container is cardboard; packing mate-
rials are a combination of Urethane foam and
2.7.3 Err Faults Polyethylene film.

Err Code faults generally cannot be corrected in

the operating room and require a repair techni-
cian. Occasionally, turning the unit off and back
on will clear an Err fault and resume normal
operation of the unit.
 |
Figure 2.2 Patient Accessory Connections

roves]
ne E
Г]
Sip io pia
[7
HAND CONTROL coor CONTROL o
να [Е] BIPOLAR

I MONOPOLAR ———— L BIPOLAR?

2-12 re
 mİ
Figure 2.3 Accessory Schematics

C_>~<<—
Le eS 一 二>
SINGLE PAD ELECTRODE DUAL PAD ELECTRODE
NEUTRAL ELECTRODE CONNECTIONS

CUT

RF
<<
MONOPOLAR HANDSWITCHED ACTIVE CONNECTIONS

©
RF

HANDSWITCH (OPTIONAL

OT A ©
BIPOLAR ACTIVE CONNECTIONS
A D
CUT
COAG

B ο

7 .
MONOPOLAR FOOTSWITCH CONNECTIONS

- A C

BIPOLAR FOOTSWITCH CONNECTIONS

re 2-13
 This page intentionally left blank.

2-14 [=
 Theory of Operation
Section 3.0

This section contains the theory of operation for sources. However, only one source may be active
the Excalibur Plus PC™ circuitry. The functional at a given time. That source is determined by the
block diagram and schematics are located in Microprocessor which drives the proper signal
Section 4.0. These figures are folded such that states out on the Address and Control busses.
they may be pulled out for viewing while reading
the appropriate section. 3.2 Power Supplies and Distribution

3.1 Functional Block Diagram Description The Power Supply for the Excalibur Plus PC™
converts ac mains power into the various dc volt-
The Functional Block Diagram appears in ages required to operate the internal circuitry.
Schematic 4.0. This diagram illustrates the func- This conversion takes place in three stages.
tional partitioning of the unit, without regard to
physical location. Each block defines a major 1. Mains power is ac-regulated and isolated by a
function (as noted inside the block) along with ferroresonant power transformer.
the reference designator(s) of the components(s)
that serve primary roles in implementing the 2. Power from the transformer secondaries is then
function. Each reference designator includes an rectified and capacitively filtered to produce three
assembly number (Al, A2, etc.) for cross-refer- separate sources of de power (nominally +110
encing to the Schematics in Section 4. Vdc, +16 Vdc and +8 Vdc). The +110 Vdc
source is used exclusively to power the RF Power
The relationships among each block are described Amplifier on the A4 Power Conversion PWB
by the signals that interconnect them. Narrow without further regulation.
lines represent individual signals and are marked
with the same signal mnemonics used in the 3. The +16 and +8 Vdc sources are distributed
schematics. throughout the unit where they are modified fur-
ther by regulation or switching to supply the vari-
Broad lines denote busses, or groups of signals ous loads in the unit.
which together serve a common function. To
avoid clutter, busses are not necessarily marked MAINS DISTRIBUTION. Refer to the
with signal mnemonics. Where a bus contains Interconnect Schematic, Figure 4.1. The mains
signals all bearing a common mnemonic form, power cord is terminated at a grounding lug and
the characters common to all of the mnemonics a nylon screw terminal block, A6TB1, for ease of
are shown, with XXs denoting characters which field replacement. Harness AW] delivers power
differ among the signal names. For example, the to the two-pole circuit breaker, A9CB1, mounted
bus marked /FXX contains the signals named on the output panel. A9CB1 serves both as a
/ECT, /FCG and /FBP. These refer to the foot lighted power switch and to protect the unit from
switch activation signals for Cut, Coag, and. overloads. On overload, this device automatically
Bipolar respectively. switches its handle to the OFF position.

Arrowheads describe the direction of signal flow. Harness A9W1 returns switched mains power to
Most signals are generated at a single source and A6TBI for connection to the primary windings
have one or more destinations. An exception is of power transformer A6T1. Strapping options
the Data Bus on the A3 Controller PWB. This on A6TBI allow setting the unit for a given
bus is bi-directional in that signals may travel mains voltage range (120 V or 240 V) by con-
either direction from any one ofa number of necting the primary windings in parallel or series,
respectively. See Section 4.2.5.1 for instructions mounted using rubber grommets because high
on changing the factory supplied strap option. core flux produces more audible hum than ordi-
nary transformers. When the core saturates, a
POWER TRANSFORMER. Power transformer burst of magnetic flux can induce mains-frequen-
A6T1 is a ferroresonant type. Also known as con- cy noise into nearby wiring. For this reason, do
stant voltage transformers, these devices provide not alter the harness dress near A9TI.
regulation against variations in mains voltage.
This feature is primarily responsible for the 5. Conventional ferroresonant transformers, used
Excalibur Plus PC™’s ability to hold RF output in all Excalibur Plus PC™’s specified for 50 or 60
power steady in the presence of mains voltage Hz only, are sensitive to mains frequency varia-
variations over the specified range. tions. Units specified for use as 50-60 Hz
employ a special Controlled Ferroresonant
Ferroresonant transformers have some unusual Transformer which electronically regulates de out-
physical and electrical properties: put voltage. The latter are equipped with a
Control Module, which samples +16 VAC via
1. A special secondary winding (red leads 5 and 6 A4P4, and an Overvoltage Protection module,
on A6T1) connects to an ac capacitor, A6C1. If which will drive the transformer to a minimum
this capacitor is open or shorted, the secondary output condition if +16 VAC or +110 VAC at
voltage will fall well below normal. A6BRI or BR2 exceed preset voltage limits.
Both modules are contained in a potted housing
>WARNING< mounted atop the power transformer.

HIGH AC VOLTAGE IS PRESENT AT CAUTION: Never operate the unit at a nomi-

A6C1 WHEN THE UNIT IS OPERATING. nal mains frequency other than that specified
USE CARE TO AVOID ACCIDENTAL on the Nameplate and A9T1.
CONTACT OR NICKING OF
THE WIRE INSULATION WHEN
WORKING IN THIS AREA. RECTIFICATION. The secondaries of A9T1 are
terminated in terminal block, AGTB1 (the termi-
2. The secondary voltage waveforms are sguare nal numbering on this block matches the lead
rather than sinusoidal in shape. Most ac volt- numbering on A9T1). Harness A6W2 connects
meters are calibrated only for sine waves, so the to the bridge rectifiers A6BR1 and A6BR2 and
secondary voltage readings on A6T1 may vary carries the rectified power to the A4 Power
widely between different instruments. The recti- Conversion PWB via A4J3.
fied de output voltage is the most repeatable indi-
cation of secondary ac voltage. A6BR2 acts as a conventional full-wave bridge
rectifier for supplying +16 V, while simultaneous-
3. A secondary overload of greater than 200% ly acting as a negative-leg full-wave center-tap rec-
will cause the transformer to go into current limit tifier in providing +8 Vdc.
with very low secondary voltage and less than full
load mains current. Before diagnosing a defective A4 POWER PROCESSING AND USAGE.
transformer, first eliminate the possibility of a sec- Refer to the A4 Power Conversion PWB
ondary fault, such as a shorted rectifier or filter Schematic 4.5. Capacitors C11 and C20 filter the
capacitor. The low power secondary (leads 9 and +110 Vdc supply delivered at A4J3, while R12
11) is provided with internal thermal fuses, since acts as both a minimum load and a bleeder to dis-
it is possible to overload the winding so that the charge the capacitors when power is turned off.
insulation rating would be exceeded without The negative leg of A6BR1 is connected to
going into current limit. ground via a 0.1 ohm current sense resistor,
A4R8. The signal -ISENSE is a negative dc sig-
4. The magnetic core saturates briefly every half- nal used on the A3 Controller PWB to monitor
cycle. This high flux density produces higher the supply current drawn by the Power Amplifier.
than normal core losses, so the core runs fairly
hot to the touch even at idle. The device is
Capacitors A4C8 and C9 filter the +16 and +8 3.3.1 Watchdog Timer (WDT)
Vdc sources. The +16 Vdc source supplies
A4VRI, which provides regulated +12 Vdc and The function of this circuit is to monitor the
+12 GND to the Power Amplifier gate driver microprocessor for a failure that would cause
ICs, A4U1 and U2. Both +16 and +8 Vdc then unpredictable results. During normal operation,
feed the rest of the low-voltage dc loads via con- the microprocessor program executes in a known
nector A4J1. sequence. If a software error is detected, an inter-
nal interrupt is generated which halts the opera-
Harness A9W6 carries +16 and +8 Vdc to the tion of the microprocessor. If there is a hardware
A2 Display and A3 Controller PWBs mounted failure sensed by software control, program execu-
inside the shield on the top cover, A8. tion will again be terminated.

3.3 Controller Hardware Should a failure occur in the CPU that prevents
the detection of a problem, thus allowing pro-
The Excalibur Plus PC™ Controller PWB gram execution in a random manner, the
Assembly is based on the 8031, a single chip, 8- Excalibur Plus PC™ is designed so that the WDT
bit microprocessor which utilizes external pro- detects the problem. The WDT shuts down the
gram memory. Refer to Schematic 4.4a. This malfunctioning unit to minimize the effects of the
controller has the following features: failure. This is accomplished by requiring the
microprocessor to write to the WDT once during
1. Four 8-bit Ports (0,1,2,3) which are individual- each program execution cycle. This WRITE
ly addressable as 32 Input/Output (I/O) lines. PULSE is referred to as the Watchdog Timer
Strobe (WDTSTB). The WDT circuit must hear
2. Two 16-bit timer/event counters, one of which from the microprocessor within a hardware set
is used as a software controlled tone generator via window. If the WDTSTB occurs early because
the serial transmit pin TXD (U3 Pin 11). the program “skipped” a portion of the software
or late because it was “hung” in a program loop,
3. 64 K bytes of externally addressable program the following results:
memory (A3U1).
1. The circuit latches in the failed condition so
4. On-chip oscillator and clock circuit which is that further strobing from the microprocessor
connected to an external 10 MHz clock signal cannot clear the previous failure.
derived from a 20 MHz quartz time base (A3Y1).
2. An interrupt (/WDTINT) is generated which
5. 128 bytes of internal RAM used as a “scratch stops abnormal program execution. If the micro-
pad” by the processor. processor can still respond to the interrupt, a
“fatal” software routine will execute, displaying an
6. Battery backed static RAM. This is used both error code “Err 4.2”.
for “scratch pad” RAM, and for storage of cali-
bration values and user stored “Program” settings. 3. The interrupt signal /WDTINT, is used to gen-
Minimum battery life is 10 years. erate /WDTFL, which disables the Base Voltage
Generator and Waveform Generator, preventing
The remainder of the controller circuitry consists further generation of RF output.
of the Watchdog Timer (WDT), Power On Reset
(POR), Address Decoder, Peripheral Interface The Watchdog Timer (WDT) is made up of a
Adapter (PIA), Base Voltage Generator (BVG), dual, retriggerable, one-shot multivibrator (U7),
Current Sensing Circuit, Waveform Generator associated RC timing components (R4, C5, R6,
(WEG), Tone Generator, and the Aspen Return and C6), the relay power enable register (U10),
Monitor (A.R.M.) DAC and current source. and associated gates (U5 and U6). A WDTSTB
is generated whenever U10-2 and U10-3 are both
low. The first stage one-shot is set to time out at
the minimum WDTSTB interval by the RC com-
bination of R4 and C5. With C5=1yf, the time
 |
is equal to R4(K ohms) in milliseconds. If the WDTSTB is generated carly, while O1 is
Example: if R4=10K, the time is 10 millisec- high, the NAND gate (U6-1 and U6-2) will both
onds. The trailing (falling) edge of WDTSTB be high resulting in U6-3 going low and resetting
triggers the first stage causing Ol (U7-6) to go the second stage. This causes the same results as
true (high) for the time interval. The rising edge the late strobe described above.
of Ol triggers the second stage one-shot via U7-
12, causing Q2 (U7-10) to go high and /Q2 Note that the signal which causes the WDT to
(U7-9) to go low. The timing of this stage is set latch and ignore all subsequent WDTSTB pulses
by the RC combination of R6 and C6. In normal is RLYEN-Q being high. The only way to reset
operation WDT strobes will occur after stage 1 RLYEN-Q is a Power On Reset.
has timed out (Q1=0) but before stage 2 times
out (Q2=1). The one-shot is retriggerable and 3.3.2 Power On Reset
the rising edge of O1 will restart the timing
seguence in the second stage even though it may The Power On Reset (POR) circuit consists of a
not have completed its current time delay. single chip specifically designed for this function,
Normal operation is indicated by /WDTINT A3U4, and associated components R1 and US.
(Q2) never going low. The POR circuit monitors +5 Vdc (U4-8) and
the output signals RST (pin 5) and /RST (pin 6)
The relay enable flag, RLYEN-Q from U10-10, is become active if +5 Vdc falls below 4.75 Vdc.
reset on power-up. This permits the microproces- The 8031 microprocessor operation is specified
sor (U3) to test the WDT during initialization down to 4.5 Vdc. This allows power supply mar-
without allowing RF to appear at the outputs. gin for proper power down of the controller until
While RLYEN-Q is disabled (low), the WDT will reset occurs. When /RST is low, the microproces-
not lock up, permitting the software to test for sor is reset via the Inverter U5-12. This prevents
correct operation. This is done by strobing the inadvertent writes to the NOVRAM during
WDT early, late and looking for the generation of power transitions, when the control and
the interrupt /WDTINT (02-0). The WDT is address/data busses are in unknown conditions.
then triggered within the correct time window On power up, RST and /RST are kept active for
and should result in /WDTINT remaining high. a minimum of 250 msec to allow the power sup-
If these results are obtained, the WDT timer cir- ply and microprocessor to stabilize.
cuitry is operating normally.
The power monitor (U4), also provides an input
After initialization is complete, the microproces- (pin 1) for direct connection to a switch (A3S1-
sor generates a WDTSTB at the start of the first 4). Anytime /PB is low for over 10 msec, the
normal program timing cycle. The relay enable outputs RST and /RST become active. They
flag, RLYEN-Q, is set by the NOR gate, U10-5 remain active for a minimum of 250 msec after
and U10-6 both going low. After this, the pro- the switch is moved from the “/RST” position.
gram enters the normal operation program loop.
One last feature of this circuit is its function as a
Ifa WDTSTB is not generated within the period secondary watchdog timer. This is enabled by the
of the previous strobe, the second stage will time connection of Address Latch Enable (ALE) from
out and Q2 will go low resulting in a /WDTINT. the microprocessor (U3-30) to U4-7. The RST
Since RLYEN-Q and /Q2 (U7-9) are high, the and /RST outputs are forced to an active state
inputs to U6-4 and U6-5 are both true resulting when the /ST input (U4-7) is not stimulated for
in its output (U6-6) going low. This resets the 1.2 seconds. This function is not normally used
first stage one-shot. Now that Ol (U7-6) cannot because it requires a failure in the microprocessor
go high, Q2 (U7-12) is prevented from being and the Watchdog Timer circuitry. This is consid-
retriggered. With the WDT Q2 output gone low, ered a double fault condition and the odds of the
the microprocessor will execute a WDT failure two occurring simultaneously are very low. Also,
interrupt routine in response to /WDTINT it is possible for ALE to continue in normal oper-
falling, and /WDTEL will disable drive to the ation while other parts of the microprocessor are
power amplifier. not. The WDT circuit described previously, is
 xcalibur

used because it is not susceptible to this failure in generated by the current monitor. Ports 3.4 and
fault detection. 3.5 control the 128 byte Pages of the memory at
U2.
3.3.3 Controller, I/O
The Address Decoder (U9), is used to select
The four digital ports of the 8031 (U3) are func- external I/O devices for reading and writing.
tionally assigned as follows. High-order address to the decoder inputs, (A10,
All, and A12) cause the corresponding output
PORT 0 (P0.0 - P0.7). This port serves two digi- (YO - Y7) to go low. After the address decode has
tal functions: 8-bit data bus for communicating stabilized, either /RD or /WR will go low to exe-
with external I/O, and low-order address bus for cute a data transfer with the addressed device.
accessing external Program Memory.
Peripheral Interface Adapter (PIA), U11, is a
PORT 1 (P1.0 - P1.7). This port is dedicated to general purpose I/O device designed to expand
discrete inputs or outputs. Port 1.2 generates the the number of addressable I/O lines available. It
signal /RFEN used to control RF output. Port has three additional 8-bit ports (PA - PC) or 24
1.3 is /LOUD which bypasses the audio volume individually programmable pins. Port A is con-
control during alarm conditions. Port 1.4 reads figured to read switch closures from hand and
the signal ARMCOMP which is supplied from foot controls; Port B supplies an address to the
the comparator U23-13. ARMCOMP is used Waveform Generator used to select specific out-
during a software controlled successive approxi- put waveforms depending on the mode and
mation routine to determine contact resistance of power selections. Port C is used to activate the
the Return Electrode. See Section 3.8. Port 1.6 is required relays to direct RF output to the appro-
used to control the upper and lower 512 byte priate accessory, and to control the Waveform
Memory Bank of U2. Port 1.7 is the Interrupt Generator latch.
Request (IRQ) from the keyboard/display con-
troller (A2U2) which resides on the Display 3.3.4 Memory
PWB. It is generated whenever a keyboard button
is depressed. IRQ does not actually interrupt the The program used by the microprocessor is stored
microprocessor, but is simply read in as another in external memory, the bytewide EPROM (U1).
1/0 line. It is programmed and verified at the factory to
ensure correct operation of the ESU. The follow-
PORT 2 (P2.0 - P2.7). This port supplies the ing is the Memory Map for the 32Kx8 EPROM.
high-order address bus which reads from external
Program Memory and writes to external I/O. All Address Code Block
I/O is memory mapped so that distinct addresses 0000-OFFFH CALONIY 4Keven
access specific devices. The system is configured 1000-1FFFH CAL and RUN 4K odd
so that only one device is addressed at a time. 2000-2FFFH CALONLY 4Keven
3000-3FFFH CALand RUN 4K odd
PORT 3 (P3.0 - P3.7). This port generates spe- 4000-4FFFH CAL ONLY 4Keven
cial signals used to control the overall system., 5000-5FFFH CALand RUN 4K odd
These are /RD, /WR for reading or writing to 6000-6FFFH CALONLY 4Keven
external I/O, /PSEN (Program Store Enable) 7000-7FFFH CAL and RUN 4K odd
which enables the external Program Memory to
the bus during instruction fetches, and ALE When the switch at A3SI is in the CAL position,
(Address Latch Enable) used for latching the low- Address Line A12 is low, and enables access to
order byte of address during access to external the entire EPROM through the OR gate (U8-3).
Program Memory. Port 3.1 generates the signal, Mutually exclusive calibration code is located in
/TONE, which is the source of the various audio the even 4K blocks. When the switch at A3S1 is
tones used to signal activation or alarm condi- in the RUN position, Address Line A12 is high,
tions. Port 3.2 is the input for external interrupt, and disables access to half the EPROM through
/WDTINT, from the Watchdog Timer. Port 3.3 the OR gate (U8-3). Run mode code (or shared
is the input for the external interrupt, /IFAIL,
 ως ο
code used in calibration) is located in the odd 4K R32 includes the power transistor A8Q] in the
blocks. The gate function at U8 thus ensures that opamp feedback loop, the combination of Q1
calibration code cannot be accessed when in the and U21 (pins 1, 2, and 3) may be considered as
run mode. a power opamp for analysis purposes.

