Operator & Service

Manual

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 LIMITED WARRANTY
For a period of two years following the date of deliv-
ery, CONMED Corporation warrants the Sabre 2400
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 per-
formed 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. 4,569,345 - 4,617,927 -

4,848,335 - 4,961,739 and other
patents pending.

© 2004 CONMED Corporation

Mailing Address:
310 Broad Street
Utica, New York 13501

Shipping Address:
7211 S. Eagle St.
Englewood, Colorado 80112

For Technical Services or Return Authorization Phone:

303-699-7600 / 1-800-552-0138

For Customer Services or to order parts phone:

1-800-448-6506 or contact your
CONMED Representative

The revision level of this manual is specified by the

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

Manual Number 60-5601-002 Rev. AA

Unit Serial Number ____________________________

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Table of Contents
& List of Illustrations

Section Title Page

1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 Precautions in Equipment Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.2 Precautions in Patient Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.3 Precautions In Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.4 Precautions When Testing or Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2.0 INSTALLATION AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Initial Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3.1 Preliminary Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3.2 Preliminary Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Controls, Displays and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.1 Front Panel Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.2 Output Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.3 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.1 Preliminary Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3.0 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Circuit Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Functional Block Diagram Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3 Controller Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.3.1 Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.3.2 Power On Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.3.3 Controller, I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.3.4 Program Memory, EPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.3.5 Base Voltage Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.3.6 IFAIL ADC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.3.7 Waveform Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.3.8 Tone Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.4 Controller Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.4.1 Software Initialization and Test Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.4.2 Working Program Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.5 Display Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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Section Title Page

3.1.5.1 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.1.6 Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.1.7 R.F. Output Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.1.8 Aspen Return Monitor (A.R.M.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.1.9 Isolated Handswitching/Footswitching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
4.0 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Assembly Breakdown and Parts Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.1 Power PWB Assembly A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.2 Micro Controller PWB Assembly A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.3 Display PWB Assembly A7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.5 Periodic Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.5.1 Chassis Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.5.2 Displays, Alarms, Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.5.3 Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5.4 RF Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5.5 RF Leakage from Inactive Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5.6 Line Frequency Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5.7 Aspen Return Monitor (A.R.M.) Calibration Check . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Calibration and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.6.1 CAL Mode General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.6.2 Power Calibration General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6.3 Output Power Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6.4 A.R.M. Calibration (Pad). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.7.1 HLP Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.7.2 Pseudo Run Diagnostics (dIA 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.7.3 Watchdog Timer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.7.3.1 Accessing Watchdog Timer Diagnostics (dIA 1) . . . . . . . . . . . . . . . . . . . . 4-16
4.7.3.2 dIA 1 Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.7.3.3 Troubleshooting with Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.7.4 Base Voltage Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.7.5 Waveform Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.7.6 Aspen Return Monitor (A.R.M.) Troubleshooting. . . . . . . . . . . . . . . . . . . . . . 4-18
4.7.7 RF Amplifier Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.7.8 Power Amplifier Transistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.8 View Mode (dIA3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.9 Parts Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.10 Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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Figure Title Page

1.1 Pure Cut Load Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.2 Blend Cut Load Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3 Coagulation Load Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4 Bipolar Load Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 Output Power vs. Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
2.1 Controls, Displays & Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2 Patient Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3.1 A.R.M. Resistance Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.2 Waveform Generator Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3 RF Output Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4.1 Rear Panel Screw Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.2 Subassembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4.3 Power Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.4 Micro/Controller Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.5 Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4.6 Power Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Schematic Title Page

4.1 Functional Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

4.2 CPU-PIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3 Vbase-Speaker-Relay-Voltage Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.4 ADC and Waveform Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.5 Display Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.6 RF Amp-Output-Arm Isolation-Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.7 Hand and Foot Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.8 Seven Segment Displays & Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.9 Indicators & Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Table Title Page

4.1 RF Output Power Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 RF Leakage to Ground Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 RF Leakage Test for Inactive Outputs Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 Unkeyed Line Frequency Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5 Keyed Line Frequency Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 CAL Mode Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.7 HLP Codes and Possible Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.8 dIA 1 Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.9 View Mode (dIA 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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General Information
Section 1.0

The Sabre 2400 electrosurgical unit has been • Microprocessor Control: this feature provides
designed to provide a broad range of electrosurgi- the user with a superior degree of safety and con-
cal capabilities in a single unit. This unit fulfills trol in solid state electrosurgery. The programmed
the needs of the modern operating room by pro- intelligence of the microprocessor has been
viding monopolar cutting and coagulation capa- exploited to provide accurate, therapeutic power,
bilities for the most demanding procedures, and digital power display, microprocessor aided
bipolar coagulation. Features of this unit include: calibration, and a comprehensive set of internal
diagnostics which continually guard against the
• ASPEN RETURN MONITOR: the Aspen consequences of an internal failure. Internal fault
Return Monitor (A.R.M.) provides an extra mar- isolation simplifies troubleshooting to ensure a
gin of safety against possible patient burns at the minimum delay in returning the unit to service.
site of the dispersive electrode. The Resistance
Indicator displays the resistance of the patient • Standard Coagulation: Monopolar Coagulation
measured between the conductive contacts of the mode. The Sabre 2400 is highly effective in the
return electrode. This information can be used by most demanding electrosurgical applications,
the operating room staff to note high risk patients including underwater coagulation.
and to indicate a loss of electrode contact with
the patient. It will also detect a return electrode • Bipolar: the Sabre 2400 Bipolar Coagulation
that is open or shorted. Microprocessor-controlled mode is optimized for effective, fast, nonsticking
circuitry prevents the unit from monopolar activa- performance.
tion when patient resistance is outside the expect-
ed range and when a return cable is defective. • Hand Switchable Bipolar Operation.

• Isolated Output Circuitry: this feature minimiz- • Presets: the Sabre 2400 features nine computer
es the probability of alternate ground site burns. memory locations for commonly used electrosur-
gical settings. Each memory location stores the
• Independent Outputs: the operation of one or operating mode, the power setting, the pad type,
two outputs will result in the supply of RF ener- and the sound volume setting. In addition, the
gy to only the active accessories. Sabre 2400 stores the last active settings prior to
power down in the "P" memory location. This
• Circuit Redundancy: this feature, in conjunc- feature is useful when the previous Sabre 2400
tion with a fault tolerant design, provides a wide settings are required.
safety margin against catastrophic failures.
• Instructions on Top Cover: an abbreviated
instruction set is printed on the top cover of the
Sabre 2400 for quick reference.

1-1
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• Simplified Controls: the user may command 1.1.1 Precautions in Equipment Preparation
the full range of capabilities of the Sabre 2400
by means of a few easily understood controls. • Visually inspect all accessories before each
Since Monopolar Cut, Monopolar Coagulation, use to verify the integrity of insulation and the
and Bipolar modes are totally independent, the absence of obvious defects.
surgeon is free to switch between modes at will,
freeing the O.R. staff for other tasks. • The Sabre 2400 is equipped to connect three
monopolar accessories at one time for the conve-
• Rugged, High Efficiency Circuitry: the Sabre nience of the surgical staff. Despite the fact that
2400 delivers full power with cool, long-life the Sabre 2400 will deliver power to only the
operation. There are no fans to compromise the commanded electrodes, unused accessories that
sterile field. are connected should be stowed in a safe, insu-
lated place such as a nonconductive holster or test
• Circuit Protection: microprocessor-controlled tube. Accessories should not be connected unless
monitoring and shutdown of circuit functions, it is known that they will be needed.
individually fused output transistors, thermally
fused short circuit proof power transformer and a • This unit is equipped with a hospital grade,
double pole circuit breaker for power line protec- 3 prong, power connector that meets all of the
tion, all contribute to increased circuit protection. requirements for safe grounding of the unit. The
user should verify that the power receptacle and
• Ease of Maintenance: to minimize the mainte- cord used with this unit are properly grounded
nance effort, the Sabre 2400 features easy access, and correctly polarized. Do not use ground
handtool-replaceable power transistors, and cheater plugs or extension cords.
microprocessor aided fault isolation and trouble-
shooting aids. • Do not place liquid containers on top of the
unit. Wipe spilled liquids off the unit immediate-
• Microprocessor-Aided Calibration: micropro- ly. To prevent inadvertent entry of liquids, do not
cessor aided calibration procedure uses state of operate this unit except in its normal position.
the art EEPROM, digital displays, and up/down
keys to easily calibrate the Sabre 2400. There are • Verify that the return electrode cable is connect-
no potentiometers or selected parts used in the ed to the appropriate return electrode connection.
Sabre 2400.
• Do not reuse disposable (single use) accessories.
• Mounting Flexibility: the Sabre 2400 is
designed to be placed on any suitable table top • Do not use cords as handles; damage to the
surface, or it may be secured to the top of a insulation and increased risk of burns or other
matching cart. injury may result.