The address latch at U24 captures the low order The -ISENSE and IGND signals are developed in
address byte (AO - A7) when control line ALE is the RF power amplifier on the Power Conversion
active. The data is then enabled on to the same Board A4. These signals are generated by the
bus when /PSEN and ALE are both low (0,0). power amplifier supply current passing through
In this manner the address/data bus (ADO - sense resistor A4R8. The resulting voltage -
AD7), alternates between carrying the low order ISENSE is proportional to the total de current
address for the next instruction from the micro- used by the RF power amplifier. The portion of
processor and reading the data, which is the code U21 that includes pins 5,6, and 7 makes up a low
for the next program step, back to the micro- pass filtered differential voltage amplifier that
processor. The high order address bus (A8 - amplifies the -ISENSE voltage by 10. The result-
A14), is used for addresses only and does not ing ISENSE voltage is proportional to the de cur-
require latching since the information is available rent drawn by the Excalibur Plus PC™ RF power
during the entire memory read operation. The amplifier from the +110V supply. When
only time /PSEN is active is during a program ISENSE exceeds the voltage at U21-3 by a diode
instruction fetch. When the microprocessor is voltage drop, the ISENSE feedback loop becomes
addressing external I/O, such as the PIA or dominant and backs VBASE down to maintain
NOVRAM, the signal/PSEN remains high. ADO- the RF power amplifier current at its limit. This
AD7 is an I/O bus whenever /PSEN is high. is independent of microprocessor control and is
an additional safety feature.
The Nonvolatile Random Access Memory
(NOVRAM), U2, is a battery backed static RAM. When the Excalibur Plus PC™ is in a monopolar
This device stores the calibration coefficients, coag mode, either WV6, WV7, or both will be
power settings and user programs used by the high, thus forcing pin U8-6 high, which in turn
microprocessor to control accurate power output makes U12-12 go low. This action prevents the
levels and to measure return electrode resistance. VSENSE voltage from turning back VBASE to
limit RF output voltage. In all other modes,
When the ESU is powered up, the data stored is U12-12 floats and allows VSENSE to be active.
accessed by the microprocessor via the When VSENSE exceeds the voltage at U21-3 by
address/data bus. a diode voltage drop, the VSENSE feedback loop
becomes dominant and turns VBASE down to
3.3.5 Base Voltage Generator limit the amount of RF output voltage. This
action occurs primarily at high power settings of
The base voltage generator is schematically monopolar cut and blend modes at high load
depicted on the A3 Controller Board Schematic impedances to prevent excessive arcing at the
4.40. It is microprocessor controlled with two active electrode.
analog feedback paths that can turn the base volt-
age down in case of excessive power amplifier The foregoing action takes place only in Spray
current and high output voltage. The high volt- Coag. In Standard Coag, VSENSE feedback gain
age shutback is not active in monopolar coag is present but highly attenuated by R43 in order
modes. to limit RF leakage.

The base voltage generator is made up of an 8 bit The inverting breakpoint amplifier (pins 1, 2, and
DAC (U20), a differential amplifier (1/4 of U21), 3 of U21) gain varies with the VDAC input volt-
an inverting breakpoint summing amplifier (1/4 age. Refer to Fig. 3.1. When VDAC is in the
of U21), and power transistor A8Q1. U20 pro- high range (producing a low VBASE since the
vides the input voltage selected by the micro- amplifier inverts), the incremental gain is -
processor by the address lines ADO-AD7. R25 is R32/R26. This low gain provides a finer control
a passive pulldown required by the DAC to reach of VBASE at the low power settings. At lower
the lower DAC output voltages. Since resistor VDAC voltages, diode D5 becomes forward

3-6
-ee
biased so that R9 is essentially in parallel with 3.3.6 IFAIL DAC
R26. Then the incremental gain is -(R32/R26
+R32/R9). This steeper gain allows VBASE to Schematic 4.4b contains the IFAIL DAC A3U19.
reach the voltage levels necessary for the higher The output of this 8 bit DAC (2.55 Vdc maxi-
power settings. The voltage where the gain slope mum output voltage) is fed into the reference
changes is determined by the Thevenin eguivalent input of U23-9. The DAC is controlled by the
of +12V, R11, R10 (shown as Vth and Rth in microprocessor to produce a reference voltage for
Fig 3.2) and R9. R23 is summed into the break- each mode of operation and power setting. The
point amplifier to subtract out the effects of the ISENSE signal (refer to section 3.3.5 for a
5V on the non-inverting pin of the amplifier, thus description of ISENSE) is voltage divided and
allowing the output of the base voltage generator lowpass filtered by R39, R49, and C61.
to go to zero. Whenever the resulting voltage exceeds the refer-
ence input voltage provided by the DAC U19,
R34 and R35 form a voltage divider to generate AFAIL will go low and an interrupt is generated,
a 5V offset for U21-3 to allow single supply
warning the microprocessor that the RF power
operation and to give a reference point for the
amplifier current is exceeding the maximum
VSENSE and ISENSE voltages. When RFEN is
allowed for that particular output mode and
low, U23-2 forces that voltage divider low, which
causes VBASE to turn off. When /WDTFL goes power setting. This is a fatal alarm that produces
low, U23-1 forces the base of A8Q1 low which a “Err 5.2” code and shuts down the Excalibur
causes VBASE to turn off. Plus PC™. Although it is possible for this to
occur because ofa temporary fault condition and
may be recoverable by cycling power, it generally
occurs because of a problem in the Excalibur Plus
PC™ circuitry and should be checked by the
Biomedical Department before returning the unit
to service.

Note that the same DAC is used for the A.R.M.

—

circuitry approximately every 12 milliseconds for

about 200 microseconds. During that time, the
Vout

microprocessor ignores /IFAIL since the reference

voltage provided by the DAC is being used to
provide a signal for the ARMCOMP comparator.
See section 3.8 for a more detailed explanation of
the A.R.M. circuitry.

3.3.7 Waveform Generator

Vdac >
Schematic 4.4b contains A3U18, a 32Kx8
Vbreak=-(R9/Rt)*(Vt-5)+5-Vd EPROM that stores the bit patterns for the wave-
Figure 3.1 Base Voltage forms that drive the RF power amplifier. The
EPROM is arranged so that the upper address
Generator Transfer Curve
lines, WVO-WV7, determine which waveform is
selected by the microprocessor, and the lower
address lines, WAO-WAó6, determine which byte
VoAc 862 of the waveform is selected at a time. The lower
address counter (A3U15 and A3U16) cycles
no20.0K
through its count to sequentially select each byte
vm ATH DA ps
of the waveform and to reload its own count
TT inatas
modulus at the beginning of each waveform. The
Figure 3.2 Basic Inverting selected byte of the waveform is then parallel-
loaded into shift register A3U17, where it is seri-
Break Point Amplifier
대
ally-shifted out to the buffers U13A and U13B A9R1(the volume control pot) and A3R18 form
one bit every 50 nanoseconds. a voltage divider to set the base voltage of A3Q2.
The emitter voltage of A3Q2 is one diode drop
A3U14 is configured as a modulus 8 counter that higher than its base voltage and is a constant for a
controls the parallel loading of the shift register given base voltage. This controlled emitter volt-
A3U17 and increments the lower waveform age across R15 means a current is flowing
address counter (A3U15 and A3U16). Both the through A3Q2 that can be controlled by the base
loading and incrementing occur on the rising voltage. That is how the volume is set for normal
edge of the 20 MHz clock when /SRLOAD operation. When an alarm is sounded, /LOUD
(U14-11) goes low and then high. A3U14 also from the microprocessor (which is buffered by
generates 2.5 MHz and 10 MHz clocks from the sections of U5 and U12) forces the base voltage
20 MHz oscillator Y1 for clocking the of A302 into saturation regardless of the setting
Display/Keyboard Driver/Encoder A2U2 and the of the volume control pot. This is to assure that
microprocessor A3U3. an alarm cannot be turned down in volume.

Each time /SRLOAD goes low and then high, 3.3.9 Base Voltage Monitor
the lower waveform address counter formed by
A3U15 and A3U16 advances its count. The out- R55,R60,R61,R62,D8,C72, and U26:A form a
puts from this counter (A0-A7) select the next 8 +5 Volt Overvoltage shutdown circuit. When the
bit word to be loaded into A3U17 from A3U18. +5 Vde supply rises above 5.4 Vdc, U26-2 forces
When the lower waveform address counter reach- the base of A8Q1 low which causes VBASE to
es it full count, i.e., the entire waveform has been turn off.
completely output, /CNTRLD goes low on the
next count and the address counter is preloaded R63,R64,R71,C69 and U26:B form a Base
to the pattern presented to it by O0-O7 of Voltage Check circuit. The DAC at UI9 is con-
A3U18. This pattern sets the modulus of the trolled by the microprocessor (with interrupts dis-
address counter and thus the length of the wave- abled to ignore /IFAIL) to produce a VBase refer-
form bit pattern. /CTRLOAD also clears the shift ence voltage for power up self tests and at least
register A3U17 to zeros to prevent putting the once every 500 mSec for each mode of operation
modulus pattern out to the power amplifier. Since and power setting when power is on during nor-
/CTRLOAD is low only at the beginning of a mal operation. When RF is activated and the
waveform, it is an excellent point to use for a resulting voltage exceeds the reference input volt-
scope trigger when examining waveforms (use age provided by the DAC UI9, VBASHI will go
TP20). high. This input is then read by the microproces-
sor, and if high, causes a fatal error that produces
U13 provides both buffer and enable functions an “Err 22.2” code and shuts down the Excalibur
for the waveform generator. U6D and U8C con- Plus PC. Power On Self Test Errors are “Err
trol the latch of the waveform. 22.0” if the VBase voltage is too low and “Err
22.1” if the VBase voltage is too high. Although
3.3.8 Tone Generator it is possible for these errors to occur because of a
temporary fault condition and may be recoverable
Schematic 4.4b contains the Tone Generator. It is by cycling power, it generally occurs because of a
a voltage controlled current source that is problem in the Excalibur Plus PC circuitry and
switched on and off at the frequency of the should be checked by the Biomedical Department
desired tone. /TONE is generated by the micro- before returning the unit to service.
processor A3U3 at the desired audio frequency
and is buffered by sections of A3U5 and A3U12 3.3.10 Waveform Monitor
to generate the signal SPKR-. When SPKR- is
inactive, no current flows through speaker R67,C70 and U26:C form an Average Waveform
A8SP1, thus there is no sound. When SPKR- is Check circuit while R65,R66,C74 and U27 form
low, the current flow through the speaker is deter- a Duty Cycle to Voltage circuit. The DAC at UI9
mined by R16 and the base voltage of A3Q2. is controlled by the microprocessor (with inter-
 OO << +++ +
rupts disabled to ignore /IFAIL) to produce a equipped with many fail detection and shutdown
Waveform reference voltage for power up self features. Further, an independent external circuit
tests and at least once every 500 mSec for each (the Watchdog Timer) guards against a malfunc-
mode of operation and power setting when tioning EPROM or CPU operation. This safety
power is on during normal operation. When RF system is discussed in the following overview of
is activated and the resulting voltage is outside the program.
the reference input voltage provided by the DAC
UI9, AWEMHI will go high if the Waveform 3.4.1. Software Initialization and Test
voltage is too high or low if the Waveform volt- Functions
age is too low. Input is then read by the micro-
processor and if the test fails, fatal errors that pro- The following list of software functions begins at
duce an “Err 23.2” code occurs and shuts down Power On Reset or by a manual reset performed
the Excalibur Plus PC. Power On Self Test Errors by an internal CAL/RST/RUN switch. The fol-
are “Err 23.0” if the Waveform voltage is too low lowing initialization sequence must be successful-
and “Err 23.1” if the Waveform voltage is too ly executed before the main working program can
high. Although it is possible for these errors to be entered.
occur because ofa temporary fault condition and
may be recoverable by cycling power, it generally 1. Initialize outputs to relays and indicators.
occurs because ofa problem in the Excalibur Plus
PC circuitry and should be checked by the 2. Initialize all data memory locations for the
Biomedical Department before returning the unit working program.
to service.
3. Verify that the Watchdog Timer is functioning
3.3.11 Tone Monitor correctly and that it can control RF shutdown.

A Tone Detector Shutdown circuit is provided to 4. Verify that the RF current circuitry is operat-
shut down the RF output in the absence of the ing.
audio tone, independent of the software function.
Dil and C73 half wave rectify the 16 Vdc tone 5. Verify that no shorts exist in the hand/foot
oscillator which is AC coupled through C71, controls.
while D12 discharges C71 during the negative
half cycle. R68 and R69 divides the 16 Vdc to a 6. Verify that no shorts exist in the membrane
maximum of 11.76 Vdc to remain below the panel.
maximum 12 Vdc input voltage to U26:11. R22,
R70 and U26:D form the comparator which will 7. Verify that internal data memory input/output
enable/disable the gate outputs through U13:A lines function properly and without crosstalk
and B. using a walking bit test.

3.4 Controller Software 8. Verify that the contents of program memory in

all locations where the program resides is intact
The behavior of the Controller is a function of using a 16 bit CRC (Cyclic Redundancy Check).
the custom program residing in the EPROM
memory (A3U1). Since U1 contains a custom 9. Verify that the contents of the calibration
program, it must only be replaced with a suitably memory (NOVRAM) in all locations where data
programmed part. Most failures of this part may resides is intact using a 16 bit CRC (Cyclic
be traced to mishandling, particularly due to stat- Redundancy Check).
ic discharge or to a secondary failure resulting
from application of excessive voltage to the cir- 10. Perform Display and Tone tests.
cuit, as may occur if a voltage regulator fails.
However, since undetected failure of the EPROM 11. Enable RF output relays and pass control to
could escalate a minor failure to a serious conse- the working program.
quence in the O.R. environment, the program is
oct 2 νὺσνὓὺρ.ὺυύς«ὓ-ντιτας
Failure of any of the above self-tests will result in 3. The current limit fail-safe is set.
the end of program executions, and a display of
“Err” or “ACC” on the Cut display. A Machine 4. The power setting is used to retrieve waveform
Fault tone is sounded to alert the operator and a and amplitude parameters from the calibration
fault code is displayed on the Coag Power Level memory which are then sent to the RF drive cir-
LEDs. See Appendix A for a list of the codes and cuits.
possible causes.
5. RF output is enabled via /RFEN.
3.4.2. Working Program Functions
Self-tests are continuously performed during
The main program loop is executed continuously operation to ensure the integrity and reasonable-
by calling the working subroutines and refreshing ness of hardware and software operation during
the Watchdog Timer circuit on each pass through the working program execution. Failure of these
the loop. tests will result in a safe end-to-program execu-
tion (RF drive and all relays are disabled). A dis-
Bipolar, hand control, foot switch, and return play of “Err” on the Cut power levels LEDs and
electrode inputs are monitored for changes. The a loud alarm tone alerts the operator to the condi-
validity of the input conditions are checked. The tion. The appropriate error code is displayed on
following conditions are considered illegal the Coag Power level LEDs to indicate the errors.
requests and result in a operator error tone:
3.4.3 CAL Mode Software
Simultaneous monopolar and bipolar requests.
*Simultaneous Coag and Cut requests. The CAL mode is used to calibrate the unit. It
*More than two simultaneous requests. also provides access to Watchdog Timer and
*Any activation request other than bipolar with Pseudo Run Mode diagnostics, which are provid-
the Return Fault indicator ON. ed to simplify troubleshooting of faults which
*Attempt to store a setup at the “0” or “P” would otherwise leave the unit inoperative due to
program locations. fault detection shutdown in RUN mode. A final
* Any request for power change while activated, function is the ability to view the Last Fault Code
except for the activated mode. (LFC) that occurred in RUN mode, and to clear
* Any request for power change in Remote Power the LFC.
Control except controlling handpiece.
When CAL mode is first entered, a display check
In the case of an illegal hand/foot request, the last occurs for 30 seconds or until any key is pressed.
valid request is the one honored. Other operator At that point an abbreviated self diagnostics
actions that can result in a pulsing operator error occurs, and if successful, CAL mode is entered.
tone are multiple or stuck key press, or attempt-
ing to increase or decrease power levels beyond 3.4.3.1 Calibration
the machine limits.
Calibration mode allows the technician to modify
The current condition of the hand/foot controls the calibration tables to correct for drift over
and the keyboard are continuously monitored. time, or to correct for new components after a
When a valid request to change mode or power repair. During Power Calibration, each calibration
level is received, the displays are updated to reflect + table value can be adjusted up or down when the
the change. When a valid request for RF activity unit is activated, The adjustment range for each
is received, the following sequence is performed: entry is limited to + 25% around a nominal set-
ting. The adjusted calibration value is stored in
1. The appropriate RF indicator lamp and tone nonvolatile memory, additionally, both the base
are activated. voltage drive (VBASE) and gate drive waveform
(/GATE) are sampled and stored to act as refer-
2. The requested accessory output relay is closed. ences for checking over power conditions.
NOTE: Since VBASE is in the output voltage

3-10 rs
 ibyrPlus,PC”

limiting circuit feedback loop, it is important that hand or foot controlled activation requests,
calibration is only done with the proper load Power settings, mode requests, and return elec-
attached. This will ensure that the unit is not in a trode alarm set point are all entered via the front
voltage limited mode and store the wrong panel membrane switches. The various indicators
VBASE value. During ARM calibration, the unit and displays supply machine operating status.
stores a value that corresponds to the resistance These include requested power, mode, program,
attached at the return pad connector. There are return electrode resistance, and alarms if they
software limits to confirm that the resistor or cir- occur,
cuit are within reasonable limits.
3.5.1 Indicators
For each mode, the software checks to see if any
points have been changed. If at least one has, it Refer to the Display Schematic 4.3. The control
will require that all points that have not yet been of the indicator lights on the Display PWB is
selected be activated. Points that have not been handled by the Peripheral Interface Adapter
checked are denoted by flashing the display when (PIA), U3. Address, data, and control signals are
those points are selected. An Err code 10.X will supplied to the PIA from connector J1. This
occur if the power calibration menu is exited with device contains three registers (one for each Port),
an incomplete calibration. Additionally, the unit which can be individually written to or read from
will check that all calibration points are monoton- by the microprocessor. The three I/O ports are
ic when the menu is exited, that is, it will verify allocated as follows.
that successively higher power entries in each
mode are equal or contain successively higher PORT A (PAO - PA7). This port is connected to
drive values. If not, an Err code 11.X will occur. the octal DRIVER, U5, which controls the num-
If both checks pass, the unit will calculate and ber of Bar LEDs that are illuminated in 122, the
store a new CRC to allow verification that the “ASSIST Resistance indicator” display. By writ-
calibration has not changed and is stored properly. ing a one to any of the eight inputs to US, the
corresponding output goes low, turning on the
During RUN Mode, the software interpolates the LED. Note that the first two LEDs of 122 and
drive value for the present power setting between the last two LEDs are connected in parallel to the
the calibration points. The drive value is then output of US. This is done to interface the ten
passed to the VBASE Generator or Waveform bar LED readout to the single byte output of
Generator necessary to produce the set power. Port A.