• Ease of Handling: low profile, front handle, • Use only suitable accessories (cables, foot-
and a cord wrap on the cart provide easy han- switches, active and neutral electrodes, etc.) in
dling. order to avoid incompatibility and unsafe opera-
tion. Refer to the “IEC Recognized Accessory
1.1 PRECAUTIONS List”, CONMED part number 60-5206-001 for
suitable accessories supplied by CONMED/Aspen
The safe and effective use of electrosurgery is Labs.
dependent, to a large extent, upon factors under
the control of the operator, and not entirely con-
trollable by the design of this equipment. It is
important that the instructions supplied with this
equipment be read, understood, and followed in
order that safety and effectiveness be enhanced.

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1.1.2 Precautions in Patient Preparation • Because of the risk of burns, needles should
never be used as return electrodes for electrosur-
• Electrosurgery should NEVER be performed gery. Return electrodes should be placed such that
in the presence of flammable anesthetics, flam- as much of their conductive area as possible is in
mable prep solutions, or in oxygen-enriched firm contact with an area of the patients' body
environments. The risk of igniting flammable that has a good blood supply and as close to the
gases or other materials is inherent in electrosur- operative site as is practical. Adhesive-type return
gery and cannot be eliminated by device design. electrodes should be reliably attached with their
Precautions must be taken to restrict flammable entire area in contact with the patients' body.
materials and substances from the electrosurgical
site, whether they are present in the form of an • In general, electrosurgical current paths should
anesthetic or skin preparation agent, or are pro- be as short as possible and should run either lon-
duced by natural processes within body cavities, gitudinally or in a diagonal direction to the body,
or originate in surgical drapes or other materials. not laterally and under no circumstances lateral to
There is a risk of pooling of flammable solutions the thorax.
in body depressions such as the umbilicus and in
body cavities, such as the vagina. Any excess fluid • Electrodes and probes of monitoring, stimulat-
pooled in these areas should be removed before ing, and imaging devices can provide paths for
the equipment is used. Due to the danger of igni- high frequency currents even if they are battery
tion of endogenous gases, the bowel should be powered, insulated, or isolated at 60 Hz. The
purged and filled with non-flammable gas prior to risk of burns can be reduced but not eliminated
abdominal surgery. by placing the electrodes of probes as far away
as possible from the electrosurgical site and the
• This unit is equipped with the Aspen Return return electrode. Protective impedances incorpo-
Monitor (A.R.M.) which verifies that the return rated in the monitoring leads may further reduce
electrode cable is unbroken and connected to the the risk of these burns. Needles should not be
return electrode and to the electrosurgical unit used as monitoring electrodes during electrosurgi-
when in Single Pad mode. It DOES NOT verify cal procedures.
that a single pad return electrode is in contact
with the patient. When in Dual Pad mode, the • The active electrode should not be used in the
A.R.M. confirms that the total resistance is in vicinity of electrocardiograph electrodes.
the expected range. Do not depend solely on
the Resistance Indicator in the Dual Pad mode. • Heat applied by thermal blankets or other
Proper application and visual inspection are sources is cumulative with the heat produced at
required for safe operation. the return electrode (caused by electrosurgical
currents). Risk of a patient injury may be mini-
• The use and proper placement of a return elec- mized by choosing a dispersive electrode site that
trode is a key element in the safe and effective use is remote from other heat sources.
of electrosurgery in monopolar procedures, par-
ticularly in the prevention of burns. Follow direc- • When using injection cannulas as electrocar-
tions and recommended practices for the prepara- diograph electrodes, the metal cone must not be
tion, placement, use, surveillance, and removal placed on the skin; this also applies to the leads to
of any return electrode supplied for use with this monitoring instruments.
electrosurgical unit.
• During the use of this RF isolated output unit,
• Apply the return electrode to a clean-shaven the patient should not be allowed to come in
surface of the patient that is thoroughly clean and contact with metal parts that are grounded or
dry. Avoid placement on scar tissue, bony promi- other conductive surfaces that have an appreciable
nences or other areas where pressure points on capacitance to ground. This will minimize the
small areas might develop. possibility of localized burns resulting from stray
electrosurgical currents to the ground.

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• Skin to skin contacts, such as between the arm output before checking for obvious defects or
and the body of a patient, should be avoided, by misapplication. Check for effective contact of the
the insertion of a cloth. return electrode to the patient anytime that the
patient is moved after initial application of the
• The use of electrosurgery on patients with return electrode.
cardiac pacemakers or pacemaker electrodes is
potentially hazardous because the pacemaker may • If a Dual Pad RETURN MONITOR Alarm is
be irreparably damaged and/or the high frequency sounded intraoperatively, visually confirm proper
energy of the electrosurgical output may interfere return electrode attachment to the patient prior to
with the action of the pacemaker and ventricu- pressing the MONITOR SET Key.
lar fibrillation may occur. Precautions should be
taken to ensure that the patient's well-being is • Electrosurgical leads should not be allowed to
maintained in the event of such interference. We contact the patient, staff, or other leads connected
recommend that the Cardiology Department and to the patient.
the manufacturer of the pacemaker be consulted
for advice before operating on a patient with a • The output power selected should be as low as
pacemaker. These precautions also apply to oper- possible and activation times should be as short as
ating room personnel with cardiac pacemakers. possible for the intended purpose.

• To minimize the possibility of cardiac pace- • When uncertain of the proper control setting
maker interference, place the return electrode such for the power level in a given procedure, start
that the electrosurgical current path is as near per- with a low setting and increase as required and/or
pendicular as possible to the pacer lead. consult the factory.

1.1.3 Precautions in Use • Observe all caution and warning notices printed
on the cover of the unit.
• Do not use monopolar electrosurgery on small
appendages, as in circumcision or finger surgery, • The operating room staff should never contact
as it can cause thrombosis and other unintended electrosurgical electrodes (either active or disper-
injury to tissue proximal to the surgical site. sive) while the RF output of the unit is energized.
Please note ANSI/AAMI Standard HF-18-1993
which currently contraindicates both monopolar • The tips of recently activated accessories may be
and bipolar electrosurgery for circumcisions. hot enough to burn the patient or ignite surgical
drapes or other flammable material. Wait a few
Urologic literature also contraindicates the use of seconds after activation for the tip to cool, then
monopolar electrosurgery for circumcision, and place the accessory into a pencil holster.
instead recommends the use of bipolar electro-
surgery where clinically indicated for hemostasis. • Interference produced by the operation of this
Physicians choosing to use bipolar electrosurgery unit may adversely influence the operation of
for circumcisions should be trained in this tech- other electronic equipment.
nique and knowledgeable of the effects of electro-
surgery on tissue of this nature. 1.1.4 Precautions When Testing or Servicing

Should you decide that the bipolar electrosurgical • This electrosurgical unit should be tested by
technique is acceptable for circumcision, do not qualified maintenance personnel on a periodic
apply the bipolar electrosurgical current directly basis to ensure proper and safe operation. We
to circumcision clamps. suggest examination of the unit at least every six
months.
• Apparent low power output or failure of the
electrosurgical equipment to function correctly • Refer all servicing to qualified personnel. Your
at otherwise normal settings may indicate faulty CONMED representative will be happy to assist
application of the return electrode, failure of an you in getting your equipment serviced.
electrical lead, or excessive accumulation of tissue
on the active electrode. Do not increase power

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• High voltages are developed within the unit • Since the clinical use of electrosurgical units
that are accessible when the top cover is removed. is intermittent in nature with duty cycles on the
These voltages are potentially dangerous and order of 10%, this unit is not designed to operate
should be treated with extreme caution. for extended periods of continuous output. When
testing, it is recommended that duty cycles be
• The high voltage dc power supply in the Sabre limited to 15 seconds on, 30 seconds idle.
2400 is equipped with a bleeder resistor to dis-
sipate the charge on the filter capacitor. When the • Life of the equipment will be extended by
red L.E.D. on the A1 Power/Output Board is lit, minimizing operating temperature and extreme
high voltage is present, and caution must be used thermal cycles.
during servicing.
• The heat dissipation capability of the heat sink
• Never remove or install any parts with power is severely impaired by activating the Sabre 2400
on. in other than its normal operating position. There
are no tests requiring operation in any other posi-
• Avoid contact with the output leads when the tion.
unit is activated. Periodically inspect the test
leads used for the output connections for obvious • Consult the factory for advice before making
defects. any modifications to the unit.