3.4.3.2 Diagnostics PORT B (PBO - PB7) and Port C (PCO - PC7).

These ports control the various modes, activation,
Sections 4.7.1 - 4.7.3 contain the details for the and alarm indicators. Whenever there is a one
use and operation of the diagnostic modes avail- (high) written to a Port line, the output of the
able from the CAL menu. corresponding driver will pull to ground turning
on the LED or lamp.
3.4.3.3 Last Fault Code
3.5.2 Displays and Keyboard.
The microprocessor will store the last fault code
that caused it to shut down in Run or Pseudo The control of the 7-segment displays and the
Run mode. From the top level Cal menu, LFC keyboard is performed by the Keyboard/Display
can be selected for viewing, and to clear the pre- Interface, U2. Scanning of the keyboard and
sent code. See Section 4.7.1 for additional details. multiplexing of the displays is implemented by
the outputs SLO - SL2 counting in a binary fash-
3.5 Display Hardware ion which is decoded by U4. The outputs of the
DECODER and Driver (U4), go low sequential-
The Display PWB Assembly (A2), in conjunction ly (0, 1, 2, etc.) scanning 11 - 18 displays and
with the Membrane Switch Panel (A1), is the both rows of the keyboard. Transistors Q4 - Q6,
user interface to the unit for all inputs except which connect the scan lines to the keyboard

[= 3-11
eceli 25 2
rows, prevent the cross connection of the multi- which delivers power to Z1. After the turn-on
plexed signal whenever one of the keys is transient, Q2 will be conducting hard and O1
depressed. If one of these transistors shorts out, will draw collector current in proportion to its
one of the 7-segment digits (I1 - 13) is written to base current, which in turn is controlled by
continuously causing it to be overdriven and glow VBASE and Rb. At sufficiently high base cur-
brighter than normal. Display I9 is lit through rent, Q] saturates (collector-base voltage nearly
driver U7 when U2 SL3 is high and U4 is dis- zero), transferring maximum available power to
abled by Q. The internal circuitry of U2 reads Z1 while QI and Q2 dissipate little power due to
each digit data stored in internal RAM and drives the low voltage across them. Turn-off commences
the segment output (BO - B3 and A0 - A3) in with VGATE quickly dropping to nearly 0 V,
sync with the scan lines. Current is then supplied shutting off Q2 and effectively disconnecting
to the correct digit, displaying the appropriate Q1's emitter from the circuit. Collector current
number. The segment outputs of U2 are con- then flows out of Ols base pin into Cb until all
nected to the current driver (U1) which delivers of the charge stored in Ol during turn-on is
approximately 40 mA to each segment. The dis- washed out. Then O1 completely shuts off, ceas-
plays are common cathode variety so that the cur- ing power transfer to Zl.
rent is supplied to the anode and pulled to
ground at the common cathode connection by I“
the scanned open collector driver.
Z1

The keyboard (Schematic 4.2) is part of the front

panel assembly and is connected to the Display DI
PWB through connector A2J3. There are also
ground connections from the front panel electro- Pb Qi
static shield which is incorporated into the mem- VBASE cb
brane switches. These grounds straps are con-
nected directly to the chassis and prevent EMI
て Re
(ElectroMagnetic Interference) and ESD
o
(ElectroStatic Discharge) from being conducted
into the logic circuitry via the keyboard. VGATE

3.6 Power Amplifier

The Power Amplifier (PA) is a hybrid cascode Figure 3.3 Basic Hybrid
amplifier made up of high voltage bipolar tran- Cascode Configuration
sistors and low voltage power MOSFETs. See
Schematic 4.5. Figure 3.3 shows the basic hybrid The collector voltage may rise to many times the
cascode amplifier configuration. The combina- value of V+ after turn off. Since the emitter is
tion of O1 and O2 make up a fast, high-voltage now disconnected, the collector-base voltage can
amplifier that can be controlled by the combina- take on the highest value which that junction will
tion of the dc voltage VBASE, and the fixed sustain with little chance of second breakdown.
amplitude, variable pulse width signal, VGATE. The base bypass capacitor, Cb, is sized to ensure
In the OFF condition, VGATE is near ground, that it can absorb all of the stored turn-off charge
turning off O2 so that no drain current can flow. without allowing Q2’s drain voltage to approach
Thus no base or emitter current can flow in the its breakdown limit. Further, this charge is now
bipolar transistor. Since V+ is always greater available to charge the base on the next cycle,
than VBASE, the collector base junction is thereby significantly reducing the net current
reverse-biased, so no collector current will flow drain from the VBASE supply.
and no power is delivered to the load. Turn-on
commences with VGATE rising rapidly to about The saturated operation described above takes
+10V. This results in a large pulse of base current place in both Monopolar Coag and during high-
flowing in Q] from Cb, quickly turning Q1 on power(>150 W) Cut. During the latter mode,
power increases take place because the dynamics

3-12
[ce
of ZI allow Çİ to saturate over a greater propor- uses a fixed VBASE and varies the number of
tion of the conduction cycle as VBASE is pulses per cycle period to control output power.
increased. Once saturation occurs, excess stored
charge accumulates, extending the time required 3.7 RF Output Section
to remove the charge on turn-off and effectively
increasing the duty cycle of the amplifier. At Refer to Schematic 4.6. RF output power may
lower Cut power settings, VBASE is too low to be supplied through one of two RF isolation
allow saturation, so Q1] conducts only partially, transformers, as selected by the Bipolar relay,
absorbing some of the power that could other- A5K6. When de-energized, K6 connects the
wise to supplied to Z1. This mode is not as effi- power amplifier collector bus to the Monopolar
cient as saturated operation because Q] sees output transformer, T3, which is resonated by
simultaneous voltage and current. However, the C28 and C29 and damped by A9R2. The main
current at this point is low enough to limit Os secondary of T3 is capacitively coupled by C41
dissipation to that Which can be dissipated by the and C30 to the patient plate output jack and via
heat sink without excessive junction temperature high-voltage reed relays, to the user selected
rise. When VBASE drops to below about 0.6 V, monopolar active accessory connectors. An auxil-
no power is delivered to the load since this volt- iary single-turn T3 secondary supplies a replica of
age is too low to cause base current to flow. the power amplifier collector voltage to the
VSENSE circuit. This rectifies and peak-detects
The PA consists of two separate Hybrid Cascode this signal for use by the control circuitry to limit
sections connected at the collector bus. Each sec- output voltage in Cut.
tion is made up of a single power MOSFET dri-
ving the emitters of three bipolar transistors. When K6 is energized, it disconnects T3 and sup-
Each bipolar base has its own base current control plies the Bipolar output transformer, T1, with
network which is driven from a common VBASE power from the power amplifier. The primary of
supply. Each collector and each base is separately TI is resonated by C27 and is damped by A9R2.
fused, allowing a failed part to disconnect itself This transformer is designed to meet the particu-
from the circuit without seriously affecting per- lar requirements of bipolar electrosurgery which is
formance. Failure of either power MOSFET will characterized by much lower impedances and per-
reduce the RF power available by about half, missible voltages than those in monopolar opera-
since the working half will continue to operate. tion. Its secondary is capacitively coupled to the
appropriate output connectors. Output wave-
Voltage snubbing networks protect VGATE, forms under various conditions are shown in
VBASE, and the power MOSFET drains from Figure 3.6.
being damaged in the event of any transistor fail-
ure. This limits the extent of failure damage. Balun transformer T6 operates to balance active
Each collector is equipped with a diode which and return currents and thus attenuate common-
allows the voltage on the output bus to swing mode RF leakage in all monopolar modes.
negative with respect to ground, as it does in all
monopolar modes of operation at sufficiently CAUTION: Because of the high peak-to-peak
high power and load resistance. amplitudes of these waveforms, use oscillo-
scope probes that can withstand 2 KVpp mini-
In Cut modes, VGATE is a fixed frequency rec- mum for cut, 12.0 KVpp minimum for coag,
tangular pulse and VBASE is varied from about and 500 Vpp minimum for bipolar.
0.3 to +8.5 Vde to control output power. The
same is true in Blend except that VGATE is fur- 3.8 Aspen Return Monitor (A.R.M.) Circuitry
ther modulated to produce dead time with no and Software
output. In Monopolar Coag Modes, Standard
and Spray, VBASE is fixed while VGATE is var- The A.R.M. Circuit converts the electrical resis-
ied in length. This variation in conduction time tance appearing in the return electrode circuit into
controls the amount of energy stored in the a digital value which can be processed by the
inductive part of Z1 every cycle and therefore microprocessor A3U3. Software processes use
varies the output power level. Bipolar Coag Mode this value in conjunction with the SINGLE

re) 3-13
 Eco ec NS
PAD/DUAL PAD and MONITOR SET POINT The A.R.M. oscillator generates a low-power
buttons to determine when a RETURN FAULT sinewave voltage of about 36 KHz. This fre-
condition exists. The ASSIST Resistance quency is determined by the inductance of T4 in
Indicator is also driven by software to indicate the parallel with the capacitance presented by C21 -
value of the measured DUAL FOIL resistance in 23, and that of C44 and C45 reflected through
the 10 to 150 ohm range. T5. Transistors Q2 and Q3 are cross-coupled via
R7 and R8, so that when one transistor is con-
Portions of this function are implemented on the ducting, the other is fully turned off due to lack
A3 Controller PWB and on the A5 Output PWB. of base drive. The conducting transistor turns off
at the next zero-crossing of the sinusoidal voltage
150-
on the primary of T4. This allows its collector
1304 voltage to rise and thus provide base current to
the other transistor to turn it on. In operation,
1104 the collector voltages appear like half-wave recti-
RESISTANCE (OHMS)

fied ac, with each collector 180 degrees out of

904 phase with the other. See Figure 3.7.
704
The A.R.M. oscillator is powered by a constant
50” 0.5 mA de current driven from the A3 PWB via
the VARM signal line. This current feeds into
304 the center tap of T4 primary. The voltage on the
center tap is the average of the two collector volt-
10. T T T T T ages, so it appears as a full-wave rectified sine
2 4 6 8
wave with a peak amplitude of one-half that on
RESISTANCE BARS
either collector. Inductor L1 helps hold the cur-
FIGURE 3.4 rent fed to T4 constant regardless of these voltage
variations, while C15 serves as a bypass to limit
the noise conducted from the A5 PWB up the
Figure 3.4 shows the approximate resistance vs. VARM line to the A3 PWB.
number of illuminated bars in the resistance indi-
cator. If no bars are lit, then the resistance is less The A.R.M. oscillator is a de-to-ac power con-
than approximately 10 ohms, if 10 bars are lit, verter, with its major losses appearing as resistors
the resistance is greater than approximately 150 in parallel with the resistance of the return elec-
ohms. It is not possible for just 1 or 9 bars to be trode circuit, RI, transformed up through T4 and
lit, unless a bar segment has failed. T5. In effect, the A.R.M. oscillator transforms RI
into an equivalent de resistance, Rin, appearing at
Schematic 4.6 contains the ARM Circuitry on the the VARM input to the circuit. Thus when RI is
A5 PWB. It is comprised of an oscillator section very high, as when no connection is made to the
and an isolation section. The isolation section Return electrode jacks, Rin is maximum, allowing
employs a shielded toroidal transformer, T5, to the VARM voltage to rise to +2.3 - 3.0 Vdc.
couple the impedance presented at return elec-
trode plate jacks, A7J8 and J9 to the ARM oscil- When RI falls into the 10 to 150 ohm range nor-
lator, while isolating that circuit from the effects mally encountered with a properly applied dual-
of applied RF electrosurgical current and voltage. foil electrode, Rin also drops and VARM falls
Capacitors C44 and 45 split the return current into the 1.0 to 2.5 V range. If RI is very low, as
evenly between the two legs, thus minimizing the when a single foil electrode is connected, VARM
RF voltage appearing across T5 windings. T5 drops to about +0.8 Vdc. Resistors R11 and
also acts to step up the return circuit impedance R12 serve to set a lower limit to the resistance
by about 10:1. The shield serves to prevent the applied across T4’s secondary. Without this lower
RF stray magnetic field generated by the limit, the effective short circuit presented by a sin-
monopolar output transformer, T3, from gle foil return electrode would reduce the Q of
interfering with the ARM circuitry during RF the 37 kHz tuned circuit to the point that the
activation. oscillator would behave erratically. Thus VARM
K
varies directly with the resistance appearing in the the relationship between R1 and the ASSIST
return electrode circuit. The relationship is essen- Resistance Indicator bars.
tially logarithmic, with increases in VARM
becoming vanishingly small as RI rises above In Dual Foil Mode, the microprocessor declares a
1000 ohms. This means that VARM will change Return Fault if RI is less than 10 ohms or greater
by a nearly constant voltage for a given percent- than 150 ohms. If VARM is within the allowed
age change in RI anywhere in the 10 to 150 ohm range, then the Return Fault Indicator will turn
range. off when the Alarm Set Point Key is pressed, and
the present value of VARM is stored for refer-
The balance of the A.R.M. Circuitry resides on ence. A new Return Fault will be declared if RI
the A3 Controller PWB, Figure 4.4b. Diode rises about 20% above this stored value or goes
VR2 is a +1.235 V regulator whose output volt- out of the allowed range.
age appears across the 2.49K resistor R47, thus
driving a constant current of 0.5 mA into the This rise indicates significant electrode detach-
VARM line. R48 allows the circuit to operate to ment. A Return Fault declared in this case will
ground, while R40 and C38 act as a low-pass NOT automatically be cleared if the patient resis-
noise filter. The voltage BVARM at U21-8 is tance drops back to near the stored value. The
essentially equal to VARM, since that opamp is Alarm Set Point Key must again be pressed to
connected as a high-input-impedance voltage fol- register the staff’s satisfaction that the electrode
lower. attachment is safe before turning off the alarm.

The digital-to-analog converter, DAC U1, is dri- Because patients’ and return site resistances vary
ven by the microprocessor to produce 0.0 to over a considerable range, it is not safe to assume
+2.55 Vdc at U19-16. This voltage is compared that any in-range resistance indicates safe elec-
to BVARM by comparator U23 to drive ARM- trode attachment. For example, a poorly placed
COMP at U23-13. Every 12 msec, the micro- electrode on a well-perfused site can show the
processor reads the ARMCOMP line in response same resistance as a safely attached electrode on
to a sequence of DAC voltages, determined by a adipose tissue. Yet the poorly placed electrode
successive approximation algorithm, to measure could still result in a burn due to low contact
the VARM voltage to a precision of 10 mV. This area. The clinical staff is responsible for the final
value is then processed along with the VARM val- judgment of safe return electrode placement.
ues for 10 and 150 ohm return circuit resistances
stored in the NOVRAM during the last Pad 3.9 Continuity Detector
Calibration to evaluate the current RI.
The Continuity Detector provides isolation by
The Return Fault process works on a 50-point both magnetic and optical coupling. Schematic
(0.6 sec) average VARM value. If Single Foil 4.6 includes a schematic of the continuity detec-
Mode is selected, the microprocessor will declare tor. A 90 kHz oscillator, A5U4, generates a 20%
a Return Fault when VARM indicates that RI is duty-cycle rectangular wave drive to transistor
10 ohms or greater. The ASSIST Resistance A5Q1, which drives the resonant primary circuit
Indicator is always dark in this mode. of a toroidal isolation transformer, A5T2. See
Figure 3.7. The energy coupled to the secondary
In Dual Foil Mode, the ASSIST Resistance windings is rectified and filtered to produce an
Indicator will be illuminated to indicate RJ in the isolated 3 to 4 Vdc source for each of the three
range of 10 to 150 ohms. At just over 10 ohms, separate RF output circuits (BIPOLAR, H1, and
the two left bars are illuminated. As VARM H2). The bipolar hand switch continuity detector
increases, additional bars are illuminated in pro- will be used as an example, since all sections are
portion to VARM, progressing to the right, until identical. When the bipolar hand switch is
RI approaches 150 ohms, where eight bars are closed, de current limited by R1 flows through
illuminated. When RI exceeds 150 ohms, all ten the LED in the optical isolator U1. This pro-
bars are illuminated. Whenever a Return Fault duces a beam of light which falls on the photo-
condition exists, all illuminated bars will flash, but transistor in U1, causing it to draw collector cur-
RI is still displayed as above. Figure 3.4 illustrates rent. This current pulls the signal line /HBP to a

[2 3-15
GGI rr ㄴㄴㄴ ㄴ‥ ㆍㄴㄴㄱ
low voltage, and this state is interpreted by the ever. This assembly is mounted to the top cover
microprocessor as a closure of the switch. When RF shield. It is inconvenient to work on the A3
the hand switch is released, the LED goes dark assembly with A10 in its normal position. To
causing the phototransistor to cease conduction facilitate that, one can easily bypass the A10
and allow the signal line to be pulled to a high assembly by disconnecting the connector from
state by resistor network A3RN1, A5C3 bypass- footswitches to A10, and the cable from A10 to
es any RF currents around the bipolar accessory A3. Connect the cable from the base to A3P7
switch than may occur due to reverse accessory (the same plug the A10 cable was using). Be sure
connection while blocking de from the Ul LED to restore original connections before returning
when the accessory switch is open. unit to service to provide the required isolation.
3.10 Footswitch Isolation
Power is provided through the line power isola-
The Footswitch Isolation Assembly, A10, pro- tion transformer A10T1, where it is rectified (D1,
vides isolation from ground for the monopolar D2) and filtered (C1) to provide the unregulated
and bipolar footswitches. This isolation is dc voltage supply. The remaining circuitry is sim-
required to prevent activation in case either side ilar in operation to the Continuity Detector (see
of the switches are shorted to ground. The Section 3.9), thus the theory will not be repeated.
exposed metal of the switches is grounded, how-

Figure 3.5 Power Amplifier Waveforms

The following waveforms are representative of those which appear in the Excalibur Plus PC" Power
Conversion Assembly at the collector bus COLL (A4TP2) and the GATE (A4TP4).

200V/aiv 7
COLL i
500V/div Di
A SINA
senden i
dere eee
„E GATE 了

σας 400nS/div 10V/div 2uS/div

Monopolar Pure, 300W, Open Circuit Monopolar Spray Coag, 80W,

Open Circuit

COLL

MW
seba

GATE
| 10V/divfle | AA 人AA 和 AA
1uS7div

Bipolar Coag, 50W, Open Circuit

3-16 [=
о İİ
Figure 3.6 RF Output Voltage Waveforms

500V/div 200V/div

1.0uS/div 1.0uS/div

Monopolar Pure, 300W, Open Circuit Monopolar Pure, 300W, 300 ohm load

‘500V/div 200V/div

İl m
10uS/div 10uS/div

Monopolar Blend 1, 180W, Open Circuit Monopolar Blend 1, 180W,

300 ohm load

500V/div 200V/div

№
10uS/div = 10uS/dv À

Monopolar Blend 2, 120W, Open Circuit Monopolar Blend 2, 120W,

300 ohm load

re 3-17
ExcaliburPUS
PC

Figure 3.6 RF Output Voltage Waveforms, cont'd.