• Although this unit will withstand momentary • Ensure that the two top cover screws are tight-
short circuits on the output, prolonged short cir- ened before returning the unit to service.
cuits may damage the unit. Short circuiting the
output should be avoided since it is neither neces-
sary nor desirable.

1.2 SPECIFICATIONS

INPUT POWER (All Units 700W max 50/60 Hz)

Mains Voltage Mains Current

VRMS ARMS
Catalog Number Nominal Minimum Maximum Nominal Idle Maximum
Nominal line
(Cut 300W)
60-5600-002 120 104 127 0.8 7.0
60-5600-003 100 90 110 1.0 8.4
60-5600-004 220 198 242 0.5 3.8
60-5600-005 240 216 264 0.4 3.5
60-5600-015 230-240 207 264 0.5 3.7

Classifications: IEC 601-2-2, Class 1

IEC 601-1-2

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LINE FREQUENCY LEAKAGE: (Per UL RF LEAKAGE CURRENT:

544) at 120 V, 60 Hz Monopolar - 100mA max. per AAMI HF18-
Patient Connections to Neutral: Less than 10 1993 Clause 4.2.10.1 and IEC 601-2-2 Clause
uA typical 19.102
Chassis to Neutral: Less than 25 uA typical
Models 60-5600-003 and 60-5600-015 addi-
tionally are 150mA max. with accessories per
IEC CLASS 1, TYPE CF, IEC 601-2-2 Clause 19.101 b) when used with
Defibrillator Proof approved accessories. See CONMED “IEC
Recognized Electrosurgical Accessories” list, Cat.
No. 60-5206-001.
POWER DISPLAY ACCURACY: The greater
of +/- 10% of display or +/-5 watts at rated Bipolar - Less than 1% per
load. IEC 601-2-2 Clause 19.101 c)

OPERATING FREQUENCY (fundamental):

Pure Cut: 416.7 KHz +/- 0.01%
Blend Cut: 416.7 KHz +/- 0.01%
RF Floating (Isolated)
F
POWER DECREASE: 1% typical, Pure Cut at
Coag: 520 KHz +/- 10% unloaded 150W, 20 seconds.
Bipolar Coag: 1.05 MHz +/-2%
SINGLE FOIL RETURN ELECTRODE
PULSE REPETITION FREQUENCY: MONITOR:
Blend: 20 KHz +/-0.01% Two wire continuity detector, typical threshold =
Coag: 25.0 KHz +/-0.01% 10 ohms.
Bipolar: 20.0 KHz +/-0.01%
DUAL FOIL RETURN ELECTRODE
LINE REGULATION: Power change < 1%/V MONITOR: Two wire resistance monitor, typi-
= (Pmax - Pmin) x 100% cal acceptance range 10 to 150 ohms, trip thresh-
Pset ( Vmax - Vmin) old typically 20% higher than last SET POINT
activation, visual indication of patient resistance.

COOLING: Natural convection, conduction and

radiation. No Fan.

SOUND FREQUENCIES:

INDICATOR TONE 60-5600-002, -004, -005 60-5600-003, -015

FREQUENCY (Hz) FREQUENCY (Hz)

CUT ACTIVATION 500 492

COAG ACTIVATION 250 450
RETURN FAULT ALARM 1000 1147
MACHINE FAULT 1000 1147
CROSS KEY 1700 1700

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OPERATING MODES AND NOMINAL OUTPUT PARAMETERS

MODE MAX. POWER LOAD CREST MAX. OPEN

(WATTS) RESISTANCE FACTOR CIRCUIT
(OHMS) VOLT P-P
MONO PURE CUT 300 300 1.8 2000
MONO BLEND 180 300 2.5 2200
MONO COAG 120 500 7.0 9000
BIPOLAR COAG 50 50 1.5-12.1* 280

*(Bipolar Coag crest factor decreases as power setting increases.)

CONTROLS:
Monopolar Cut Power Increase Key: Gray UP push button
Monopolar Cut Power Decrease Key: Gray DOWN push button
Monopolar Pure Mode Select Key: Gray push button
Monopolar Blend Mode Select Key: Gray push button
Monopolar Coag Power Increase Key: Gray UP push button
Monopolar Coag Power Decrease Key: Gray DOWN push button
Bipolar Power Increase Key: Gray UP push button
Bipolar Power Decrease Key: Gray DOWN push button
Single Pad Select: Gray push button
Dual Pad Select: Gray push button
Monitor Set Point Key: Gray push button
Volume Increase Key: Gray button
Volume Decrease Key: Gray button
Circuit Breaker: Lighted rocker switch
Preset Select ("SEL") Gray push button
Preset Store Gray push button

INDICATORS:
Monopolar Cut Mode Indicator: Yellow LED
Monopolar Coag Mode Indicator: Blue Incandescent Light
Bipolar Mode Indicator: Blue Incandescent Light
Monopolar Cut Power Digital Display: Red LED digital displays
Monopolar Coag Power Digital Display: Red LED digital displays
Bipolar Power Digital Display: Red LED digital displays
Return Monitor Indicator: Red LED
Resistance Indicator: Green LED bar graph
Return Monitor Dual Pad Indicator: Green LED
Return Monitor Single Pad Indicator: Green LED
Monopolar Cut Mode Select: Yellow LED
Power Line Breaker: Green light
Preset Memory Location Red LED digital display

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CONNECTIONS:
Monopolar Foot Switch Connector: Threaded, 4 Pin
Bipolar Foot Switch Connector: Threaded, 3 Pin
Two Pin Return Electrode Jack: A.R.M. and REMTM compatible connector
Bipolar Accessory Jacks: Two blue banana jacks for RF output, plus black
miniature banana jack referenced to bottom blue jack for
handswitched bipolar operation.
Hand Switchable Monopolar
Accessory Jack: Two sets of 3 banana jacks (two black and one red)
Foot Switch Controlled Monopolar
Accessory Jack: Bovie #12 Standard Active

NORMAL USE & ENVIRONMENTAL RESTRICTIONS:

Drip-proof equipment, IPX1
Equipment not suitable for use in the presence of a flammable
anaesthetic mixture with air or with oxygen or nitrous oxide.

Continuous operation with intermittent loading, Duty Cycle 15s on / 30s off.
Operating Ambient temperature range +10O C to +40O C
Relative Humidity 30% to 75%
Altitude -60 to +4500 meters (-197 to +14,760 feet) above Sea Level.
Mounting Restriction: 2 inch (5cm) clearance required on each side of unit for cooling.

SHIPPING AND STORAGE ENVIRONMENTAL RESTRICTIONS:

-40O C to +70O C; 10% to 95% Relative Humidity when sealed in original polybag,
packing material and shipping carton.

REGULATORY CERTIFICATION:
UL Listed, Medical and Dental Equipment (E68077)
ISO 9002: 1994 Registered Facility

POWER CORD: AWG 16-3 Yellow, Type ST, 15' 6" (4.7 M) [-002 model only]

WEIGHT: 32 lb. (14.5 Kg)

HEIGHT: 6.75 inches (17.1 cm)
WIDTH: 14.25 inches (36.2 cm)
DEPTH: 21.5 inches (54.6 cm)

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

REMTM is a trademark of Valleylab, Inc.

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1.3 EXPLANATION OF SYMBOLS

CUT HANDSWITCHED OUTPUT-CONNECTION
FOR HANDSWITCHED MONOPOLAR
PURE CUT WAVEFORM WITH MINIMUM ACCESSORIES
THERMAL DAMAGE AND HEMOSTASIS
FOOTSWITCHED OUTPUT-CONNECTION
BLEND CUT WAVEFORM WITH FOR FOOTSWITCHED MONOPOLAR
HEMOSTASIS ACCESSORIES

STANDARD MONOPOLAR COAGULATION HIGH VOLTAGE OUTPUTS

SINGLE FOIL-USED WITH ELECTRODES
THAT DO NOT MONITOR CONTACT BIPOLAR OUTPUT-CONNECTION FOR
QUALITY BIPOLAR ACCESSORIES
DUAL FOIL-SETS MONITOR TO USE
ELECTRODES THAT DO MONITOR HANDSWITCHED BIPOLAR OUTPUT
CONTACT QUALITY
BIPOLAR COAGULATION FOOTSWITCHED BIPOLAR OUTPUT
TYPE CF-PATIENT CONNECTIONS
DECREASE VOLUME SETTING ARE ISOLATED FROM EARTH AND RESIST
THE EFFECTS OF DEFIBRILLATOR DISCHARGE
INCREASE VOLUME SETTING RETURN ELECTRODE-CONNECTION FOR
MONOPOLAR DISPERSIVE ELECTRODE
REPLACE FUSE ONLY WITH
A V TYPE AND RATING AS SHOWN RF ISOLATED-PATIENT CONNECTIONS
PROTECTIVE EARTH
F ARE ISOLATED FROM EARTH AT
HIGH FREQUENCY
(INLET CONNECTOR)
CONSULT ACCOMPANYING DOCUMENTS
HIGH VOLTAGE CIRCUITRY PRIOR TO PLACING EQUIPMENT IN SERVICE
EXPLOSION RISK IF USED WITH
CAUTION - HIGH VOLTAGE INSIDE FLAMMABLE ANESTHETICS
REFER SERVICING TO QUALIFIED
PERSONNEL THIS EQUIPMENT INTENTIONALLY SUPPLIES
NON-IONIZING RF ENERGY FOR
IPX1 ENCLOSURE RESISTS ENTRY OF PHYSIOLOGICAL EFFECT.
VERTICALLY FALLING WATER

Figure 1.1 Pure Cut Load Regulation

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Figure 1.2 Blend Cut Load Regulation

Figure 1.3 Monopolar Coagulation Load Regulation

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Figure 1.4 Bipolar Load Regulation

300
OUTPUT POWER (WATTS)

250
200
150
100
50
0
0 50 100 150 200 250 300
POWER SETTING

Figure illustrates the output power delivered to the rated load for all available output modes.

Figure 1.5 Output Power vs. Power Setting

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Installation & Operation

Section 2.0

This section contains initial installation, prelimi- 2.3 PRELIMINARY CHECKS

nary checks and operating instructions for the
Sabre 2400. 2.3.1 Preliminary Functional Testing

2.1 INITIAL INSPECTION The following checks are recommended upon

initial installation of the equipment and prior to
Unpack the unit upon receipt and physically each use of the instrument to avoid unnecessary
inspect it for any obvious damage that may have delays in surgery. See Figure 2.1 for location of
occurred during shipment. We recommend that controls and connectors.
this inspection be performed by a qualified bio-
medical engineer or other person thoroughly 1. Ensure that the Power Switch is OFF and no
familiar with electrosurgical devices. If the unit is accessories are connected.
found to be damaged, notify the carrier and your
CONMED representative immediately. 2. Connect the power cable to a properly ground-
ed and polarized mating power receptacle.
2.2 INSTALLATION
3. Connect a two-treadle monopolar foot switch
The unit may be mounted on the CONMED and a single treadle bipolar foot switch to their
cart, P/N 60-5201-004, or any stable cart or mating connectors at the rear of the unit.
table.
4. Make no connection to the Return Electrode
>WARNING< jacks at this time.
THE POWER CORD OF THE UNIT
SHOULD BE CONNECTED TO 5. Set the Power Switch to the ON position. The
A PROPERLY POLARIZED AND green lamp in the power switch shall illuminate.
GROUNDED POWER SOURCE Within one second, the machine should respond
WHOSE VOLTAGE AND FREQUENCY by:
CHARACTERISTICS ARE COMPATIBLE
WITH THOSE LISTED ON THE a) Sounding each of the four tones in ascending
NAMEPLATE OF THIS UNIT. order over a one second interval.

CAUTION: Since the unit depends on natural b) During that interval, displaying a total of nine
convection of air for cooling, it should not be "8"s on the four digital displays.
installed in a cabinet or similar enclosure. If
mounted on a shelf, or otherwise near a wall, c) Illuminating all three mode indicators, all nine
allow a two inch clearance around the unit to selection indicators, the Return Monitor, and all
permit free circulation of air at the sides of the of the Resistance Indicator bars.
unit.

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d) After the fourth tone is complete, the machine 9. Connect a two-wire, single pad Return elec-
should beep the highest frequency tone twice, and trode to a Return Electrode jack. Confirm that no
light the Return Monitor. A single zero should Resistance Indicator bars are lit, and the Return
appear in each of the four digital displays. If Monitor Indicator remains lit. Press the Single
the unit is in Single Pad Mode, the Resistance Pad key to select single pad mode, and confirm
Indicator should be extinguished. If the unit is the Return Monitor Indicator extinguishes.
in the Dual Pad Mode, the Resistance Indicator
bars will continuously flash. 10a) Depress the Cut treadle of the Monopolar
foot switch. The Cut Activation indicator shall
6. Depress the Cut treadle of the monopolar foot light and the Cut tone shall sound. While depress-
switch. The Return Alarm tone should sound ing the Cut treadle, press the Cut Up power key.
and the Monitor Lamp should continue to glow. The power should increase from zero to 5 watts.
While holding the Cut treadle, advance the vol- Press the Cut Down key and the power should
ume control over its full range and verify there is decrease to zero watts. Press all eleven other keys
no significant change in sound level. Release the and an operator error tone should sound.
Cut foot switch and the tone should stop.
10b) Depress the Coag treadle of the Monopolar
7. Verify that each mode can be set to the power foot switch. The Coag Activation indicator shall
level corresponding to the table below, and that light and the Cut tone shall sound. While depress-
no other displays are affected. ing the Coag treadle, press the Coag Up power
key. The power should increase from zero to 5
MODE MAX POWER watts. Press the Coag Down key and the power
Pure Cut 300 should decrease to zero watts. Press all eleven
Blend Cut 180 other keys (except volume controls) and an opera-
Coag 120 tor error tone should sound.
Bipolar Coag 50
10c) Depress the Bipolar foot switch. The Bipolar
Return all power settings to 0. Activation indicator shall light and the Coag tone
shall sound. While depressing the Bipolar foot
8. Select Bipolar Coag and depress the Bipolar switch, press the Bipolar key. The power should
foot switch. Confirm that the Bipolar Indicator increase from zero to 5 watts. Press the Bipolar
illuminates, and a Coag tone is sounded. While Down key and the power should decrease to zero
still depressing the Bipolar foot switch, advance watts. Press all eleven other keys and an operator
the Sound Volume Control over it's full range to error tone should sound.
verify the function of that control and that sound
is audible at all positions. This control may be left 11. While continuing to press the Cut treadle
at any desired position. Confirm that releasing the of the foot switch, depress the Coag treadle. A
Bipolar foot switch returns the Sabre 2400 to its cross key alarm tone shall sound. Release the Cut
idle state. Verify that the Bipolar hand switch con- treadle, continue to press the Coag treadle and
trol is functional by use of the appropriate forceps confirm that the tone changes to the Coag tone,
or by connecting a jumper between the center and the blue Coag Mode indicator is illuminated
and bottom Bipolar Output jack on the Output until the Coag treadle is also released.
Panel. The effect will be identical to depressing
the Bipolar foot switch.