500V/div 200V/div

ly
i
10uS/div 10uS/div É

Monopolar Blend 3, 80W, Open Circuit Monopolar Blend 3, 80W, 300 ohm load

2000V/div 500Vidiv

和 мм A]
диам = 4.0uS/div 7

Monopolar Standard Coag, 120W, Monopolar Standard Coag, 120W,

Open Circuit 300 ohm load

2000V/div 500V/div
fare

10uS/div 10uS/div =

Monopolar Spray Coag, 80W, Monopolar Spray Coag, 80W,

Open Circuit 500 ohm load

3-18 (=
 + ©
Figure 3.6 RF Output Voltage Waveforms, cont'd.

50V/div 50V/div

1.0uS/div É

Bipolar Coag, 50W, Open Circuit Bipolar Coag, 50W, Open Circuit,
Expanded Scale

50V/div

mil |
104S/div

Bipolar Coag, 50W, 50 ohm load, Bipolar Coag, 25W, Open Circuit
Expanded Scale

50Vd 50V/div

|
CAN

|
| ΙΙ
|
|

|
Ι
il
KI:

ΠΠ
Ι | ALANI
i || y
| WEI

V
10uS/div 1.0uS/div

Bipolar Cut, 50W, Open Circuit Bipolar Cut, 50W, Open Circuit,
Expanded Scale

re 3-19
Eco >
Figure 3.6 RF Output Voltage Waveforms, cont'd.

50V/div

1.0uS/div

Bipolar Cut, 50W, 50 ohm load,

Expanded Scale

Figure 3.7 Miscellaneous Waveforms

NE INS 그

mal. Pi |JN - YA

T4-1
V ON GN GN AN AN NL Eo yal |
SuSidiv i 2.0uS/div |

A.R.M. Oscillator Waveforms - Continuity Detector Waveforms

(Output Board) (Output Board)

3-20 ¡e
 Maintenance
Section 4.0

4.1 GENERAL MAINTENANCE Slots are free and then lower it onto the Base
INFORMATION Assembly. Reengage the Front Closure Pins into
the Base Assembly slots before replacing the rear
This section contains information useful in the screws.
maintenance and repair of the Excalibur Plus
PC". While the unit has been designed and >WARNING<
manufactured to high industry standards, it is rec- HAZARDOUS VOLTAGES ARE PRESENT
ommended that periodic inspection and perfor- ON ALL BASE SUBASSEMBLIES WHEN
mance testing be performed to ensure continual THE UNIT IS OPERATING.
safe and effective operation.
NOTE: The Excalibur Plus PC™ may be operat-
Ease of maintenance was a primary consideration ed with the Top Cover open and the RF Shield
in the design of the Excalibur Plus PC™. removed for test purposes. Avoid drawing arcs
Maintenance features of this unit include micro- with the RF Shield removed. Failure to replace
processor aided troubleshooting aids and push the RF Shield when returning the unit to service
button calibration, built in fault detection, circuit may cause erratic operation and/or cause error
protection, easy access to circuitry while the unit codes to occur.
is operational, and fused, screwdriver replaceable
power transistors. These features coupled with 4.2.1 Display PWB A2
the warranty, local support, loaner equipment,
factory support, toll free phone service to the fac- To gain access to the Display Assembly A2,
tory and available factory training ensure the user remove the nine nuts attaching the RF Shield to
of a minimal maintenance effort with extensive the Top Cover. See Fig. 4.2. Access to the com-
support available. ponent side of the A2 Display Assembly is gained
by removing the five screws. See Fig. 4.3. Verify
4.2 ASSEMBLY BREAKDOWN & PARTS cable connections when reinstalling the Display
ACCESS PWB. When replacing the RF Shield take care
not to pinch any of the cables.
>WARNING<
HAZARDOUS VOLTAGES ARE PRESENT CAUTION: Many of the components on the
ON INTERNAL COMPONENTS. BE A2 and A3 assemblies are static sensitive.
SURE THAT THE UNIT IS TURNED OFF Take appropriate precautions when servicing
AND THE POWER PLUG IS DISCON- these boards.
NECTED BEFORE DISASSEMBLY.
4.2.2 Controller Assembly A3
The Excalibur Plus PC™ opens into a Base
Assembly and a Top Cover Assembly. To gain To gain access to the Controller PWB A3, remove
access to the internal parts remove the two the RF Shield. See Fig. 4.2. Access to the cir-
Phillips head screws on the Rear Panel. Refer to cuit side of the A3 Controller Board is gained by
Figure 4.1. Slide the Top Cover forward and lift removal of the six fasteners and eight cable con-
its front edge. The Top Cover can be held open nections. Verify cable connections when rein-
vertically by sliding the Rear Support Bracket stalling this board. Take care not to pinch any of
Slots onto the top edge of the Rear Panel Base the cables when replacing the RF Shield.
Assembly. See Figure 4.2. To close the Top
Cover, lift it upward until the Support Bracket
Exc Cs
4.2.3 Power Conversion Assembly A4 TB2. A lead number is printed on each of these
wires which corresponds with its terminal number
The Power Conversion PWB A4 contains the A4 on TB] and TB2.
PWB and the six Power Transistors. See Figure
4.3. Refer to Section 4.7.8 for precautions to be The transformer frame is grounded via a green-
taken when replacing these devices. yellow wire with a ring lug secured to a ground-
ing stud on the bottom of the Base Assembly.
Most A4 PWB components may be replaced
without removing the A4 Assembly from the The two red resonating winding leads, #5 and
unit. Removal of A4C8, C9, C11, and C20 can #6, connect to A6CI via slip-on connectors
be accomplished by removing the A4 PWB. It accessible after pulling up the insulating boot.
should be removed as a unit including the
heatsinks. Removal is accomplished by removing Capacitor A6CI is secured to the Rear Panel
the heatsink mounting fasteners and five harness Assembly by a strap.
connections. See Figure 4.3. When replacing this
assembly, tighten all heatsink mounting fasteners 4.2.5.1 Primary Strapping
before tightening the PWB fasteners.
The unit may be adapted to various mains volt-
CAUTION: This assembly is fragile when not ages by changing connections on A6TB1 and
mounted in the unit. Do not bend or flex the replacing A9CB1. Figure 4.1 and 4.7 illustrate
A4 assembly. the variations available for each model. If possi-
ble, reuse the factory supplied wires. Note that
4.2.4 Output Assembly A5 the transformer and its accompanying capacitor
must be changed between 50 and 60 Hz only
Removal of A5 the Output PWB is accomplished versions. Otherwise use #18 AWG stranded wire
by removing ten cable connections, three screws with 300 V, 80° C insulation or better. Ensure
and unsnapping the four plastic support posts. that all strands are inserted into the terminals
Refer to Figure 4.3. before tightening the terminal screws. Chassis
leakage tests per Section 4.5.6 should be conduct-
4.2.5 Power Transformer and Resonating ed after restrapping to verify the safety of the
Capacitor unit.

Refer to Schematics 4.1 and 4.7. The ferroreso- 4.2.5.2 Replacing A9T1 and A6C1
nant power transformer A9T1 and its resonating
capacitor A6C] are conservatively rated and are A9TI and A6CI can only be ordered and
unlikely to require replacement due to failure. The replaced as a unit. AGC] may be removed by dis-
most common reason for replacing these compo- connecting red leads A9T1-5 and -6 and loosen-
nents is to change mains frequency. Consult the ing one of the strap mounting nuts enough to
factory for information on changing the mains permit the capacitor to slide out. Before remov-
frequency. The Excalibur Plus PC™ should be ing the A9T1 mounting screws, disconnect all of
operated ONLY at the mains frequency marked the transformer leads from A6TB1 and TB2, the
on the unit’s Nameplate. frame grounding lead from the grounding stud.
Replace the other grounding lugs which also are
Transformer A9T1 is supplied with captive, self- connected to this stud and loosely reinstall the
locking nuts in each of its four feet. The feet are nut.
secured to the bottom of the Base Assembly with
Allen-head screws and lock washers through Disconnect and remove A6C1. On 50-60 Hz
vibration isolating grommets. units, disconnect A4P4 and the OVP sense con-
nections at A6BR1, A6BR2 and the lugs connect-
Primary and secondary electrical connections to ing to A6W1. Reconnect A6W1 lugs to the
A9TI are via leads terminated on A6, TB1 and proper terminals on A6BR1 and A6BR2 to aid
correct reassembly.
 m
Close the top cover, tip the unit backwards and male nesting lug should be oriented toward the
remove the two mounting screws and flat washers insulated rectifier mounting nut to prevent acci-
nearest the front of the unit. The transformer dental short circuits to the grounded metal rectifi-
will rest against the Rear Panel. Return the unit er case.
to its normal operating position and place it on a
workbench with the rear panel projecting past the Install A6C1, ensuring that it is the proper value
edge only far enough to gain access to the two for the mains frequency marked on A9T1. Slide
rear transformer mounting screws. the capacitor down until its bottom just touches
the top of the bent edge on the Base Assembly,
After all four mounting screws and flat washers then tighten the strap mounting nut.
have been removed, carefully lift A9T1 out of the
unit, rotating it forward to prevent damage to the Insert red leads A9T1-5 and -6 through separate
A4 PWB or nearby harnesses and components. holes in the boot, then reconnect the slip-ons to
Avoid disturbing the routing of harnesses. separate terminals on A6C1. This capacitor is not
polarized, so the leads may be connected in either
Before installing A9T1, remove any debris which order.
may have accumulated under the transformer and
inspect the vibration isolation grommets for dam- Install cable ties on the secondary leads, if neces
age and proper insertion in the Base Assembly. sary. Carefully dress all transformer leads so that
Torn or missing grommets should be replaced they are clear of sharp edges and completely
before installation of A9TI. below the top edge of the Rear Panel. Restore
the original routing of any other harnesses which
If the replacement transformer leads have not may have been moved.
been trimmed and sleeved, cut and strip each lead
to the same length as on the transformer which Test the installation by performing the
was removed. DO NOT tin the stripped ends. Preliminary Tests in Section 2.3, Chassis Leakage
Sleeving from the old transformer may be reused tests in Section 4.5.6, and Output Power tests in
if not damaged. Cable ties on the secondary leads Section 4.5.3.
are most easily installed after the transformer is
mounted and reconnected. 4.3 CLEANIN

Installation of A9T1 and A6CI is in the reverse The interior of the unit may be vacuumed or
order of removal. blown out as required. The exterior of the unit
may be cleaned by wiping it with a cloth that has
NOTE: The transformer mounting screws should been dampened (not dripping) with a mild deter-
be tightened only one-half turn beyond the point gent such as Windex® or Formula 409®
where the grommet is in contact with both the Windex® is a registered trademark of the
flat washer and mounting foot. Drackett Products Company. Formula 409® is a
registered trademark of the Clorox Company.
Place the green-yellow frame bonding wire on the
grounding stud along with all of the other
grounding lugs originally there. Tighten the nut
securely.

Reconnect the primary and secondary leads to

A6TB1 and 2, ensuring that each is securely con-
nected to the proper terminal with no stray
strands.

On 50-60 Hz units only, reconnect A4P1 and

A4J1 and reconnect the OVP leads in their origi-
nal order to A6BR1, A6BR2 and A6W1, the
Figure 4.1 Rear Panel Screw Location

HEATSINK MOUNTING FASTENERS.

и, COVER SCREWS - REMOVE TO OPEN

© © I

A©
 Figure 4.2 Display, Controller & Footswitch Isolation PWB Locations
(Shown with RF Shield cutaway)

FRONT
CLOSURE
PINS

A2 DISPLAY
ASSEMBLY E
| | ORE SHIELD

Top SS P
COVER RE SHIELD
ASSEMBLY FASTENERS

A3 AN ) — Al0
CONTROLLER р FOOTSWITCH
ASSEMBLY : 5 ISOLATION
ASSEMBLY

CABLE

了FAR 一 aa
SUPPORT
BRACKETS
Exe |

nm
Figure 4.3 Power Conversion & Output PWB Locations

BASE
ASSEMBLY
a
©
Z
<
m
m
站
o
Z

HES
ASSEMBLY

A5 OUTPUT

we
See
EM
M

BASE ASSEMBLY
SLOTS
m

A©
m
Œ
4.4 PERIODIC INSPECTION Equipment: 2 Hand controls, Single and Dual
Foil Return Electrodes, Foot switches, Jumper
The Excalibur Plus PC™ should be visually wire.
inspected at least every six months. This inspec-
tion should include checks for: 4.5.3 Output Power

* Damage to the power cord and plug. Equipment:

* Tightness of the power plug. * Monopolar Footswitch
* Tightness of the volume control knob. * Bipolar Footswitch
* Proper mating and absence of damage to the
patient connectors. Preferred:
* Obvious external or internal damage to the * RF true rms millivoltmeter with 5 MHz fre-
unit. quency response, current probe with | Khz to 5
+ Accumulation of lint or debris within the unit MHz frequency response and: 300 ohm 250W
or heatsink. noninductive resistor (all monopolar modes
* Control Panel cuts, punctures or dents. except Spray), 500 ohm 250W noninductive
resistor (Spray), 50 ohm 50W noninductive resis-
4.5 PERIODIC PERFORMANCE tor (Bipolar).
TESTING
Alternate:
The Excalibur Plus PC" should be performance * Commercial ESU Tester with 50 ohm for bipo-
tested at least every year. Every unit is supplied lar, and 300 ohm loads for monopolar.
with a serialized Production Test Data Sheet that
tabulates the results of the factory tests that were Alternate:
performed on the unit. This data is supplied so * Commercial ESU Tester with 100 or 125 ohm
that it may be used as a reference for subsequent loads for bipolar, and 400 or 500 ohm loads for
tests. Recommended periodic performance tests monopolar.
are listed in the following sections.
* Return Electrode Adapter Plug (shorting).
4.5.1 Chassis Ground Integrity
* Bovie #12 Adapter Plug or Hand Control.
Equipment: Volt-Ohmmeter, Simpson 260 or
equivalent. * 3 test leads, Im max. length

Procedure: Connect the ohmmeter between the NOTE: RF power measurements are difficult to
earth ground prong of the power plug and the achieve with accuracies better than 5%. This 5%
exposed screw heads on the bottom of the error in reading can add to a similar 5% error
Output Panel, and the Equipotential Ground induced by instrumentation error during calibra-
Connection. Confirm less than 0.2 ohm resis- tion and result in an error due to instrumentation
tance. alone of 10%. To achieve the unit’s rated error
tolerance, it’s best to use the same instrumenta-
4.5.2 Displays, Alarms, Commands tion to calibrate and check calibration. Since
that will not be possible on new units already cali-
Preliminary checks of the items listed below brated, allowance should be made. However, out-
appear in Section 2.3. put errors of less than 20% are generally not clini-
cally noticeable.
* Return Fault Alarm
+ Mode Indicator Lamps Note: The RE output power level checks of Table
* Sound Tones and Volume Control 4. 1 correct for the load regulation characteristics
* Hand control/Forceps Operation of the Excalibur Plus PC™. This results in output
* Foot switch Operation current levels that differ from the power setting
* ASSIST Resistance Indicator when the P=PR calculation is done at other than
* Return Fault Indicator the rated load. Refer to the Load Regulation
* Power Indicators

4-7
пд 2 Hg-
Curves for details. Best results occur when rated 4.5.4 RF Leakage
load is used. It is not necessary to check
calibration at each of the listed loads, they are Equipment:
there only to allow for the use of a tester that * ESU Tester with RF Leakage function OR a
does not have the exact rated load. 0-250 mA RF Ammeter and a 200 ohm 10 W
Noninductive Resistor
Note: Bipolar is particularly sensitive to the load + Patient Plate Adapter Plug
resistance. A 50 ohm load should be used for * Bovie #12 Adapter Plug
checking power for best results. * 2 - Test leads, 1 m max. length
* 3 - Test leads, 10 cm max. length
1. Use test leads to connect the ESU tester to the * Wooden table approximately 1 m from floor.
unit’s return electrode jack and the footswitch
Procedure:
controlled active jack.
1. Ensure that the unit is fully assembled and all
2. Perform the monopolar power tests indicated fasteners are tight.
in Table 4.1, depending upon the value of the
load resistor used. 2. Place the meter and resistors on the table so
that they are at least 0.5m away from the unit
3. Disconnect the ESU tester from the unit. under test and any other conductive surface.
4. Use test leads to connect the ESU tester to the 3. Set the unit for full power Standard Coag and
units blue Bipolar Accessory Jacks. Bipolar Coag. Connect the 200 ohm noninduc-
tive resistor in series with the 250 mA RF amme-
5. Perform the bipolar power tests indicated in ter, the Equipotential Ground Connection on the
Table 4.1 depending upon the value of the load Rear Panel. One at a time, connect this series
resistor used. combination to each RF output terminal indicat-
LOAD 300 ohms 400 ohms 500 ohms

Mode Set | Min Pow Max ow Mina MaxA | Min Pow Max Pow Mina мыл | Min Pow Max Pow MinA Max A
Pare no] | 20zo MU30 oa7ì 0208
0306 360 5 HIISA oue
0256 019
028 We 96 97zo oo 0189
300Do) | 2700Ne Rb Ro nam
099 eş
109 1206 3254
2062 1587 0 Osio056 6902
na 1303 306
282 0528 024
OU
1703 0713
ai ml 20zo 120
90 ода 0208 253 asa ama 3 0198 wilvà Sa37)из Doù
OM 00187
120io | || 160
oso 280 nari
nano
NRO 07
0306
0663
ome 178
1570
6287
0000
0.693 1172
129 ied 0552 0611
022
ms | 2070 120
mo ms 0208 sa258 0.196 931730136 0186
DOB| | rogo zio om 0206
060 006 1045 0.286
0565 290369024.
1011 136 0450 02720407
Benda | 70 mo ms 020 57oonsi 0.196 EEGaP
so| | 2070 MwMo vari 0.306
040 ost 0286
0462 ARA 028.029
a 046
Standard Sİ | 70 moво où 0.208 31272 0.183 0774 RSZİ17 0471
om 0168
DO | ioas 120 oa
060 0356
01008 1104 0207
ossi noe DAR 0521
0272
spay οἱwf] 70 8409 02 0207
bam où
0.380 3Ro WSο..."M3 0301 sumo20 40MO10 0268
ous 0297
ol
do | Mi Mo oi νά ο0383 0 0420
LOAD 50 ohms 100 ohms 125 ohms

A οἱsv] vo50 Шо mae

230 0469 4406 0209 0310 M9419145189 0 090
owmé 0270
450 So 00% 5 bor
10 as167199.am 0383 0446
vto 364 UM
0 080
eew 050 0 20501100316 046 63 YA18 0372 оDa66 HIм145 OS0229 v0475
a
SO | | vo
30 os
09 ve
109 202
9 0523
0710 он 0620