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12. Connect a hand control to Hand Switchable If no tester is convenient, the availability of thera-
Monopolar Accessory Jack #1. Activate, one at peutic current may be ascertained subjectively
a time, the Cut and Coag hand switch controls by attempting to cut and coagulate on surrogate
verifying that each control causes the correct indi- tissue such as a piece of meat or fresh fruit, a
cator and tone to sound. Move the hand control wet bar of soap, or a sponge moistened in saline.
to Hand Switchable Monopolar Accessory Jack Although not recommended, a last resort verifica-
#2 and repeat. tion of available power can be made by drawing
arcs between active and dispersive electrodes.
13. Press the Monopolar Foot Switch Cut Treadle Due to the low voltages used in bipolar mode,
and confirm the yellow Cut mode indicator lights this test may not produce arcs between the tips of
and the Cut tone sounds. While still pressing the bipolar forceps. Such a test will not damage the
treadle, press the Cut mode hand switch control Sabre 2400 at moderate power settings (below
and confirm that the Sabre 2400 continues to half the maximum power for the mode of inter-
indicate actuation of cut-mode. Cross key tone est) if carried out for no more than a few seconds.
will sound while both switches are pressed. A However, one should expect that the electrodes
very short discontinuity in the activation tone may be damaged due to the extreme temperatures
when pressing or releasing the Hand-trol activa- generated by the arc.
tion switch may be noticed.
2.4 CONTROLS, DISPLAYS AND
14. Continue pressing the Monopolar Foot CONNECTORS
Switch Cut treadle, and then press the Coag
mode hand switch control. A cross key tone will The numbers preceding the following paragraphs
sound. Release the foot switch and confirm that correspond to the numbered items in Figure 2.1.
the blue Coag mode indicator lights and that
the Coag tone is sounded until the hand control 2.4.1 Front Panel Controls and Displays
switch is released.
All controls except the power circuit breaker
15. Confirm that the cross key alarm tone sounds are located on the control panel. Refer to the
when the Monopolar Foot Switch Coag Treadle CONTROL PANEL portion of Fig. 2.1
and the Bipolar Foot Switch are depressed simul-
taneously. 1. MONOPOLAR CUT MODE INDICATOR:
This lamp lights when the unit is keyed in either
16. Remove the two wire, single pad return elec- monopolar cut mode.
trode, and confirm that the Sabre 2400 beeps
twice, and the Return Monitor indicator illumi- 2. MONOPOLAR CUT POWER DIGITAL
nates. DISPLAY: Indicates the cutting power level
selected via the Cut power level controls in
17. Press the Monopolar Foot Switch Cut Treadle the currently selected monopolar cut modes.
and confirm that a loud, steady return alarm tone Calibrated in watts deliverable to rated load.
is sounded.
3. MONOPOLAR PURE CUT INDICATOR:
2.3.2 Preliminary Performance Testing Illuminates when Monopolar Pure Cut has been
selected.
After the unit passes the Preliminary Functional
Tests of Paragraph 2.3.1, preliminary performance 4. MONOPOLAR PURE CUT MODE
testing may be conducted. Such testing is best SELECT KEY: Selects the Pure Monopolar Cut
carried out by use of an electrosurgical generator Mode by pressing and releasing the key. Pure Cut
tester, as described in Section 4. Note that the yields minimum hemostasis and Blend Cut pro-
power display of the tester will be most accurate vides moderate hemostasis.
when a noninductive resistor of the rated genera-
tor output impedance for the selected mode is
used.

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5. MONOPOLAR BLEND CUT 12. BIPOLAR POWER DIGITAL DISPLAY:

INDICATOR: Illuminates when Monopolar Indicates the bipolar power level set via the
Blend Cut has been selected. Bipolar Power Level Control. It is calibrated in
watts deliverable to rated load.
6. MONOPOLAR BLEND CUT MODE
SELECT KEY: Selects the Blend Monopolar Cut 13. BIPOLAR POWER DECREASE KEY:
Mode by pressing and releasing the key. Decreases the output power level of the Bipolar
mode when depressed.
7. MONOPOLAR CUT POWER DECREASE
KEY: Decreases the output power level of the 14. DECREASE SOUND VOLUME: Pressing
selected cut mode, Pure Cut or Blend modes this key will decrease the volume of the sound
when depressed. tones produced by the unit during normal activa-
tion of the unit.
8. MONOPOLAR COAG POWER DIGITAL
DISPLAY: Indicates the power level set via the 15. INCREASE SOUND VOLUME: Pressing
Coag power level control. It is calibrated in watts this key will increase the volume of the sound
deliverable to rated load. tones produced by the unit during normal activa-
tion of the unit.
9. MONOPOLAR COAGULATION POWER
DECREASE KEY: Decreases the output power 16. STORE KEY: Allows the user to store
level of the Coag mode when depressed. Mode, Power, Pad, and sound volume settings for
a procedure. When this key is pressed, the Mode,
10. MONITOR SET KEY: Push when in the Power, Pad, and sound volume settings will be
DUAL pad mode after a dual pad electrode has stored in the Preset Memory Location (1 through
been properly applied to the patient and con- 9) shown in the Preset Numerical Display.
nected to the unit. Pressing this key notifies the
unit that the present return circuit resistance rep- NOTE: Pressing the Store Key will overwrite
resents safe return electrode placement and causes any settings that exist in a Memory Location, and
the Resistance Indicator (11) to stop flashing if the earlier stored settings will be lost.
the patient's resistance is within the acceptable
range (see Resistance Indicator). The unit will 17. “SEL” KEY: Allows the user to change the
then monitor the patient's resistance and produce Memory Location shown in the Preset Memory
an alarm if the resistance rises by more than 20% Display. Using this key will select a new group
+/-5%, or if a short is detected in the patient of ESU settings, or an empty memory location
circuit. where a new group of settings can be stored.

11. RESISTANCE INDICATOR: This bar graph 18. PRESET MEMORY DISPLAY: Indicates
is a visual indicator of patient resistance measured the Memory location, “1” through “9” or “P”,
between the contacts of the return electrode. that is currently selected for the ESU.
The number of bars illuminated increases with
increasing resistance and may be used as an aid Each memory location will record the Modes,
in detecting high risk patients. The Resistance Power settings, Pad, and sound volume settings.
Indicator will flash if the Sabre 2400 is in Dual The “P” location stores the Mode, Power, Pad,
pad mode and the Set Point (10) has not been and sound volume setting last used before the
properly established (see Monitor Set Key). The ESU is turned off (powered down).
Resistance Indicator will light 2 to 8 bars when
the patient's return electrode resistance is within 19. BIPOLAR POWER INCREASE KEY:
range. Increases the output power level of the Bipolar
mode when depressed.

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20. BIPOLAR MODE INDICATOR: This 2.4.2 Output Panel

lamp lights when the unit is keyed in the bipolar
mode. The output panel contains the power circuit
breaker and the required patient connection jacks
21. SINGLE PAD MODE INDICATOR: The for electrosurgery. Refer to the OUTPUT PANEL
indicator will light when this mode is in effect. portion of Fig. 2.1.

22. SINGLE FOIL PAD SELECT: Selects the 1. CIRCUIT BREAKER: Primary power switch
Single Pad (Foil) Mode by pressing and releasing for the unit; turns unit on and off. Also provides
the key. double-pole power line overload protection.

23. RETURN MONITOR: Illuminates when 2 & 3. HAND SWITCHABLE MONOPOLAR

the unit detects a problem in the return electrode ACCESSORY JACKS: Two independent sets of
circuit. In DUAL pad mode, the indicator will color coded banana jacks are provided for the
illuminate when the Monitor Set has not been connection of hand switched monopolar accesso-
set, or a return electrode cable is open or shorted, ries, such as the Aspen Hand-trol. Hand switch-
or the type of return electrode used does not able monopolar coagulating forceps may be used
match the type selected, or when patient resis- by connecting to the red and lower black jacks.
tance is out of range. In SINGLE pad mode, These jacks may be activated only by the accesso-
it will illuminate if either of the return electrode ries connected to them.
cables is open. In addition, an alarm tone will
sound when a Return fault is detected for either 4. FOOT SWITCH CONTROLLED
type of electrode AND a monopolar activation is MONOPOLAR ACCESSORY JACK: This jack
attempted. The unit will not produce monopolar accepts accessory cables or adapters equipped
energy when this indicator is illuminated. with standard active (Bovie #12) plugs. This
jack can be activated only by the monopolar foot
24. DUAL PAD MODE SELECT: Selects the switch.
Dual Pad (Foil) Mode by pressing and releasing
the key. 5. TWO-PIN RETURN ELECTRODE JACK:
This is a standard two-pin return electrode jack.
25. DUAL PAD MODE INDICATOR: The
indicator will light when this mode is in effect. 6 & 7. BIPOLAR ACCESSORY JACKS: Bipolar
output, activated by the bipolar foot switch or
26. MONOPOLAR COAGULATION POWER by hand switchable bipolar accessories, appears
INCREASE KEY: Increases the output power between these blue banana jacks.
level of the Coag mode when depressed.
8. BIPOLAR SWITCH JACK: Hand switchable
27. MONOPOLAR COAG MODE bipolar accessories must be connected such that
INDICATORS: This lights when the unit is the hand switch contacts are connected between
keyed in the monopolar coagulation mode. this black miniature banana Bipolar Switch Jack
and the lower blue Bipolar Accessory Jack (6).
28. MONOPOLAR CUT POWER INCREASE
KEY: Increases the output power level of the
selected cut mode, Pure Cut or Blend, when
depressed.