Table 4.1 RF Output Power Checks

48
 MEASURED OUTPUT ACTIVATION AAMI MAXIMUM IEC MAXIMUM
[TERMINAL COMMAND LEAKAGE (mA) LEAKAGE (mA)

RETURN ELECTRODE FOOT COAG 120 90

RETURN ELECTRODE LEFT HAND CONTROL COAG 140 100
RETURN ELECTRODE RIGHT HAND CONTROL COAG 140 100
RETURN ELECTRODE BOTH HAND CONTROL COAGS 150 N/A
FOOT ACTIVE FOOT COAG 120 100
BIPOLAR TOP FOOT BIPOLAR 20 20
BIPOLAR BOTTOM FOOT BIPOLAR 20 20

Table 4.2 RF Leakage to Ground Tests

ed in Table 4.2, and activate the unit using the each RF output terminal shown in Table 4.3, and
corresponding command. Confirm that no meter activate the unit using the corresponding com-
readings exceed the specified maximum. Hand mand. Confirm that no meter readings exceed the
control coag activations are accomplished by con- specified maximum. Hand control coag activa-
necting a jumper between the lower black jack tions are accomplished by connecting a jumper
and the red jack of the desired hand switchable between the lower black jack and the red jack of
accessory jack. the desired hand switchable accessory jack. Repeat
test using Spray Coag at full power.
>WARNING<
HAND CONTROL ACTIVATIONS >WARNING<
SHOULD BE KEYED USING 3” OR LESS HAND CONTROL ACTIVATIONS
WELL INSULATED JUMPER(S). USE OF SHOULD BE KEYED USING 3" OR LESS
AN INSULATING ROD TO INSERT THE WELL INSULATED JUMPER(S). USE OF
JUMPER IS ADVISED TO PREVENT RF AN INSULATING ROD TO INSERT THE
BURNS. JUMPER IS ADVISED TO PREVENT RF
BURNS.
4.5.5 RF Leakage From Inactive Outputs
CAUTION: TO AVOID DESTROYING
Equipment: Same as in Section 4.5.4
THE METER, NEVER ACTIVATE OUT-
Procedure: PUT TERMINAL CONNECTED TO THE
METER.
1. Set the unit for full power Standard Coag and
Bipolar Coag. Connect the 200 ohm, noninduc- 2. Disconnect the meter and resistor from the
tive resistor in series with the 250 mA RF amme- unit. Turn unit Power Switch OFE
ter, One at a time, connect that series combina-
tion between the return electrode connector and

IMEASURED OUTPUT ACTIVATION MAXIMUM

¡TERMINAL COMMAND LEAKAGE (mA)

FOOT ACTIVE LEFT HAND COAG 50

FOOT ACTIVE RIGHT HAND COAG 50
FOOT ACTIVE * FOOT BIPOLAR 20
LEFT HAND ACTIVE FOOT COAG 50
LEFT HAND ACTIVE RIGHT HAND COAG 50
LEFT HAND ACTIVE FOOT BIPOLAR 20
RIGHT HAND ACTIVE FOOT COAG 50
RIGHT HAND ACTIVE LEFT HAND COAG 50
RIGHT HAND ACTIVE FOOT BIPOLAR 20

Table 4.3 RF Leakage for Inactive Outputs Test

 I —_————_—_
4.5.6 Line Frequency Leakage CAUTION: To prevent RF current from
destroying the test equipment and/or affecting
Equipment: These tests are performed most con- leakage readings, set all power settings to
veniently using any good quality biomedical elec- zero.
trical safety tester. If you do not have such a
tester, then it is possible to construct your own 3. With all power controls set to zero, measure
using a millivoltmeter and a simple RC network the leakage current as in step 1 from each of the
constructed according to IEC 60601-1, Clause three active output terminals to neutral (see Table
19.4 e). 4.5) while that output is activated in Cut by the
appropriate footswitch or hand control jumper.
1. Connect the electrical safety analyzer to make Hand control cut activations are accomplished by
the measurements indicated in Table 4.4. connecting a jumper between the lower black jack
and the red jack of the desired hand switchable
2. Since the Excalibur Plus PC monopolar active accessory jack.
outputs are disconnected by relays when the unit
is not activated, active-to-neutral leakage tests
must be performed with the unit activated in
order to be valid.

Leakage Line Case Test

Path Polarity Ground Limit

Bipolar-Neutral Normal Closed 5uA

Bipolar-Neutral Normal Open SuA
Bipolar-Neutral Reversed Closed SuA
Bipolar-Neutral Reversed Open SuA
Return Electrode-Neutral Normal Closed SuA
Return Electrode-Neutral Normal Open SuA
Return Electrode-Neutral Reversed Closed SuA
Return Electrode-Neutral Reversed Open SuA
Chassis-Neutral Normal Open 40uA

Table 4.4 Unkeyed Line Frequency Leakage Tests

Leakage Line Case Test
Path Polarity Ground Limit

Foot Active-Neutral Normal Closed 5uA

¡Controlled Active-Neutral Normal Open 5uA
Active-Neutral ‘Reversed Closed 5uA
Active-Neutral Reversed Open 5uA
Hand Control Active-Neutral Normal Closed 5uA
1 Active-Neutral © Normal Open SuA
Active-Neutral Reversed Closed 5uA
Active-Neutral Reversed Open 5uA
Hand Control Active-Neutral Normal Closed 5uA
2 Active-Neutral Normal Open 5uA
Active-Neutral Reversed Closed 5uA
Active-Neutral Reversed Open 5uA

Table 4.5 Keyed Line Frequency Leakage Tests

4-10 [©
4.5.7 Aspen Return Monitor (A.R.M.) the Return Fault Indicator goes dark. Confirm
Calibration Check that the DRB reads from 1 to 4 ohms less than
the resistance read in Step 7.
This section describes the method to check the
calibration of the A.R.M. circuitry. 9. Disconnect the DRB. This completes the
A.R.M. calibration test. If any readings were
Equipment: Decade Resistance Box (DRB) with
only slightly out of range, first check the DRB
attached dual foil return electrode cable. The
with an accurate ohmmeter. If the DRB is accu-
DRB must be adjustable from 0 to 160 ohms in
rate, recalibrate the A.R.M. limits in CAL Mode.
1 ohm steps and accurate to 1%. A dual foil
See Section 4.6. If one or more readings were far
return electrode cable can be made by cutting the
from the mark, troubleshoot the A.R.M. circuitry
cable to about 3 ft. from the connector from a
before attempting recalibration. See Section
dual foil return electrode, and stripping the wires
4.7.6.
for connection to the DRB.
NOTE: Some DRBs may present a brief open 4.5.8 +5 Over Voltage Monitor Check
circuit at the output terminals during switch
movement. This may cause the A.R.M. software 1. With power off, remove the RF shield and
to calculate an erroneously high resistance read- place a short between A3TP3 (OVCHK) and
ing. This effect may be minimized by making A3TP22 (+5). This will simulate the +5V supply
DRB setting changes quickly. If the resistance exceeding specified limits.
read during any of the following tests is above the
upper limit, repeat the test carefully stopping in 2. Turn unit on and confirm unit fails power-on
each 1 ohm step for at least 1 second. self-test (POST) and goes to an Err 22.0
(VBASE too low during POST). This occurs
Procedure:
because the simulated overvoltage turns VBASE
1. Disconnect all accessories from the Excalibur off.
Plus PC™ front panel.
2. Power up the Excalibur Plus PC™ in the
3. Remove jumper, replace shield, and confirm
unit powers up normally.
RUN Mode, and confirm that ASSIST Resistance
Indicator has all 10 green bars flashing, and that
4.6 Calibration and Adjustments
the Return Fault Indicator and the Dual Foil
Mode Indicator are illuminated.
The Excalibur Plus PC™ is calibrated without
3. Using the test cable, connect the DRB to the selecting or adjusting components. Instead, cali-
Return Electrode Jack. bration factors necessary to compensate for unit-
to-unit circuit variations are stored digitally in a
4. Carefully advance the DRB in 1 ohm steps
battery backed Nonvolatile Random Access
until all 10 bars of the ASSIST Resistance
Memory or NOVRAM A3U2. The battery has a
Indicator are flashing. Confirm that the DRB
lifetime of 10 years.
reads between 137 and 163 ohms.

5. Set the DRB to 7 ohms and confirm that the A special operational mode, called CAL Mode,
ASSIST Resistance Indicator is dark and the permits the NOVRAM data to be updated to
Return Fault Indicator is lit. compensate for circuit performance changes due
to aging or replacement of components. In CAL
6. Select Single Foil Mode. Confirm the ASSIST
Mode, the microprocessor guides the technician
Resistance Indicator stops flashing and the
to simplify and expedite a complete and accurate
Return Fault Indicator is not illuminated.
recalibration.
7. Increase the DRB in 1 ohm steps until an
audible Return Fault Alarm is sounded and the CAL Mode also provides microprocessor aided
Return Fault Indicator is lit. Confirm the DRB is diagnostics modes to help troubleshoot hardware
between 8 and 12 ohms. problems which disable the unit in normal ser-
vice, and can display the last fault code.
8. Decrease the DRB setting in 1 ohm steps until

Te 411
 때때
ㄴㄴ
NOTE: CAL Mode should not be used to per- 4.6.2.1 Entering a Mode and Returning to the
form routine calibration checks. Those tests are Menu
better conducted in RUN Mode per Section 4.5.
If the unit proves to be out of calibration, the When the desired Mode and Option are dis-
possibility of a component failure should be elim- played, that mode is entered by pressing the
inated as the cause before recalibrating. Once the “STORE” key. Operation in each of the modes is
physical condition of the unit as been confirmed, described in detail in following Sections.
then CAL Mode may be entered to correct the
calibration. In each of the three Calibration modes there are a
number of calibration points, which may be
4.6.1 CAL Mode Entry selected, checked and adjusted. When work in a
CAUTION: Do not enter CAL Mode with- mode is completed satisfactorily, pressing the
out first reading and understanding the fol- “STORE?” key will save all calibration changes
lowing material and ensuring that the neces- along with an updated CRC to the NOVRAM
sary equipment is on hand and accurate. and will return to the menu. If the calibration is
Improper calibration procedures can cause an incomplete or nonmonotonic, an error code will
otherwise serviceable unit to become unusable be displayed. Pressing the “STORE” key again
until calibration is corrected. will restore the menu, from which the mode may
be reentered.
The CAL Mode is entered by powering up while
pressing the internal CAL switch, A3S1. If the The Diagnostics modes are removed from the
key is held for more than 30 seconds, the unit menu after RF is activated in either of the Power
will display an “Err 13.0” fault code. Calibration modes. It is not possible to return to
the menu from either of the Diagnostics modes
Upon successful entry to CAL mode, a display without turning power off and reentering CAL
check occurs for 30 seconds or until any key is mode.
pressed, and then “SLF dIA” is displayed in the
Cut and Coag power windows. The Bipolar 4.6.2.2 Calibrated/Uncalibrated Status
power display window shows the last two digits
of the Software part number, and the Program If the menu MODE display for one of the three
window indicates the software revision level. Calibration modes is flashing, then one or more
After the self diagnostics are run, the unit will dis- points in that mode is uncalibrated. That mode
play “C-C, 300, A”. At this time the CAL mode should be entered and calibration completed or
entry is complete and calibration or diagnostics corrected.
can begin.
4.6.2 CAL Mode Menu Each point within a mode can be declared cali-
brated or uncalibrated by the microprocessor. An
After entry to CAL Mode, the CUT power win- uncalibrated point is flagged by a flashing display.
dow will display “C-C”, which is one of five avail- That point may be restored to a calibrated status
able mode selections. Any of the other modes by recalibrating.
may be selected sequentially by pressing the CUT
Power Increase or Decrease keys. In some of the On initial entry to CAL Mode, the unit confirms
modes, the other displays will display an option that the stored values haven't changed since the
applicable to that mode; these options are similar- last valid calibration. If there have been any
ly selectable by pressing the Increase or Decrease changes, all points are considered uncalibrated
keys next to the display. Activating an inappro- and a complete calibration will be required to
priate key or control will result in a pulsating Key make the unit functional. In this case, the unit
Error tone. Details of how to use each mode does load a set of nominal calibration values
appear in following sections. The available CAL which will bring a normal unit close to final cali-
modes, options and their uses are summarized in brated values. The technician can use these values
Table 4.6. by activating the unit for each calibration point,
but a real calibration should be done before
returning the unit to service.

4-12
K -<
NOTE: The correct load must be connected, even If a PAd calibration point is out of range, due
if nominals are being loaded. Otherwise, the either to a circuit fault or connection of an incor-
VBASE check can cause a fault in RUN mode. rect resistor to the return electrode terminals,
both PAd calibration points will be declared
After a fully calibrated mode is entered, making a uncalibrated. Attempts to store an out of range
change to any one calibration point will cause all value in this mode will result in a Key Error alarm
of the other points in that mode which have not tone.
yet been checked to be declared uncalibrated.
Those points must then be calibrated prior to When the “STORE” Key is pressed to exit a
returning the unit to service. This precaution is Calibration mode, the unit first checks for any
taken on the assumption that if some part of the uncalibrated points in that mode. If any exist,
circuitry has changed enough to justify adjust- then an Err 10.X code is displayed where the “X”
ment of one calibration point, then it is likely that corresponds to the mode that is not calibrated.
the other points have been affected as well. See Appendix A. The values of all of the points
remain as they were at the time of exit, eliminat-
4.6.2.3 Calibration Limits and Validity Tests ing the need to repeat the adjustments that were
Each calibration value is based upon a VBase and already made.
Waveform drive value to set the output power.
When the unit is calibrated, the VBase or Pressing the “STORE” Key again will restore the
Waveform value requested for the mode is adjust- menu, and the menu display for the partly cali-
ed for the correct power output at that calibration brated mode will flash. The calibrated and uncal-
point. The VBase or Waveform is tested to be ibrated status for all points in that mode is pre-
within +25% ofa nominal value. If the value is served while in CAL Mode, so that when the
within the range, the calibration value is stored as mode is reentered, it is necessary only to calibrate
calibrated, otherwise, it remains uncalibrated. At the flashing points to fully calibrate that mode.
the same time, a separate VBase and Waveform
average voltage is taken and stored to correspond Because the VBase or Waveform drive values
with each calibrated point for failure analysis. increase steadily with increasing output power for

IMODE MODE USE OPTIONS OPTION USE

C-C Monopolar (Cut-Coag) 300, 400, 500 RF load resistance

Power Calibration A,P (ohms) for monopolar
calibration and display
in current (A) or power (P)
bP Bipolar 50, 100, 125 RF load resistance (ohms)
Power Calibration A,P for bipolar calibration and
display in current (A) or
power (P)

РАЗ A.R.M. (Pad) Resistance -blank-

Calibration

АТА Diagnostics Watchdog Timer

Pseudo Run Mode

ЕС Read Last Fault Code Check last fault code that

happened in RUN mode
and clear the code.

Table 4.6 Cal Mode Options

[2 4-13
때 υυ ν«ὕ-ὃ««ὃὂὓ
the mode, i.e., they vary monotonically with Unforeseen circuit problems which prevent a
power, then calibration values stored at succes- good calibration can be troubleshot in
sively higher power calibration points in a given Diagnostics 2 mode. Simply enter CAL Mode,
operational mode should increase steadily. and go into Diagnostics 2. After the trouble is
Although the limits applied to each value can pre- corrected, recalibrate the unit.
vent disastrous numbers from being stored, the
settable ranges for some adjacent points overlap. 4.6.3 Output Power Calibration Procedure
So it is possible for a lower power calibration
point to be set to a larger value than its higher The “C-C” (Monopolar Cut and Coag) and “bP”
power neighbor. Such nonmonotonicity is (Bipolar) modes are used to calibrate output
indicative ofa miscalibration or possible failure in power. The only equipment necessary to conduct
the VBASE or WEG hardware, so calibration power calibration is an electrosurgical output
under such conditions cannot be valid. power tester having load resistances of 300, 400
or 500 ohm for Monopolar and 50, 100, or 125
The individual variable VBase or Waveform aver- ohms for bipolar and an RF rms current indicator
age voltage changes tracks the calibration value capable of accurate measurements from 50 to
change, i.e., if the calibration value is nonmonot- 1200 mA, or power indicator capable of accurate
onic, then the VBase or Waveform average volt- measurements from 0 to 350 watts. These units
age is also nonmonotonic. Adjusting the calibra- are commercially available from a number of
tion value for monotonicity will also store the sources, or can be constructed using 250 watt 3%
correct VBase or Waveform since they cannot be or better noninductive resistors and a selection of
set independently. RF ammeters ranging from 150 mA to 2A full
scale for the current indicator.
If nonmonotonicity is detected on exit from a
Calibration mode, an Err 11.X code is displayed After entering a Power Calibration mode with
where the “X” corresponds to the mode that is either “A” or “P” set, the particular operational
nonmonotonic. See Appendix A for reference. mode to be calibrated is selected by the appropri-
ate MODE SELECT key and by the particular
During run time, the VBase and Waveform aver- mode activated. For example, points in the Coag
age voltages are tested for failure every 500mS or Spray mode are calibrated by selecting Spray with
less. failure in either of these will result in an the COAG MODE SELECT key, and then acti-
error code. See Appendix A. vating the unit with the Coag foot switch or hand
switch,
4.6.2.4 Exiting CAL Mode
Each calibration point is displayed in the appro-
CAL Mode may be exited by turning the priate power window in terms of target RF out-
POWER switch OFE This operation should only put current in amps or watts (user selectable) to
be performed AFTER returning to the main the selected load resistance option.
menu.
If the selected load resistance is other than the
NOTE: If ANY of the modes in the menu are rated load, the target will deliver some other
flashing or if there was an Err 10.X or 11.X, exit- power which takes into account Excalibur Plus
ing CAL Mode will result in an immediate PCs typical load regulation characteristics in
NOVRAM FAIL (Err 3.0) alarm on powerup in that mode. The actual load regulation curve for
RUN mode. Complete recalibration will then be a particular unit may vary somewhat from typical,
required in order to return the unit to service. so the most accurate calibration is obtained when
calibration is performed using the rated load.
It’s a good practice to be sure that each menu Bipolar is particularly sensitive to this and rated
mode shows as calibrated (not flashing) before load (50 ohms) should be used if available.
departing CAL or entering Diagnostics modes.
о 3
Since the displayed target is computed from tar- Standard Coag and Spray Coag to be adjusted to
get power and the load resistance option, satisfac- set output power to rated load as close as possible
tory calibration is possible ONLY if that option to the displayed power in RUN mode.
and the actual load resistance are the same.
Connect the output power tester to the Return
Before activating a newly selected point, be sure Electrode jack and one of the active RF output
that the tester RF full scale current or power jacks, depending on how one wishes to activate
range is at least as great as the displayed target the unit. Most Biomeds prefer to use the foot
current. Bear in mind that a unit which is far out switch, in which case the tester should be con-
of calibration may deliver considerably more than nected to the foot switched controlled Monopolar
the target. The most accurate current readings Accessory Jack. If possible, set the tester for the
will appear on the lowest RF current range which rated load resistance, since this will yield the most
reads on scale for target current. accurate calibration results. If this resistance is
not available, the Excalibur Plus PC™ may be cal-
Calibration of a point consists of keying the unit ibrated to meet specifications using 300, 400 or
and adjusting the output until the RF ammeter 500 ohm loads.
(or power indicator) reads as closely as possible
to the displayed target. Since the amplifier drive Use a short alligator clip jumper (3"-6") to short
can change only in discrete steps, it may not be A4R8 (0.1 ohm, 5W resistor) before turning unit
possible to match the target exactly, but the set- on. Be careful not to touch other components
ting which reads closest to the target will be with- until A4DS1 extinguishes. This jumper is only
in the specified tolerance. required for high power monopolar calibration,
but will not affect calibration if left on through-
After a point is calibrated, deactivate the unit. out the entire procedure. Be sure to remove it
The last drive setting used while activated will be after calibration is completed.
stored for that point. Additionally, both the wav
form and base voltage drive are sampled and Connect the power plug to a source of AC power
stored to detect over-power conditions. of the same frequency and within 5% of the volt-
age specified on the nameplate. Enter CAL
With the unit deactivated, the Power Incre: nd
Decrease keys are then used to select another cali-
bration point. When the highest calibration point When the “C-C” selection is in the CUT window,
in a mode is displayed, the Power Increase key set the load resistance Option in the COAG win-
will have no further effect, the same is true for dow to match the tester load resistance and select
the Power Decrease key when the lowest point is “A” or “P” option in the bipolar window. Then
displayed. This is useful in determining when a press the “STORE” Key to enter the Monopolar
mode is fully calibrated. Calibration Mode.