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2.4.3 Rear Panel 3. POWER CORD: Supplies ac mains power

to the unit. It should only be connected to a
The rear panel contains the foot switch connec- source of power corresponding to that listed
tors and power cord. Refer to the REAR PANEL on the nameplate. Supplied with a standard 3-
portion of Fig. 2.1. prong, parallel-blade, hospital grade plug (U.S.A.
Domestic only).
1. MONOPOLAR FOOT SWITCH
CONNECTOR: This 4-pin threaded connector 4. NAMEPLATE: Specifies Aspen model name,
is designed to accept plugs attached to any two serial number, nominal line voltage, frequency,
treadle monopolar foot switch available from current, and power consumption.
Aspen Labs.
5. POWER INLET CONNECTOR: Accepts a
2. BIPOLAR FOOT SWITCH CONNECTOR: CEE22 6A or 10A mains power cord (IEC units
A 3-pin threaded connector designed to accept a only).
single-treadle bipolar foot switch.

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Figure 2.1 Controls, Displays & Connectors

1 28 27 26 25 24 23 22 21 20 19

18
2 MONOPOLAR BIPOLAR

CUT COAG RETURN MONITOR COAG PRESETS

DUAL SINGLE 17
3 PAD
SEL
16
4 POWER POWER
RESISTANCE
POWER STORE
PURE BLEND LO HI

MONITOR
MODE SET

5 6 7 8 9 10 11 12 13 14 15
CONTROL PANEL

1 2 3 4 5 6 7 8

PATIENT CONNECTIONS
ELECTRICALLY ISOLATED.

POWER I

F
HAND CONTROL FOOT CONTROL BIPOLAR

4 OUTPUT PANEL

1
MONOPOLAR
FOOTSWITCH
2

BIPOLAR
FOOTSWITCH

REAR PANEL 3

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2.5 OPERATING INSTRUCTIONS >WARNING<

ALWAYS STOW UNUSED ACCESSORIES
2.5.1 Preliminary Set Up IN A SAFE, INSULATED LOCATION
SUCH AS A HOLSTER.
1. Ensure the Power Switch is OFF, then con-
nect the power cable to a properly grounded and 4. Connect the foot switches, as required, to the
polarized mating power receptacle. Do not con- rear of the unit (not required if only hand switch-
nect a Return electrode at this time. able accessories are to be used).

2. Set the Power Switch to the ON position. The 5. Inspect, then connect the plug of the dispersive
green lamp in the Power Switch shall illuminate. electrode cable to the return electrode jack or to
Within one second, the machine should respond an appropriate adapter. Refer to Figure 2.2. A
by: dispersive electrode need not be connected if only
Bipolar operation is required.
a) Sounding each of the four tones in ascending
order over a 1 second interval. NOTE: This electrosurgical unit incorporates the
Aspen Return Monitor. The monitor will inhibit
b) During that interval, displaying a total of nine monopolar operation of the unit if its require-
“8”s on the four digital displays. ments for the return electrode have not been satis-
fied (see instruction 7).
c) Illuminating all four mode indicators, all selec-
tion indicators, and all of the Resistance Indicator 6. Select and prepare the patient return electrode
bars. site and apply the return electrode in accor-
dance with the manufacturer's instructions. If no
d) After the fourth tone is complete, the machine instructions are given, observe the guidelines pro-
should beep the highest frequency tone twice, and vided in Section 1 of this manual.
light the Return Monitor. A single zero should
appear in each of the four digital displays. If 7. Use the RETURN MONITOR buttons to
the unit is in Single Pad Mode, the Resistance select DUAL or SINGLE Pad Mode. Confirm
Indicator should be extinguished. If the unit is in that the Resistance Indicator and the RETURN
the Dual Pad Mode, the Resistance Indicator bars MONITOR Indicator are blank if SINGLE pad
will continuously flash. mode is selected. If DUAL pad mode is selected,
press the MONITOR SET key. Confirm the
After two seconds, the unit is ready for use. If the RETURN MONITOR indicator is dark, and the
unit sounds a continuous high tone, or otherwise Resistance Indicator stops flashing and displays
fails to respond as above, the unit has failed one 2 to 8 bars. The number of bars indicates the
of its internal tests and is not suitable for use. patient's resistance and can be used as an indica-
Before turning the power off, note the “HLP” tor of patient risk. See Figure 3.1 for the patient
code displayed in the Power Displays to assist in resistance vs. Resistance Indicator bar graph.
the diagnosis by a biomedical technician.

3. Inspect, then connect the desired monopolar

accessories to the hand controlled or foot switch
controlled connectors of the unit. Refer to Figure
2.2 for typical monopolar accessory connections.
Connect the desired foot switchable bipolar acces-
sory to the two blue bipolar banana jacks. (Refer
to Figure 2.2). If a hand switchable bipolar acces-
sory is to be used, connect the RF lines to the
two blue jacks with the switch connected between
the black jack and the bottom blue jack.

2-8
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>WARNING< of factors including waveform, electrode size,

DO NOT DEPEND SOLELY ON electrode geometry, power level and surgical tech-
THE RESISTANCE INDICATOR nique.
FOR CONFIRMATION OF GOOD
RETURN ELECTRODE APPLICATION. The size and geometry of monopolar electrodes
QUALIFIED PERSONNEL SHOULD are significant in that a large electrode, absent of
MAKE THE FINAL DECISION ON sharp features (e.g., a ball electrode) will have
PROPER ELECTRODE PLACEMENT. no tendency to cut, regardless of the waveform
power level. Conversely, a small, sharp electrode,
8. Set the Monopolar Cut Mode to Pure for such as a needle or wire loop, will be likely to
cutting with minimum hemostasis, or Blend cut simply from mechanical pressure. Therefore,
for moderate cutting hemostasis. The mode is when coagulating with small geometry electrodes,
changed by pressing the PURE or BLEND but- it is advisable to use only coagulation waveforms,
tons. The selected mode is indicated by the back- use little if any mechanical pressure, and operate
lighting of the PURE or BLEND button. with lower power levels.

9. Adjust the CUT, COAG, and BIPOLAR The waveform is selected by the user via hand or
power level controls to the desired levels. If foot switch and the setting of the active Mode
unsure of the proper settings, use low power switches. Cutting waveforms are generally contin-
settings initially and make adjustments intraop- uous (Pure) or high duty cycles with wide pulse
eratively according to the surgeon's requests. A widths (Blend). Monopolar Coagulation wave-
written record of each surgeon’s preferred power forms are generally of narrow pulse widths with
setting for various procedures will expedite subse- very low duty cycles. In general, the lower the
quent pre-op setup. duty cycle, the less tendency a waveform will have
to cut and the greater its tendency to coagulate.
In case of an internal failure, the Sabre 2400 will
emit a loud tone to indicate that it has shut itself The Bipolar Coagulation waveform is designed to
down. A visual HLP Code is then displayed on minimize tissue sticking and popping by limiting
the Cut and Coag power indicator displays. The the output voltage regardless of power setting.
HLP code should be recorded and reported to Bipolar hemostasis is more localized than that in
Bioengineering. Repairs will be necessary before monopolar, since only the tissue grasped between
returning the unit to service unless the fault con- the forceps tips is affected. This is particularly
dition was transient in nature. Refer to Section 4 desirable in vascular surgery, where monopolar
for a list of HLP (HELP) codes and their mean- current may concentrate in the affected vessel
ings. This alarm is silenced only by turning off resulting in undesired electrosurgical effects in
the power switch. tissue remote from the point of application. This
easily controlled localization is also of benefit in
2.5.2 Operation plastic and neurosurgery.