It is only necessary to activate the unit for the The Pure and Standard modes are selected by
selected point to be considered calibrated. No default, and the lowest power points in those
actual adjustment is required, but the output cur- modes will be displayed. Target output current is
rent (or power) should still be measured and veri- displayed in amps to the nearest 10 mA in the
fied against the target value. Cut and Coag power windows if “A” was selected.
Targeted output power is displayed in watts to
Although the points in a Calibration mode may the nearest 1 watt in the cut and coag windows if
be calibrated in any order, it’s best to use a “P” was selected.
sequence which insures that calibration is com-
plete before returning to the menu. Using the procedures described in Section 4.6.3,
activate the unit in each of the points in all four
4.6.3.1 Monopolar Power Calibration (C-C) operational modes, making adjustments only as
required to set output current or power to match
This mode permits the calibration tables for Pure the displayed target as closely as possible.
Cut, Blend 1 Cut, Blend 2 Cut, Blend 3 Cut,
cl vr: 1.5. “ὕ«υϊῦὓὺὓὃὓὐσρ,ν
Zero power points should be calibrated by setting Select “bP” in the CUT window, set load resis-
the tester to the most sensitive range, then raising tance Option in the COAG window to match the
output until there is readable output. Find the tester load resistance and select “A” or “P” option
output setting which yields the smallest percepti- in the bipolar windows. Then press the
ble output change between activated and deacti- “STORE” Key to enter the Bipolar Calibration
vated conditions; the correct calibration setting Mode.
for zero power is one step below that one.
Coag will be selected by default. Target output
Because heating tends to change the gain of the current is displayed in amps to the nearest 10 mA
power amplifier slightly, a slow change in load in the Bipolar power window if “A” was selected.
current may be noted while the unit is activated. Target output power is displayed in watts to the
This may cause the unit to appear slightly off nearest 1 watt in the CUT and COAG windows if
when calibration is rechecked in Run after cooling “P” was selected. For target current, the decimal
down. These errors may be minimized by allow- point is NOT displayed, but is effectively located
ing the unit to cool for 15 to 20 seconds between at the left side of the two digit Bipolar power dis-
activations. Coag power calibration is affected by play. Thus a display of “99” should be read as
heating to a much smaller extent than is Cut. “0.99” amps.

This phenomenon is not ordinarily a problem Using the general procedures described in Section
unless the unit is far out of calibration, requiring 4.6.3 above, activate the unit in each of the
extended activations in order to bring it in. In points in both operational modes, making adjust-
such cases, first perform a complete rough cali- ments as required to set output to the displayed
bration. After the unit has cooled for several target as closely as possible.
minutes after the last activation, repeat the cali-
bration. Now the activation time necessary to When all points have been calibrated satisfactorily,
close in on final adjustments will be very brief. pressing the “STORE” Key will store the updated
values and restore the menu.
When all points have been calibrated satisfactorily,
pressing the “STORE” key will store the updated 4.6.4 A.R.M. Calibration (PAd)
values and restore the menu.
This mode calibrates the A.R.M. circuitry to
4.6.3.2 Bipolar Power Calibration (bP) Return Electrode resistances of 10 and 150 ohms.
The only equipment required to complete
This mode permits the calibration tables for A.R.M. Calibration are 10 and 150 ohm resis-
Bipolar Coag and Bipolar Cut to be adjusted to tances accurate to 5% or better. Power ratings
set output power to 50 ohms as close as possible are unimportant, but wirewound resistors should
to the displayed power in RUN mode. not be used. A means to connect the resistance
between both pins of either of the Return
Connect the output power tester to the Bipolar Electrode jacks is also required.
RF output jacks. If possible, set the tester for a
50 ohm load resistance, since this will yield the While at the menu level in CAL Mode, select PAd
most accurate calibration results. If this resistance in the Cut window and press the “STORE” key.
is not available, the Excalibur Plus PC™ may be The Coag window will display the value in ohms
calibrated using 100 or 125 ohm loads, however of the resistance to be calibrated, and the ASSIST
the accuracy will be degraded. Resistance Indicator will be lit with a correspond-
ing number of bars. A flashing ASSIST
Connect the power plug to a source of AC power Resistance Indicator denotes an uncalibrated
of the same frequency and within 5% of the volt- point.
age specified on the nameplate. Enter CAL,
Mode as described above. Connect the selected resistance to the Return
Electrode jack. Wait a second or two, then press
the Alarm Set Point key to store the calibration
value.

4-16 [=
 iburPIUS PCT

Use the Coag Power Increase or Decrease keys to cord and all other wiring for evidence of mechan-
select the other calibration point, connect the new ical damage. Check the regulated and unregulat-
indicated resistance, pause and press Alarm Set ed power supply voltages. Improper supply volt-
Point key. ages can produce a multitude of problems. Check
that the RF shield is in place and all mechanical
If an error tone is sounded when the Alarm Set connections are secure. Check all fuses. Check
Point key is pressed, then the calibration point is the operating instructions and see if the suspected
out of range, and both points will be declared problem was actually designed to work that way.
uncalibrated. Check to insure that the resistance
has the value as displayed in the Coag window 4.7.1 Fault Codes
and that it is well connected to the Return
Electrode. Then repeat calibration of both values. The Excalibur Plus PC™ microprocessor is pro-
grammed with a number of fault detection rou-
Calibration was successful if the ASSIST tines designed to shut the unit down safely if a
Resistance Indicator is lit steadily for both points. failure has occurred. This shutdown procedure
Pressing the “STORE” key will restore the menu will produce a fault code that can help with the
immediately and save the new values. trouble shooting process. Refer to Appendix A
for a complete list of the Fault Codes and their
If calibration is incomplete or unsuccessful, press- possible causes.
ing the “STORE?” key will yield an Incomplete
Cal error code, Err 10.9. Pressing the “STORE” Two types of Fault codes can be generated by the
key again will return the menu, and the PAd dis- unit. An “Err” fault code indicates a problem
play will be flashing. If calibration was inadver- internal to the machine and generally requires a
tently incomplete, then the A.R.M. calibration technician to fix the problem. Accessory prob-
mode may be reentered to correct the situation. lems, such as a stuck activation key, footswitch or
control panel key are denoted by “ACC” fault
If a circuit fault is suspect, Diagnostics 2 should codes. These codes can generally be cleared by
be entered for troubleshooting. Complete recali- turning the unit off, ensuring that no switches are
bration will be required after the circuit fault is pressed during power up, and turning the unit
corrected, on. If this does not clear an ACC code, remove
the accessory indicated and turn the unit on
4.7 TROUBLESHOOTING again. An ACC code not cleared by this will
require repair.
This section explains the troubleshooting aids
built in to the Excalibur Plus PC™ and provides a Upon fault detection, the program displays a fault
guide to their use. Not all failures can be covered code in the Monopolar Cut and Coag power level
in a guide such as this, so the troubleshooter displays. This loop takes /RFENA low, forces
must by necessity understand the full operation of VBASE and the waveform generator output to
the unit. Read Section 3 for the description of zero drive condition and commands the relays to
system and circuit theory. open. Further, it ceases generation of Watchdog
Timer strobes and redundantly disables base and
>WARNING< gate drive to the Power Amplifier.
READ THE SAFETY SUMMARY IN SEC-
TION 1.1.4 BEFORE TROUBLESHOOT- If the Watchdog Timer detects a processor fault, it
ING THE UNIT. will issue an interrupt to the processor, causing a
branch to the same routine as above if the proces-
If trouble is suspected, perform a thorough visual sor is healthy enough to respond; if not, RF will
inspection, looking for loose or burned compo- still be disabled, but the front panel may not be
nents which may point to the source of the prob- capable of displaying the code. Additionally, if
lem. Verify that all connections are clean and able, the unit will store the fault so it can be read.
seated properly and that soldered harness connec- later.
tors are sound and not shorting. Check power

[2 4-17
esli vr. ㄴㄴ eum
4.7.1.1 Checking and Clearing Last Fault RF to the output jacks, except the following soft-
Code ware routines which detect hardware faults are
not executed:
The Last Fault Code (LFC) that occurred during
RUN mode can be viewed and also cleared if * External NOVRAM validity.
desired, IPs good practice to clear the LFC so * Program EPROM CRC validity.
that recurring problems can be confirmed. To use * Calibration NOVRAM CRC validity.
LFC mode: * Watchdog Timer Lockout interrupt processing.
* Power Amp Overcurrent interrupt processing.
1. Enter CAL mode by pressing A3SW land turn- + Activation Switch Closure.
ing unit on. ¢ Membrane Panel switch closure.
+ A.R.M. circuit failure.
2. Press any key to end the display check more * Power settings in data memory does not
quickly. The unit will then go through self diag- match display.
nostics and sound a two tone signal that it passed * Relay test.
the diagnostics.
CAUTION: If any of those failures exist, the
3. Press the Monopolar Cut Power adjust keys microprocessor may not shut the system down
until “LFC” appears in the Cut power window. or display a fault code. One should be pru-
dent in deciding whether or not to enter this
4. Press “STORE”. At that time, the display will mode without first attempting to identify the
show the last fault code or, if no Fault Code has fault while powered down.
occurred since the unit was last cleared, a series of
dashes will appear on the display Note the LEC To start Pseudo Run:
for later reference.
1. Enter CAL mode. See Section 4.6.
5. TO KEEP THE LEC: press “STORE” to
return to the top level. 2. Use the Cut Power adjust keys to select “dIA”
in the Cut Power display.
6. TO CLEAR THE LFC: Press the “MONI-
TOR SET" key. The display will then change to 3. Use the Coag Power adjust keys to select “2”
a series of dashes. Return to the top CAL menu in the Coag Power Display.
by pressing STORE.
4. Press the Store key to activate mode. At that
4.7.2 Pseudo Run Diagnostics (dIA 2) time, the unit will perform an abbreviated Self
Diagnostics and then will operate normally except
Armed with a good understanding of the Theory it will not perform the self checks listed above.
of Operation in Section 3, one can make effective
use of Pseudo Run Diagnostics (dIA 2) in cor- 4.7.3 Watchdog Timer Trouble-
recting any of the faults which result in Err shooting (dIA 1)
alarms in Run mode.
This section contains help in troubleshooting the
Pseudo Run Diagnostics (dIA 2) is provided to Watchdog Timer on the Controller PWB (A3)
permit troubleshooting problems which cause the
unit to lock up with a fault code in RUN mode. A faulty Watchdog Timer (WDT) will cause the
Such failures can be in the current limit circuitry, microprocessor to stop generating the /WDT sig-
continuity detectors, or power amplifier, to name nal in RUN mode. Troubleshooting this circuit
a few. These problems can be more effectively is difficult without that signal, and setting up an
diagnosed if the unit is made operational. external generator and connecting it to the circuit
is time-consuming.
In Pseudo Run Diagnostics (dIA 2), the unit
operates as in normal RUN mode and will deliver

4-18 (=
Watchdog Timer (dIA1) mode solves that prob- The menu cannot be restored from this mode.
lem by using the microprocessor as an on-board When work is complete, exit CAL Mode by using
programmable pulse generator to allow selection the RST switch or by powering down. This
of one of three pulse frequencies. One of the mode has no effect on the NOVRAM, so the cali-
selections places pulses continuously inside the bration and CRC are unchanged.
normal Watchdog Timer window, while the oth-
ers are too early and too late. It is also possible 4.7.3.2 dIA 1 Mode Selection
to set RLYENA to verify operation of the lockup
circuitry. An indication of the currently selected mode
appears in the Bipolar Power window. Modes are
4.7.3.1 Accessing Watchdog Timer selected by using the Bipolar Power Adjust keys.
Diagnostics Table 4.7 lists the available modes and the
response for a normal unit.
Since this mode is useful only with the RLYENA
flag in the reset state, “dIA” will not appear in the 4.7.3.3 Troubleshooting with Watchdog Timer
menu once RF has been activated in any of the (dIA1)
power calibration modes. On the other hand, if a
faulty WDT is detected on initial entry to CAL Since the WDT timing accuracy and ability to
MODE, Watchdog Timer (dIA1) will be auto- interrupt RF output are verified by the micro-
matically entered, bypassing the menu, since or on every power up, there is no need to
proper calibration may be impossible if the WDT k these parameters periodically. The only
is faulty. feature not checked automatically is lockout,
which is extremely reliable due to its simplicity:
To enter Watchdog Timer (dIA1) voluntarily, If the unit declares an Err 4.X in RUN mode,
enter CAL MODE per Section 4.6.1 above, then then the timing is incorrect. For large timing
select “AIA” in the Cut window and “1” in the errors, the Err Code may not correctly indicate
Coag window. Then press the “STORE” button. the problem stage. In that case Watchdog Timer
Entry will be signified by “1” appearing in the (dIA1) should be used. Select Late Mode 2 to
Bipolar Power window. observe timing of both WDT one-shot stages at
their test points. Stage 1 should go high for 9 to
[DISPLAY /WDT PERIOD WDTSTB2 /WDTINT
|& MODE (msec) First Stage Second Stage
(A3TP8) (A3TP2)

1 12.0 High for period of High

Normal first one-shot.
Nominally 10 msec.

2 20.0 Same as Mode 1 High for period of

Late second one-shot.
Nominally 15 msec

3 2.0 High Low

Early

4 12.0 Same as Mode 1 High until Mode 2

Lockup* until Mode 2 or 3 or 3 is selected,
is selected. Then Then latched to Low.

*RELYEN-Q (A3TP5) is Low until Mode 4 is entered. At that time, it is latched High.
Table 4.7 dIA 1 Modes

re 4-19
 SS |
11 msec after each WDTSTB, and Stage 2 should will increase with power setting up to about 5.6
run from 13.5 to 16.5 mS. WDTSTB is a very Vdc. At that point, there should only be a slight
short pulse and may be difficult to see with an increase in TP13 voltage. If TP13 fails to
oscilloscope. Slight timing errors are most likely increase towards 5.6 Vdc, do not proceed with
due to a faulty timing resistor or capacitor. this test; find the failed components and repair
Failure of the pulses to respond at all are more them.
indicative of an IC failure.
After successful testing of the VSENSE circuit,
An Err 7.0 indicates that the WDT did not shut connect a 300 ohm 250W load resistor to the
down RF when Stage 2 timed out. This may be unit’s RF outputs. Select Monopolar Pure Cut
caused by failure of any of the components carry- and slowly increase the power setting while mon-
ing the WDTEL signal to the WFG and VBASE itoring A3TP15. The de voltage at TP15 should
circuits. increase as power increases, but should not exceed
5.4 volts at full power.
4.7.4 Base Voltage Generator Troubleshooting
Units that have passed the troubleshooting steps
Remove all base fuses on the A4 Power so far should be checked for properly oriented
Conversion Assembly before checking a suspect diodes, mismarked resistors, and correct divider
Base Voltage Generator (BVG). Enter the dIA 2 voltages. If the unit has passed these BVG checks,
mode (see section 4.7.2). Check that A3U20 is then the problem is likely elsewhere.
producing the proper VDAC voltage at A3TP14.
Do this by selecting the Monopolar Blend 1 Cut 4.7.5 Waveform Generator Troubleshooting
mode, and increasing the power setting from 0 to
180W. Monitor TP14 to see that VDAC goes Enter the dIA 2 mode (see section 4.7.2). Check
from approximately 9.95 Vdc at 0W to 2.5 Vdc that a 20.0 MHz clock appears at A3TP32. Select
at 180W when activated. The VDAC voltage at a power setting and mode that corresponds to the
180W will vary from unit to unit, the important photos in Fig. 3.5 and confirm the waveforms are
factor is that the voltage changes in small incre- similar to that at A4TP4 when activated (use
ments. A3TP20 to trigger the oscilloscope to get compa-
rable results). If they are not, suspect one of
Next monitor A3TP12 and repeat the above pro- A3U13-U18 as being bad. Another problem
cedure. Confirm that TP12 voltage increases could be in the waveform select lines WVO-WV7.
from no more than 0.4V at OW to approximately
4.5 Vdc at 180W. If it fails to do so, check that 4.7.6 Aspen Return Monitor (A.R.M.)
VSENSE and ISENS are both less than 0.6V Troubleshooting
(this is true only if the base fuses have been
removed). The overall functionality of the A.R.M. circuitry
may be checked per Section 4.5.7.
Other problem sources could be one of the resis-
tor divider chains in the BVG, a bad RFEN or If these tests pass, but the unit still declares unac-
WDTEL signal. Also check that the other compo- countable Return Fault in operation with the
nents in the BVG chain are correct and function- ESU activated, interference from electrosurgical
al. current is the likely cause. Check the A5T5 shield
lid for good electrical and mechanical contact
If the BVG performs correctly as tested so far, with the shield cup, and capacitors A5C44 and
and the Power Amplifier and Waveform C45 for proper value and connection. Also check
Generator both test good, proceed with the fol- bypass capacitors ASC15, A3C25 and low pass
lowing test. Turn off the unit and replace the filter capacitor ASC38.
fuses in the PA. Reenter dIA 2 and select
Monopolar Blend. Monitor A3TP13 (VSENSE) If the ASSIST Resistance Indicator vs. resistance
and slowly increase the power setting on the test fails, check BVARM at A3TP16 with 10 and
front panel. When functioning correctly, TP13 150 ohms connected to the Return Electrode