Activate the electrosurgical unit in the desired

operating mode by depressing the appropriate
treadle of the foot switch or switch of a hand
accessory. Adjust the corresponding power level
control until the desired results are obtained. The
available power in watts will be displayed on the
digital display corresponding to activation mode.
Noting this wattage may be useful in attempt-
ing to derive similar surgical effects from several
machines of different manufacturers. The surgi-
cal effects obtained are dependent on a number

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Figure 2.2 Patient Accessory Connections

PATIENT CONNECTIONS
ELECTRICALLY ISOLATED.

POWER I

F
HAND CONTROL FOOT CONTROL BIPOLAR

MONOPOLAR BIPOLAR

2-10
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Theory of Operation
Section 3.0

3.1 CIRCUIT THEORY OF OPERATION The switched AC is wired to TB1 for connection
to the primary windings of power transformer
This section contains the theory of operation for A5T1. Strapping options on TB1 set the unit for
the Sabre 2400 circuitry. The functional block a given mains voltage range. Schematic 4.6 indi-
diagram and schematics are located in Section cates the strapping options for the various mains
4.0. These schematics are folded such that they voltages.
may be pulled out for viewing while reading the
appropriate section. The high power secondary of A5T1 (wires are
marked 4 and 5) is wired to full wave rectifier
3.1.1 Functional Block Diagram Description A5BR1, and the DC output of the rectifier is
connected to the Power Board through J3 on the
The Functional Block Diagram appears in Figure Power Board. A1C1 and C2 are filter capacitors
4.1. This diagram illustrates the functional blocks for the resulting dc voltage RFSUP. The LED,
and their physical location by assembly number. A1DS1, is an indicator that high voltage is still
Each block defines a major function (as noted present, even when the power switch is off. R64
inside the block), the reference designator(s) of acts as a bleeder to discharge C1 and C2.
the primary components(s), and the schematic
number where the block is detailed. The low power secondary of A5T1 (wires 1, 2,
and 3) is wired directly to the same connector J3.
The relationships among each block are described A5BR1 acts as a conventional full-wave bridge
by the signals that interconnect them. Narrow rectifier for supplying +22UNREG, while simul-
lines represent individual signals and are marked taneously acting as a negative-leg full-wave cen-
with the same signal mnemonics used in the sche- ter-tap rectifier in providing +11UNREG. A1C7
matics. Broad lines denote busses, or groups of and C10 are the filter caps for the low voltage
signals which together serve a common function. supplies.
To avoid clutter, busses are not necessarily marked
with signal mnemonics. +22UNREG is the source for the +12V
regulator on A2, the transistor drive (Vbase),
Arrowheads describe the direction of signal flow. and the relay power supply voltage RLYSUP.
In the case of bidirectional signals, there are +11UNREG supplies the raw voltage for the
arrowheads on each end of the signal lines. +5V regulator, also on A2.

3.1.2 Power Supplies

Refer to Schematic 4.6. The mains power cord

terminates to a grounding lug on the base, and
the two-pole circuit breaker, CB1, mounted on
the output panel. CB1 serves both as a lighted
power switch and to protect the unit from over-
loads. On overload, this device automatically
switches its handle to the OFF position.

3-1
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3.1.3 Controller Hardware is referred to as the Watchdog Timer Strobe

(WDSTR). Each cycle is 25 +/- 2 milliseconds
The Sabre 2400 Controller PWB Assembly is long. The WDT circuit must hear from the
based on the 8031, a single chip, 8-bit micropro- microprocessor within a 18 to 34 msec window.
cessor which utilizes external program memory. If the WDSTR occurs early because the pro-
Refer to schematic, Figure 4.2. This controller has gram “skipped” a portion of the software or late
the following features. because it was “hung” in a program loop, the fol-
lowing results:
1. Four 8-bit Ports (0,1,2,3) which are individu-
ally addressable as 32 Input/Output (I/O) lines. 1. The circuit latches in the failed condition so
that further strobing from the microprocessor
2. Two 16-bit timer/event counters. cannot clear the previous failure.

3. 64 K bytes of externally addressable program 2. An interrupt is generated which stops abnor-

memory. mal program execution. If the microprocessor can
still respond to the interrupt, a “fatal” software
4. On-chip oscillator and clock circuit which is routine will execute, displaying an error code
connected to an external 10 MHz clock signal HLP-4.
derived from a 20 MHz quartz time base (A2Y1).
3. The interrupt signal, is used to gener-
5. 128 bytes of internal RAM used as a “scratch ate WFAIL, which disables the Base Voltage
pad” by the processor. Generator and Waveform Generator, preventing
further generation of RF output.
The remainder of the controller circuitry consists
of the Watchdog Timer (WDT), Power On Reset The Watchdog Timer (WDT) is made up of a
(POR), Address Decoder, Peripheral Interface dual, retriggerable, one-shot multivibrator (U1),
Adapters (2x) (PIA), Base Voltage Generator associated RC timing components (R1, C2, R2,
(BVG), Output Current and Line Voltage and C3), and associated gate (U2). The first
Current Sensing Circuit, Waveform Generator stage one-shot is set to time out at the minimum
(WFG), Tone Generator, and the Aspen Return WDSTR interval of 20 msec by the RC combi-
Monitor (A.R.M.) DAC and current source. nation of R1 and C2. The trailing (falling) edge
of WDSTR triggers the first stage causing Q1
3.1.3.1 Watchdog Timer (WDT) (U1-6) to go true (high) for approximately 18
msec. The rising edge of Q1 triggers the second
The function of this circuit is to monitor the stage one-shot via U1-12, causing Q2 (U1-10) to
microprocessor for a failure that would cause go high and /Q2 (U1-9) to go low. The 34 msec
unpredictable results. During normal operation, timing of this stage is set by the RC combination
the microprocessor program executes in a known of R2 and C3. In normal operation WDT strobes
sequence. If a software error is detected, an inter- will occur after stage 1 has timed out (Q1=0) but
nal interrupt is generated which halts the opera- before stage 2 times out (Q2=1). The one-shot
tion of the microprocessor. If there is a hardware is retriggerable and the rising edge of Q1 will
failure sensed by software control, program execu- restart the 34 msec timing sequence in the second
tion will again be terminated. stage even though it may not have completed its
current time delay. Normal operation is indicated
Should a failure occur in the CPU that prevents by (Q2) never going low.
the detection of a problem, thus allowing pro-
gram execution in a random manner, the Sabre
2400 is designed so that the WDT detects the
problem. The WDT shuts down the malfunction-
ing unit to minimize the effects of the failure.
This is accomplished by requiring the micropro-
cessor to write to the WDT once during each
program execution cycle. This WRITE PULSE

3-2
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The relay enable flag, /RLYEN-Q from U2-11, is 3.1.3.2 Power On Reset
reset on power-up. This permits the microproces-
sor (U3) to test the WDT during initialization The Power On Reset (POR) circuit consists of a
without allowing RF to appear at the outputs. single chip specifically designed for this function.
While RLYEN-Q is disabled (low), the WDT will The POR circuit monitors +5 Vdc (U50-8) and
not lock up, permitting the software to test for the output signals RST (pin 5) and /RS (pin 6)
correct operation. This is done by strobing the become active if +5 Vdc falls below 4.75 Vdc.
WDT early, then late, and looking for the genera- The 8031 microprocessor operation is specified
tion of the interrupt (Q2=0). The WDT is then down to 4.5 Vdc. This allows power supply mar-
triggered within the correct time window (20 to gin for proper power down of the controller until
30 msec) and should result in Q2 remaining high. reset occurs. On power up, /RS is kept active for
If these results are obtained, the WDT timer cir- a minimum of 250 msec to allow the power sup-
cuitry is operating normally. ply and microprocessor to stabilize.