4-20 (=
 alibur

Jacks. With 10 ohms connected, BVARM should Check the Base Voltage Generator and Waveform
be +0.85 to 0.98 Vdc and with 150 ohms, it Generator for proper function before proceeding.
should be +1.89 to 2.18 Vdc. BVARM should If everything checks this far, enter dIA 2 (See sec-
also match VARM at A3TP17 to within 10 mV tion 4.7.2) and select Monopolar Pure Cut from
dc. If this test passes, then the trouble is most the front panel. Confirm that A4TP10 and TP4
likely in the DAC A3U19 or A.R.M. comparator are approximately 0 to 10V signal swings, and
circuitry around A3U23. Note that a faulty DAC the same shape as A3TP10.
is also likely to cause Err 5.X Alarms.
Turn off the power to the unit and replace the
If the VARM vs. resistance test fails, check the de base fuses. Reenter dIA 2 and select Monopolar
current source A3VR2 and A3U21D by connect- Pure Cut from the front panel. Use an oscillo-
ing a dc milliammeter from A3TP17 to ground. scope on the drains of A4Q4 and Q5 to confirm
The meter should read from 0.49 to 0.51 mA. that the power MOSFETs are switching properly.
Check the voltage on the cathode of D10 for
If VARM test reads near zero and the de current approximately 39 Vdc.
is low, repeat the current test with A3J2 discon-
nected to eliminate a possible VARM short to If the unit has passed all tests to this point, it will
ground in the A9W5 harness or on the A5 PWB be necessary to replace the collector fuses to trou-
and shorted transistors A5Q2 or Q3. bleshoot further. Proceed with caution!
With the Return Electrode Jacks open-circuited,
check the waveforms on the A.R.M. oscillator 4.7.8. Power Amplifier Transistor
collectors, A5Q2 and Q3. See Figure 3.7. They Replacement
should appear as half-wave rectified sine waves
with a frequency of 34.5 - 38.1 KHz. If the fre- All bipolar power transistors A4Q1-Q3 and Q6-
quency is too high, A5C22, 23, 44 or 45 may be Q8 may be replaced singly without replacing the
open. If the circuit is not oscillating and VARM entire set. Calibration should be checked after
is 0.6 - 0.8 Vdc, check the feedback resistors transistor replacement. When replacing the power
A5R7 and R8, transformer AST4 for opens or transistors:
shorts and transistors A5Q2 and Q3 for opens.
1. Be sure to install the insulator pad. No ther-
If the circuit is oscillating at the correct frequency mal compound is necessary, but the mating sur-
but VARM does not respond to resistance faces of the transistor, insulator and heatsink
changes, check the circuitry from the secondary to should be clean. Replace any insulator which is
A5T4 to the Return Electrode jacks for shorts or torn, punctured or dirty.
open circuits.
2. Ensure that both pins of the transistor are
4.7.7 RE Amplifier Troubleshooting properly centered in the socket before setting the
transistor.
The first step in trouble shooting a Power
Amplifier (PA) is to remove all PA collector and 3. Tighten the screws to 4-6 inch-pounds.
base fuses (check the fuses as you remove them Excessive torque may cause the insulator pad to
and note if any of them are blown). This will be cut, destroying its dielectric strength and
prevent possible secondary failures in the PA due shorting +110 Vde to ground.
to overload.
4.7.9 Troubleshooting Resets
Use a VOM to check for shorted bipolar power
transistors (A4Q1-Q3, Q6-A8), power MOS- Apparently random restarts of the unit are gener-
FETS (Q4-Q5), and snubbing networks (A5D9- ally due to temporary loss of power. If the unit is
11, D14). Check to see that diodes (D1-3, D6-8) the only machine in the room to restart, check for
are functional. Check TP9 for approximately loose connectors in power supply circuits, broken
+110 Vdc and U2-6 for +12 Vdc. or weakened power cords, and a disconnected or
broken +5 volt regulator on the A3 assembly.

ra 4-21
 I rr.
4.7.10 Interference with Other Equipment To ensure prompt service, please provide the fol-
lowing information:
Most, but not all equipment, for use in the oper-
ating room environment is designed to tolerate Model Number
the interference created by electrosurgical genera- Serial Number
tors. If other equipment does show interference, Number Reference Designator and
check that equipment for broken cable shields, Description of Part
faulty connectors, or open grounds. Video cam- Aspen Part Number (if known)
eras are particularly prone to faulty cable shields Quantity Desired
since they are subject to flexing and sterilization Mailing or Shipping Address
procedures. The manufacturer of the equipment Preferred Shipping Means (if any)
may be able to provide guidance in fixing the Purchase Order Number (if applicable)
problem. Your Name

Improperly terminated video lines can also If you are returning a unit, obtain a Return
increase susceptibility to interference by loading Authorization (R.A) Number from CONMED
the video signal level. As an example, when coaxi- Technical Services. Please mark the R.A. number
al cable is used to route video signals to several on the outside of the carton for prompt service.
locations, a 75 ohm terminator is sometimes used
at each location, creating an extra load on the sys- 4.9 Parts Lists, PWB Layouts & Schematics
tem. The other extreme is when no terminator is
used. When long runs of coax are used to multi- The following section contains printed wiring
ple loads, it may be best to use a video distribu- board layouts, parts lists and schematic diagrams.
tion amp to solve the load matching problem.
The parts lists are shown on the same page as the
Interference problems can also be minimized by corresponding schematic fold-out.
repositioning equipment, rerouting cables, power
cords, or using a different power outlet. Listed are the replaceable parts available from
CONMED. Many of the more common parts
4.8 PARTS ORDERING INFORMATION may be available from local electronic suppliers.
To obtain replacement parts or additional infor-
mation regarding your unit, write or telephone
according to the contact information as listed on
the inside front cover of this manual, or contact
your CONMED distributor.

4-22
K +:
Schematic 4.0 Functional Block Diagram

CAL
SWITCH
RETURN Asst
RESISTANCE
BAR GRAPH ICAL
LAMP pe 1210 FOOTSWITCH FOOTSWITCH OX HANDSWITCH
REGISTERS CONNECTORS | EX | ISOLATION SOA CONTINUITY
AQUI Lul ACTIVATION 4931832 VO PORT 2000 DETECTORS
MODE & ASUT-U6
FAULT INDS. ( Asun
A2DS1-4
wvo7
POWER ON waArcHpoG 上 SRLY
2 ву —=] RESET TIMER &
GENERATOR RLYENA ANDTFL GATE DRIVERS
A3U4 ASU7 & Q1 T CLOCK&
WAVEFORM
GENERATOR
し ADDRESS, DATA & ) σι | A4U1 8 U2
BIPOLAR
> HYBRID RF ISOL.
CONTROL BUS İz 25442 10MHZ CASCODE COL) OUTPUT
XFORMERS — | MONO ACTIVE JACKS
E E POWER AMP & RELAYS
E È © A401-08 AS MONO RETURN AT7J1-J12
Е 8 ほ BASE DRIVER
8 ВАЗЕ
PROGRAM NOVRAM VOLTAGE
EPROM RE GENERATOR
save A3U20 8.21 <a
pl mma nor.
DISPLAYS
LA
42179

DISPLAY/ MCRO- CURRENT RETURN

KEYBOARD ia CONTROLLER 7FAL LIMIT & VARM ELECTRODE
o & ADDR DEC. Mp | VARM ADC
A2U2 10MHz A3U3&U9 ARCO! A3U19 A5Q2.Q3

CONTROL & 6| à CURRENT

25MHZ >| DISPLAY 티 ミ SOURCE
PANEL TONE AGUZI, VR2
AIDSI-DS11
KYBD A1SWI-20 ASRI
VOLUME - | GENERATOR ABSP1 DWG 62-4517
A302

4-23
 Schematic 4.1 Interconnect and Power Supply

men ||
"i
"i
日 asas
We
A1 A2 se
CONTROL jg DISPLAY a A3 A10
n11i 66Noroua
FOOTSMTON
PANEL pus É „| 盖| Foorswrch | aoe
(42) (43) CONTROLLER ГISOLATION (4.8) spona
OSTATO
s PWB sn ー sanosumones, vanni : € ο A9WS
(4.4a & 4.4b) !
lo “ налив
A8 5 vene
ΤΟΡ ΟΟΝΕΒ = Je
ASSEMBLY ABVRI A801 NUMBERS IN PARENTHESES
+5V VBASE D VBASE, GATES — REFER TO SCHEMATIC NUMBER
asus SENSE FOR ASSEMBLY
ーー == ーー == == =
ES

mv | | ニュ
FCH

STRAPPING Cri

100/120V eis 33 s su
STRAPPING -53s A4 A5 HAND 1 A7
== A Êo (em i вши, > POWER e o > OUTPUT * genoa OUTPUT
。 fe | [om AK. ο... | cou lo PWB 。 > PANEL
İİ ¡E
eeovac ”- | | * (4.6) бот (48)
so fe ponei y, > (4.5) so eve
oo で*
ond WHT >
hr leNo
> RETURN

< — as! = “ Broun

a [o n BOS A >
STRAPPING A9CBI = L
100-120 V 10A
220-240 V SA A6 and A9
μα”... REAR PANEL BASE
Geese ASSEMBLY ASSEMBLY
[ee 100/200V 50Hz or 60Hz 20
= 120/240V 60Hz VERSIONS
SEE FIGURE 4.7 FOR OTHER MAINS VOLTAGE AND FREQUENCY VARIATIONS.

4-24
Ref. Aspen Ref Aspen
Des DIN Description Des PN Description
‘ASSEMBLY: Rectifier Harness AOW2, 61-4191-001 NA 62033503 STANDOFF HEX632X 1 172
NA 620260002 TIE WRAP
MPa 624193-006 CONNECTOR HSG MOLEX 19-09-1069 NA 605285001 VIDEO TAPE, VHS, EXCALIBUR PLUS
A4P3 620976002 TERMINAL MOLEX 0209-1112 NA 620419002 WASHER, FLAT 44
AGBRIZ 620288005 TERMINAL SLIPON 1/4 #14-16 NA 20419.093 WASHER FLAT #6
6102 62.4168 005 TERMINAL BLOCK NYLON POLE
NA 620339004 TUBING : Rear Panel (A6) Not available as A completed assembly.
ASSEMBLY: Resistor Harness A9R2, 61-4185-001 62-1206 003 EQUIPOTENTIAL GND STUD
620419.002 FLATWASHER, #4
MPS 62-3682.003 CONNECTORHSG3-PIN HEATSHRINK TUBING, 3
서며 62-3682-201 CONNECTOR DISC. WIRE TERMINAL LOCKWASHER, INT TOOTH, #4
A9R2 62.0362.004 RESISTOR WW 250 OHM 50W 3% NUT KEPS #1032
ΝΑ 620620004 TUBING 3/16 NUT KEPS 46:32
NUT, SMALL PATTERN, HEX, #440
ASSEMBLY: Circuit Breaker Harness AOW1, 61-4187-001 POWER CORD ASSEMBLY
REAR PANEL
AŞINI 624168006 TERMINAL BLOCK NYLON SOLE RECTIFIER, BRIDGE 400V 25
49081 620288008 INAL SLIPON 1/4" 418.22 SCREW, #440 X 1/2" FH SLOTTED
NA 620339003 NC-1082 SURAIN RELIEF
TERMINAL, 1/4" RING BLUE
ASSEMBLY: A3/A4 Control Harness A9W2, 61-4188-001 62.0419.008 WASHER, FLAT #6
2.001 WIRE BRAID
ASPSMP2 62-1389-012 LUG 100 13 PIN 625349.001 HANDLE, REAR
ASS ASP) 621388001 TERMİNAL 62.5339001 SCREW 14230X 1/2 FLT HD PH
NA 620339005 TUBING
ASSEMBLY: Base (A9) Not available as a completed assembly.
ASSEMBLY: Volume Control Harness A9W3, 61-4755-001
ΝΑ. 624814001 SCREW SELETAPPING TYPE F
ο FOE MOD, 500 OHM CW LOG TAPER ΝΑ 620260001
NA 62:0431-001 m ΝΑ 62.0272001
wane È ANG TWISTED ORGWHT 62-0287.008
62-0337-002 FOOT PLASTIC

>>>>>>>>>>>
TURİNG, #2 PVC 105 62.0339 005 TUBING PVC-105 x 7/16
WIRE, 24 AWG TWISTED BRN/WHT 62.0343.001 NUT KEPS #:
CONNECTOR, 4 PIN
TERMINAL, CRIMP NUT KEPS #10-32
SCREW #4-40 X 5/16 PH. PHILLI
ASSEMBLY: A3/AS VSENSE/RELAY Harness AWS, 61-4223-001 SCREW 26-32 X 1/4 T HEAD PHILLIPS
SCREW 26-32 X 1/2 T HEAD PHILLIPS
ASPAASPA 62-1727.002 CONNECTOR IDC 14 PIN DIP SCREW 26-32 X 1/2FLH PHILLIPS
A9Wá 621705001 RIBBON CABLE 14-#28 47° WASHER LK #10
WASHER FL #10
ASSEMBLY: A3/AS Handcontrol/VARM Harness A9WS, 61-4223-002 CIRCUIT BREAKER 120V 108
‘CIRCUIT BREAKER 240V 5A
ASPAGP3. 62-1727-003 CONNECTOR 16 PIN DIP SCREW 6-32 X 3/8 BINHD CAP
АЗ 62.170002 RIBBON CABLE 16-#28 31° SCREW 6.32 X 3/8 SCH CAP
KNOB
ASSEMBLY: Ad to A2/A3 Power Harness ASW6, 61-4190-001 ‘CAP COLORED
SCREW 10-32 X 3/8 SKT BINHD CAP
A2PI, ASP2 62.3682.004 CONNECTOR HSG 4-PIN SCREW 6.32 X 1/2 TC TYPE F
AP 62:3682.008
AZPIASP2, 62.3682201
MP1
NA 62035900 TUBING PVC-105-7/16
ASSEMBLY: Miscellaneous CABI
SCREN 1032 X 5/8SKT BTNHD CAP
N/A 62:1763.001 ADHESIVE, TAK-PAK HANDLE. FRONT. ESU
N/A 62374101 BRACKET HOOD RIGHT
N/A 623742001 BRACKET HOOD LEFT N
N/A 625294001 CARTON, SHIPPING, EXCAL PLUS SCREW, 10.32 X 3/4 SKT BINHD CAP.
NA 62-4231:001 CLAMR CABLE GASKET RE
NA 623739007. COVER TOP TERMINAL WIRE #6 RED
NA 623734001 GASKET SWITCH INL

USHING, 600€
TRANSFORMER FERRO 120/240V60H:
TRANSFORMER FERRO 100/200VS0H:
MANUAL, OPERATOR (TRANSFORMER FERRO 100/200V60Hz
MANUAL, SERVICE TRANSFORMER FERRO 220/240/270V50Hz
NUT #632 KEPS (TRANSFORMER FERRO 100/200V50.60Hx
NA NUT #440 KEPS WASHER STEEL 300 OD
N/A PIN 025D X OSL. WASHER STEEL 500 OD
N/A POLY BAG 24/36 IN SCREW #6-32 X 38 T HD PH
NA RECEPTACLE 9 PIN 62.5837.001 CLAMP CABLE HINGED
N/A SCREW 6:82 X 3/8 T HEAD PHILLIPS
NA SCREW 8:22 12 BDGH PIL
N/A SCREW6-32 X 1/4 T HEAD PHILLIPS
N/A 62370001 SHIELD, CONTROL
 Schematic 4.2 Control Panel

A1: SWITCH PANEL o FUNCTION TABLE

O 0 SHIELD Laver

11-24

11-23
11-22

11-20
ns

nur
BT
ns

PROM A233 na
nz

mn
31-28
31-26

DWG A 62-5438

425
VA Schematic 4.3 Display PWA

a
Conn-48tn
sache
mai τν ， =Ba avre
TY sa
-a conn-26r1n

14 tr

Duo 62-5273

4-26
 BE om Description Figure 4.4 A2 Display PWA
‘ASSEMBLY:Display PWA (A2) 61-5271-001
아대 62026702 cano1,s0v
bi 620860001 DIODE, IN4148
DS 824056003 LED,VĚL
Dsapst
29 62528800
4056001 LAMRINCANDTI
TEDJREDHLSA,LED,7SEG DISPLAY dle
Dee 61361003 DSP.
1EDBARGRN :i 5 i3
HEADER,
HARNESS, FRICTION
26718 LOCK, 4: o2 : Е
HEADER, CONNECTOR RA, 264118 る
TRANSISTOR,13K.NPN,1002N4401
RESISTOR, 6% 258
RESISTOR, 47K, /4W 5% a4
RESISTOR, 10K,2k, 1,96
RESISTOR, VA 5% az
8
η we
yz
DIPI6, 2% ὥς
Rs
U 62286001
623459001 ΚΕ ОЗНА
ΝΕΤ ΑΠ SIP DISPLAY2N DRIVER ES
o면 a
6230200 82079725 KEYB,DISPLAY INT
bå Grissom J AD R. DISE DRIVER
USVii”67 2140
620517008 IVOLTAGE
CL ULNZ80SA,
REG, 8 CH οTRANSIST 2%ARY
Xbsixpss 24910001 MOUNT LED
XDS2NDS4
MIO 625389001
622772001 SOCKEE LAMP 10 PIN
SOCKET'STRIR
NA 23008004 SEREW #440 8/162 HEAD, PHILIPS
NA romeo! NUTKEPS, 440
ο ο ο ο τν PLUS

so
ASSY, PWB A2 DISPLAY
Gant nev.
 lExcalibyrAus PC"

Schematic 4.4a Controller PWA, Sheet 1

UATCHDOS
TIMER

CAL SUITCH

4-27
Ref Aspen Ref Aspen
Des. PN Description Des. PŘ Description
ASSEMBLY: Controller PWA (A3) 61-5751-001 622860002 HEADER, KT ANGLE, 6 PIN
622861-001
A3W1 61-3461.001 HARNESSASSY EXCAL A3W1 623062 001
A3W2 613461002 HARNESS ASSY EXCAL A3W2 623394001
미 6142465017 ICPROG ROM IEC EXCAL «PC 623457001
vis 614266002 IC WAVEFORM ROM 3 BLEND 623464001 TRANSISTOR PNP 2N3906
uz 010861001 IGFET DRIVER 7667 62.466003 IC NOVRAM EXCAL +
‘TPI-58,10, 020361101 TEST POINT, BLK. 62.3598.002
12182023, 623957001
2425 62-4253-001
с 62:0266-002 CAP CER 150PF 200V 10% 624254001
C18,19.21. 62-0267-001 CAP DIP CER 0.01UF 62-4255.001
26. 624257001
624258001
62.0267-002 CAP DIP CER O1UF 624597.001
62-4855-002
62:4929.001
4 62-4931-001
620267003 CAP DIP CER 33UF 62-5833.000
y 625833-014
62-0267-004 CAP DÎP CER 100PF 625833032 LC. 2 INPUT OR 74ALS32
62-0267-006 CAR CER, LOUF 50V
620267.013 CABCER, ISuE SOV
62:0268.002 CAP ELEC 47UF 63V
620289001 DİODE İNAL
620364015 RES, 10, 1/4, 59%
R36 62036403 RES, 100, 14W5%
RI921 62-0364.046 RES, 200, 1/41, 5%
Ral 62-0364083 RES, 390, 1/48 5%
RSS 62-0364085 RES 470, LAW 5%
R45 62-0364-056 RES,510, 14W 5%
Ra 62036406! RES, 820, 1/48 5%
R$2248 62-0364-063 RES, 1000, 1/4, 5%
RIGSIP 620364070 RES, 2000, 14 5%
R25 62036072 RES, 2400, 14W.5%
RIZIS 62034075 RES, 3300, JAM, 5%
R59 62-0364078 RES, 4300, LAW, 5%
6203607 RES ZOO AMES
62.0364081 RES,5600, 1/45%
20364087 RES ОК, АИ
62.0364.100 RES 36K 1/45%
62.0364-105 RES, 56K, 1/4 5%
620364111 RES, 100K, 1/4W, 5%
620364135 5%
620365022
62.0365-060 RES, 750,1/2M 5%
62-0365-063 RES, 1000, 1/2W 5%
62:0365-070 RES, 2000, 12, 5%
62.0451.001 CAR CER 0.057UF 100V 20%
620565001 DİODE
62001213 RES, L62K, 1/41, 196
62.0961.231 RES, MET, 249K, 1/4W, 1%
62:0961-252 RESAI2K, 1ÆW 1%
62.0961-260,
620961289

RESME200K LAVE
Rê DIODE
164446 621357001 CAP TANTIUF 25V 10%
w 6213704 IC DUAL ONE-SHOT 4538
U1222 62.1374001 ICXSTR ARRAY ULN2003
四 2-1377.002
B 62137708 SOCKET
XLS 62197708 SOCKET DIP 28 PIN
16 62-1390003 RECEPTACLE
7 62-1390-005 RECEPTACLE
5 62-1390-012 RECEPTACLE
U1416 —62-1711-001 ICABIT BIN 74LS163
9 62-1714001 ICOCTAL DECODER 7415138,
00 62171001 ICOUAD 2NOR 741502
m 621718002 CLOCK OSCILLATOR 20 MHZ
γαι 62:1719.002 REGULATOR VOLT TO92 12V.
00 621854001 CAP TANT IOUF 16V 10%
Us 622569002 ICMICROCNTRLA BITA0CS1
05661 — 622844001 CARLOUF AV
 Schematic 4.4b Controller PWA, Sheet 2

BASE VOLTAGE

881 EXCALIBUR Plus PC

4-28
EL

VMd PINOBUO) EY Sp 319

 Excalibyr?iUs PC"

version PWA Schematic 4.5 Power Conversion

DUG 62-5247

4-29
Ref Aspen
Des PN Description Figure 4.6 A4 Power Conversion PW,
ASSEMBLY: Power Conversion PWA (A4), 61-4120.001
620364016 RESISTOR 11 1/4W 5% CF
60364-050 RESISTOR 300 1/4W 5% CF
62.036063 RESISTOR 1K 1/4W 5% СЕ
62.0364.066 RESISTOR 1.3K 1/4 5% CI
62.0365.105. RESISTOR 56K, 1/2W 5% CC
62.0367039 RESISTOR 100 2W 5% CE
62-4243-001 RESISTOR 0.1. SW 5% WW.
621695008 RESISTOR 0.62 2W 5% WW
62-1693-002 RESISTOR 3 3 2W 5% WW
62-0363-007 RESISTOR 4K_8W 5% WW
624243004 RES, CERAMIC FLAMEPROOF 120, SW 5%
62:3314-008 CAP ELEC 820 200V
623314004 CAP BLEC 22000 25V
623314005 CAP ELEC 27000 16V
623314006 CAP ELEC 33000 16V
62272000 CAP ELEC 22 25V
621679 001 CAPACITOR PP 10 200V
‘62-1680.001 CAPACITOR PC 1.0 63V
62-1681-001 CAPACITOR PE .01 1007
62.0267.002 CAPACITOR CER 0.1 50V
62.0267-008 CAPACITOR CER 0.33 SOV
62-1684-001 DIODE ZEN N
62-1687-001 DIODE ZENER 18V 1N5355A
62-4865-001 DIODE, 145401
62-1683-001 DIODE, HIGH VOLTAGE/SPEED
62.0417.005 REGULATOR, VOLTAGE +12V LM340AT
LED, RED
VARISTOR 17V
IC DUAL CLOCK DRIVER 0026
62-2845-012 RECEPTACLE STRAIGHT 13 PIN
62:3598-001 HEADER 156 (SRJ1) (2R Já -002)
62-4248.006 HEADER 093"6 PIN
62.0295.001 BAG
620295.003 FUSE CLIR 2AG (XF13 -002 ONLY)
622725.001 TEST POIN
624244001 WIRE, 14 AWG, RED
62424002
624247001
615246001
615246002 ASSY Ad PWR CONVERSION 50-60 Ha
624773004 TRANSISTOR, NEN, MJW16018
624242001 TRANSISTOR, FET BUZ 71
62:3429.008 INSULATOR FADS TO-247
62:3429.002 INSULATOR PADS TO.220
BRACKET MOUNT
SCREW, SOCKET HEAD, 6-32 X 3/8
SCREW, SOCKET HEAD, #4-40X 1/2
WASHER COMPRESSION #4
CLAMR TO-220
FUSE, 1 SA, 250V, 3AG
624866005 FUSE, 025À, 2AG
62.5297-001 HEATSINK, EXCALIBUR
62.0649.002 LOCKTITE, TYPE 222
62.019.008 WASHER, FLAT, #6
62-4878-002 SCREW SOCKET H AD, #6 X 3/16
 Schematic 4.6 Output

CONTINUITY DETECTOR

na Qu
na om
nes Qu

A?
OUTPUT
PANEL

sea ©
Tia

LL
DUG 62-5385
 Da = Description Figure 4.7 A5 Output PWA
ASSEMBLY: Quepue PWA (AS), 61-5249-001 (IEC Units Only)
RIA
RZ
620364108
620364081
RESISTORSIKIANSA
RESISTOR 5.6K, 1/4W5% & a,
lale, 620368068 RESISTOR, LOR, TA 5%,
8172021
NES 28
RILIS19, 620366055 RESİSTOR 470, 1/40, 5% ーー*
RSRasa? 620364052 RESISTOR, 360,14W5%
Riou,
rane GO RESISTOK 150.14W5% ©
620364425 RESISTOR 271445
620345077 RESISTOK 39K12W5%
$20365061 RESISTOR. 8204/2009
62036081 RES. SOR IWS% _ Z
62135600 CAR PC,I 0u63V5% 8 È E
CARMET PE: 32uR100v5%
ČÁEMET PB 22081005%
CARCERO
ČÁEMETPE 1ursovaDe
22NE250V10%
ры PE bni 1600V 6 sl
20267001 CARCERGOINSOV3OW 8 =
“Tp:
0 9
6221675005 CABMET PR27NE2000V85%
01:0261-472 CAPMET PRA7NE2000V5%
CAE PS, 220F 100V 5%
CAP 104F 16V 20%
соло CAEPE2 NEI600VS%
© CARCER,100pE50V,10%
us LC. TIMER 565
KI RELAYSPSTI2V
NPN TRANSISTOR, 2N3904
TRANSISTOR, FET. VNOI 3
DIODE, IN914B
DIODE, HV. FAST RECOVERY
OPTOISOLATOR OPTIL264A
XFORMER, BIPOLAR, IEC EXCALIBUR +
614176006 XFORMER, ARM/ISO, TEC EXCALIBUR +
61:5393-001 XPORMER, MONO, IEC EXCALIBUR +
624177001 XFORMER, ARM OSCIL, EXCALIBUR.
61417005 XFORMER, CONT DET, IEC EXCALIBUR +
615392001 XFORMER BALUN IEC EXCALIBUR+
62-3473.003 RELAY REED/HVI4V FLYING LEADS
621719002 (GULATOR, VOLTAGE, TO92, 12V, 3%
SOCKETDIRIAPIN
SOCKETDIFIGPIN Ba
HEADER FRICTION LOCK
HEADER, 24 PIN GOLD FRICTION LOCK
TERMINAL, MALE deLE]
TEST POINT 55
ii
CABLE TIE 08SW
CABLE TIE, 190W 8
NYLON WIRE STANDOFEI
NUT, HEX, NYLON, #6-32
SCREW, NYLON, 9632 X 1/2 BH
PWB, AS OUTPUT, [EC EXCALIBUR PLUS
SPACER, SA ROUND, NYLON
WASHER, NYLON(1-1/2" OD.)
KEP NUE #10
WASHER, FLAT, #10
SCREW, #10.32 PAN HD (2.1/2°LG)
SCREW NYLON 46-32 X 3/47
BUSHING, SHLDR, RUBBER
NUT, NYLON, 46-82
CHOKE, 20Mit
jm JUMPER, ZERO OHM RES
NA KTV SEALANT - GRAY
NA RIV SEALANT - CLEAR я 2.
NA HEATSHRINKABLE TUBING, 3/8", CLEAR č 5

σηa

i
3
 Schematic 4.7 Mains Voltage and Freguency Variations

100/200V CONTROL MODULE VERSION

SERIES
STRAPPING
E (ALLOWS 50Hz AND 60Hz OPERATION)

PARALLEL
STRAPPING POWER
CONVERSION
5> PWB
o>

E
>
>
>
STRAPPING A9CBI ‘CONTROL
PARALLEL 10A
SERIES SA MODULE Ke
2x
A6W1 ove
MODULE
10

tam ABOVE BR!

POWER
CONVERSION
a> РАВ
>
>
a>
1
«>
LS
DWG 624518
 ExcalibyrPiUs PC”

itch Isolation PWA Schematic 4.8 Footswitch Isolation

1
A
A9J1
MONOPOLAR B
FOOTSWITCH
%
c ar 27-4

7一 一 , , ^” ета
dm i
| >» i

i
A9W7

i us
! wir
!
i
xf
M
ТеM me
i вк Pr
wat arrasa
A9J2 “ a
BIPOLAR y BLK T 3
roorswren | ® > < me * 더Bu SME
>, *

Ÿ
mve
n o sm
A6T82-9
hows MET mi
= Ly
E mm di
개 I 2 Ť 、 62-4751-002 PWB
So m
rão
A6TB2-1 ΜΗ da

ALL RESISTORS ARE IN OHMS, 1/4W 5x CF.

ALL CAPACITORS ARE IN MICROFARADS

四 4-32
Ref Aspen
Des. DIN Description Figure 4.8 A10 Footswitch Isolatic
"ASSEMBLY: Footewitch Isolation PWA (A10), 61-4750-002
τι 624749001 XEMR PWR 2.5VA 50/60 HZ.
Č2C7 62:0267-001 CAP DIP CER OOIUF
62.0268-005 CAP ELEC 470UF SOV
62036403 RES. CE 150, LAW 5%
1 620864055 RES, 470, 1/4W, 5%
, 62.0364.068 RES, 1600, 14M, 5%
620565-001 DIODE
62-1389.005 CONNECTOR PLUG6-PIN
622725-001 POINT TEST 0.200" CENTER
622845.001 RECEPTACLE STRT 2 PIN
62-2845.008 RECEPTACLE STRT 6 PIN
ULU3 624238001 OPTOISOLATOR OPTI264A
91.02.08 624239001 TRANSISTOR NPN 2N3904

7
at Di

È Ш I

cz T

MN 05/419
[KE
„BBS

ATEMESSV OU
FO. EORO's
R= 3 3 Jos
вк ин вк ви вк.
 -6
Appendix A - Fault Codes

NOTE: Although many of the Possible Causes of the Err Codes are digital IC’s, their failure rates are very
low. Eliminate other possibilities (such as IC sockets, open pull up resistors or shorted bypass capacitors)
before changing them.

ACC CODES MEANING POSSIBLE CAUSES

FS Monopolar Footswitch Shorted. -Monopolar footswitch pressed
while turning power on.
-Faulty ribbon cable or connector.
-Shorted Footswitch.
-Shorted bypass capacitors or open pull up
resistors on control lines.
-A3U11 Failure (8255).

LH Left Handswitched Monopolar -Left Handswitched Accessory pressed while

Accessory Shorted. turning power on.
-Shorted Left Handswitched Accessory
-Faulty ribbon cable or connector.
-A5 U2 or U3 shorted.
-Shorted bypass capacitors or open pull up
resistors on control lines.
-A3U11 Failure (8255).

rH Right Handswitched Monopolar -Right Handswitched Accessory pressed

Accessory Shorted. while turning power on.
-Shorted Right Handswitched Accessory.
-Faulty ribbon cable or connector.
-A5 U5 or U6 shorted.
-Shorted bypass capacitors or open pull up
resistors on control lines.
-A3U11 Failure (8255).

bP Bipolar Accessory Shorted. -Bipolar Accessory pressed while turning

power on.
-Shorted Bipolar Accessory.
-Faulty ribbon cable or connector
-A5 U1 shorted.
-Shorted bypass capacitors or open pull up
resistors on control lines.
-A3U11 Failure (8255).
CP “xx” Control Panel key -Control Panel key pressed while turning
Note: “xx” displayed in power on.
Bipolar Power window corresponds -Shorted Control Panel key.
to the stuck key using Figure 2.1 as -Faulty ribbon cable or connector.
a reference. Multiple keys show as “88”. -A2Q4, Q5 or Q6 shorted.
-A2U2 (8279) or A2U4 (NE5090) Failure.

I È es
erco. Hg"
Err CODES MEANING POSSIBLE CAUSES
1.0 Read/write of 8031 internal -Faulty A3U3 (8031 microprocessor).
memory is impaired. -RF Shield not properly installed.
1.1 Read/write of external -Faulty A3U2 (DS1220).
memory is impaired. -Shorted or open bus lines.
-RF Shield not properly installed.
2x Program Memory CRC error. -Faulty A3U1 (270256).
(“> is for mfr's. -Faulty A3U3 (80C31).
internal use.) -Shorted or open bus lines.

3.0 Calibration Memory CRC error. -Calibration incomplete when exited

CAL mode.
-Faulty A3U2 (DS1220).
-Shorted or open bus lines.
-Faulty A3U6 or U8.

4.0 First Stage of Watch Dog Timer -A3U7, R5, or C5 incorrect.

incorrect. Note: If error is very -Microprocessor frequency incorrect
large, the unit cannot tell which (A3Y1 or U14).
stage is incorrect. -A3U6 or U10 incorrect.

4.1 Second Stage of Watch Dog Timer -A3U7, R6, or C6 incorrect.

incorrect. Note: If error is very -Microprocessor frequency incorrect
large, the unit cannot tell which (A3Y1 or 014).
stage is incorrect. -A3U6 or U10 incorrect.

4.2 Watchdog Timer Pulse is outside -Faulty A3U1 (27256).

of allowed timing window. -Faulty A3U3 (8031).
-Clock freguency incorrect (A3Y1 or A3U14).

5.0 RF PA current too low during -RF Output transistor(s) (A4Q1-Q8) faulty.
power on tests. -Open fuse on A4 assembly.
- +5Volt supply faulty A8VRI connection.
-RF power supply faulty or not connected.
-A8Q1 connections faulty.
-Gate or base signals faulty or not connected.
-Isense circuitry faulty.
-faulty relays A5K1-K6.

5.1 RF PA current too high during -RF Output transistor(s) (A4Q1-Q8) faulty.
Power on Tests. -Gate or base signals faulty.
-A4D10 shorted.
-Isense circuitry faulty.
-faulty relays ASK1-K6.

5.2 RF PA current too high for -RF Output transistor(s) (A4Q1-Q8) faulty.
power setting. -Gate or base signals faulty.
-A4D10 shorted.
-Isense circuitry faulty.
-faulty relays A5K1-K6.
-RF shield improperly installed.
-Vsense circuit faulty (high power cut only)

ns ©
 -260 <>
Err CODES MEANING POSSIBLE CAUSES

6.0 Attempted entry to guarded -RF Shield not properly installed.

memory location or CPU failure. -Faulty A3U3 (8031).
-Faulty A3U1 (27256).

Watchdog Timer does not -A4R8 shorted.

disable RF drive. -Faulty A3U5 (74LS14).
-Faulty A3U13 (74LS140).
-Faulty A3U23 (1M339).
-A3 +12V supply incorrect.
-Faulty A3R50 or R51.

Incomplete Calibration -10.0 Multiple modes not calibrated on

Note: The suffix determines which return to CAL top level menu.
mode was not calibrated. -10.1 Pure
-10.2 Blend 1
-10.3 Blend 2
-10.4 Blend 3
-10.5 Standard Coag
-10.6 Spray Coag
-10.7 Bipolar Coag
-10.8 Bipolar Cut
-10.9 ARM

Nonmonotonic calibration; i.e.; -11.0 More than one mode is nonmonotonic

at least one calibration point is on return to CAL top level menu.
lower than the preceding point. 11.1 Pure
The suffix determines which mode -11.2 Blend 1
is nonmonotonic. -11.3 Blend 2
-11.4 Blend 3
-11.5 Standard Coag
-11.6 Spray Coag
-11.7 Bipolar Coag
-11.8 Bipolar Cut

Power setting in data memory -RF Shield not in place.

doesn't match display. -Faulty A2U1 (8279).
-Faulty A3U3 (8031).
-Faulty bus connection to A2J2

A3U11 RESET after power up. -RF Shield not in place.

-Faulty A3C67.
-Faulty A3U11.

Safety Critical Variables do not match. -Faulty A3U2 (DS1220).

-Faulty A3U3 (80C31).
-Shorted or open bus lines.
-Faulty A3U9 (74LS138)
Stuck CAL switch. -CAL Switch (A3S1) is stuck or held for
more than 30 seconds.
-Faulty A3R54
-Faulty A3U11
ER
Err CODES MEANING POSSIBLE CAUSES

21.0 ARM voltage less than or -Faulty A5Q2 or Q3.

equal to 0.4V. -A3U21 or VR2 faulty.
-Bent pin on ribbon cable.
-Shorted bypass cap on VARM line.
-Shorted VARM sense line.
-Shorted A5T4.

22.0 Base Voltage drive (VBASE) is too “Test jumper A3TP3 to A3TP22 is still
low during Power On Self Test. installed. (Remove it.)
-Faulty A8Q1 or connections.
-+5V Over Voltage Shutdown Circuit
malfunction.
-Base voltage Check circuitry (A3R64, R63,
C69, U26B) failure.
-Any failure in the VBASE circuitry.

22.1 Base Voltage drive (VBASE) is too -A801 shorted to supply.

high during Power On Self Test. -Base voltage Check circuitry (A3R64, R63,
C69, U26B) failure.
-Any failure in the VBASE circuitry.

22.2 Base Voltage drive (VBASE) too high in -Unit calibrated without load or too high a
Run Mode. load Recalibrate with rated load connected
to unit.
-A801 shorted to supply.
-Base voltage Check circuitry (A3R64, R63,
C69, U26B) failure.
-Any failure in VBASE circuitry.

23.0 Waveform too low during Power on Waveform detection circuitry (A3U27A,
self tests. R66, R65, C70, U26C) malfunction.
-Ripple on +12V supply.
Tone detector or tone generator circuitry
failure keeping waveform drive off.

23.1 Waveform too high during Power on -Waveform detection circuitry (A3U27A,
self tests. R66, R65, C70, U26C) malfunction.
-Ripple on +12V supply.

23.2 Waveform too high in Run Mode. -Waveform detection circuitry (A3U27A,
R66, R65, C70, U26C) malfunction.
-Ripple on +12V supply.
-Stuck address lines to A3U10 orU17.

24.1 Tone detector can't disable RE - Failure in tone detect circuitry ( A3U26D,
C71, D11, D12, R68, R69, R70, R22
prevents TONEDET from pulling low
during power on self test.

| O