After initialization is complete, the microproces- One last feature of this circuit is its function as
sor generates a WDSTR at the start of the first a secondary Watchdog timer. This is enabled by
normal program timing cycle. The relay enable the connection of Address Latch Enable (ALE)
flag, /RLYEN-Q, is set by the NAND gate, U2-9 from the microprocessor (U3-30) to U50-7. The
going low. After this, the program enters the nor- RS and /RS outputs are forced to an active state
mal operation program loop. when the /ST input (U50-7) is not stimulated for
1.2 seconds. This function is not normally used
If a WDSTR is not generated within 34 msec of because it requires a failure in the microproces-
the previous strobe, the second stage will time sor and the Watchdog Timer circuitry. This is
out and Q2 will go low resulting in a WFAIL. considered a double fault condition and the odds
Since RLYEN-Q and /Q2 (U1-9) are high, the of the two occurring simultaneously is very low.
inputs to U2-1 and U2-2 are both true resulting Also, it is possible for ALE to continue in normal
in its output (U2-3) going low. This resets the operation while other parts of the microprocessor
first stage one-shot. Now that Q1 (U1-6) cannot are not. The WDT circuit described previously, is
go high, Q2 (U1-12) is prevented from being used because it is not susceptible to this failure in
retriggered. With the WDT Q2 output gone low, fault detection.
the microprocessor will execute a WDT failure
interrupt routine in response to /INTO falling 3.1.3.3 Controller, I/O
and WFAIL will disable drive to the power ampli-
fier. The four digital ports of the 8031 (U3) are func-
tionally assigned as follows.
If the WDSTR is generated before 18 msec,
while Q1 is high, the NAND gate (U2-1 and U2- PORT 0 (P0.0 - P0.7). This port serves two digi-
2) will both be high resulting in U2-3 going low tal functions: 8-bit data bus for communicating
and resetting the second stage. This causes the with external I/O, and low-order address bus for
same results as the late strobe described above. accessing external Program Memory.

Note that the signal which causes the WDT to PORT 1 (P1.0 - P1.7). This port is dedicated to
latch and ignore all subsequent WDSTR pulses discrete inputs or outputs. Port P1.0 and P1.1
is RLYEN-Q being high. The only way to reset are used to generate the serial signals necessary
RLYEN-Q is a Power On Reset. to write or read to the calibration EEPROM U4.
Ports P1.2 and P1.3 communicate serially with
the Quad DAC U11 and Ports P1.4 and P1.5
with the 8 channel ADC U16 which converts
Current sense, Line sense and Return Monitor
voltages to digital form. Ports P1.6 and P1.7 pro-
vide clock and data lines for the display drivers.

3-3
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PORT 2 (P2.0 - P2.7). This port supplies the The nonvolatile EEPROM memory U4 is a
high-order address bus which reads from external serial device which stores calibration coefficients
Program Memory and writes to external I/O. All and program presets. Validity of these values is
I/O is memory mapped so that distinct addresses insured by also storing a CRC check sum anytime
access specific devices. The system is configured these values are changed.
so that only one device is addressed at a time.
When the ESU is powered up, the data stored
PORT 3 (P3.0 - P3.7). This port generates spe- in the non-volatile section of U4 is automatically
cial signals used to control the overall system. copied onto the static RAM where it is accessed
Ports P3.0 and P3.1 are used for factory test only. by the microprocessor via the address/data bus.
Port P3.2 is the watchdog fail interrupt. Port
P3.4 provides the relay enable strobe, Port P3.5 3.1.3.5 Base Voltage Generator
controls the Digital I/O chip U10 address space
for either Memory of I/O. The base voltage generator is schematically
depicted on Schematic 4.3. It is microprocessor
The Address Decoder (U7), is used to select controlled with two analog feedback paths that
external I/O devices for reading and writing. can turn the base voltage down in case of exces-
High-order address to the decoder inputs, (A10, sive power amplifier current or high output volt-
A11, and A12) cause the corresponding output age. The high voltage shutback is divided down
(Y0 - Y7) to go low. After the address decode to have a higher threshold in monopolar coag
has stabilized, either /RD or /WR will go low to mode.
execute a data transfer with the addressed device.
The base voltage generator is made up of two sec-
There are two Peripheral Interface Adapters (PIA) tions of the Quad DAC (U11), an inverting sum-
U6 and U10. U6 is a general purpose digital I/O ming amplifier (U12:A) and a power integrated
device which is used to input the hand and foot circuit Q6. The two DAC sections VOUTA and
activation controls, control the relays and wave- VOUTB are resistively summed together to form
form generator and provide Watchdog Strobe and one 10-bit DAC which controls VBASE setting.
VSENSE Disable. U10, in addition to providing Q6 has internal current and temperature limit
digital I/O also contains the tone generator fre- shutdown. It cannot be checked by the standard
quency divider and a 256 x 8 byte RAM memory. base-emitter and base collector diode checks with
The digital I/O functions control RF enable, chip a DVM.
select, keyboard scan and display drive functions.
The -ISENSE and IGND signals are developed in
3.1.3.4 Program Memory, EPROM the RF power amplifier on the Power Conversion
Board A1. These signals are generated by the
The program used by the microprocessor is stored power amplifier supply current passing through
in external memory, the 32 K byte X 8 EPROM sense resistor A1R2. The resulting voltage
(U91). It is programmed and verified at the fac- -ISENSE is proportional to the total dc current
tory to ensure correct operation of the ESU. The used by the RF power amplifier. The portion of
lower order address A0-A7 is latched into U8 by U12 that includes pins 8, 9, and 10 makes up
line ALE. A0-A7 in combination with the higher a low pass filtered differential voltage amplifier
order address A8-A14 provides the total address that amplifies the -ISENSE voltage. The resulting
to the program EPROM U9. The EPROM ISENSE voltage is proportional to the dc cur-
is enabled by line PSEN going low during an rent drawn by the Sabre 2400 RF power ampli-
instruction fetch. Address lines A13-A15 provide fier from the RF supply, RFSUP. When ISENSE
memory mapped I/O decoding when PSEN is exceeds the voltage at U12-3 by a diode voltage
high to select one of the two PIA devices. drop, the ISENSE feedback loop becomes domi-
nant and backs VBASE down to maintain the
RF power amplifier current at its limit. This is
independent of microprocessor control and is an
additional safety feature.

3-4
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In all modes except a monopolar coag mode, the U25 also generates 2.5 MHz and 10 MHz clocks
signal VDIS will be low, thus forcing U14-10 (an from the 20 MHz oscillator Y1 for clocking the
open collector) to float. When VSENSE exceeds Display/Keyboard Driver/Encoder U26 and the
the voltage at U12-3 by a diode voltage drop, microprocessor U3.
the VSENSE feedback loop becomes dominant
and turns VBASE down to limit the amount of Each time /SRLOAD goes low and then high,
RF output voltage. This action occurs primarily the waveform address counter formed by U23
at high power settings of monopolar cut at high and U24 advances its count. The outputs from
load impedances to prevent unwanted arcing at this counter (WVA0-6) select the next 8 bit word
the active electrode. When VDIS is high, U14-10 to be loaded into U26 from U27. When the
drops and forms a voltage divider through R65 waveform address counter reaches it full count,
with VSENSE and delays the onset of VBASE i.e., the entire waveform has been completely
shutback from limiting RF output voltage until output, /CNTRLD goes low on the next count
the output voltage is much higher. and the address counter is preloaded to the pat-
tern presented to it by O0-O6 of U27. This
3.1.3.6 IFAIL ADC pattern sets the modulus of the address counter
and thus the length of the waveform bit pattern.
The current level of the RF amplifier is moni- /CNTRLD also clears the shift register U26 to
tored by U12:C to provide a voltage (ISENSE) zeros to prevent putting the modulus pattern out
to one channel of the ADC (U16). This value is to the power amplifier. Since /CNTRLD (TP14)
compared to an anticipated value for the machine is low only at the beginning of a waveform, it is
settings. In the event that this value is exceeded, a an excellent point to use for a scope trigger when
fatal alarm results that produces a “HLP-5” code examining waveforms. See Figure 3.2 for repre-
and shuts down the Sabre 2400. sentative waveforms.

3.1.3.7 Waveform Generator U22 provides both buffer and enable functions
for the waveform generator.
Refer to Schematic 4.4. U27 is a 32 K x 8
EPROM that stores the bit patterns for the wave- 3.1.3.8 Tone Generator
forms that drive the RF power amplifier. The
EPROM is arranged so that the upper address The tone frequency generator is located within
lines, WV0-7, determine which waveform is PIA U10 which produces a square wave at U10-
selected by the microprocessor, and the lower 6 (SPKR). This signal is buffered by U14:B and
address lines, WVA0-6, determine which byte of provides the sink side of the speaker drive. The
the waveform is selected at a time. The address source side of the drive is a DC voltage controlled
counter (U23 and U24) cycles through its count by one section of the Quad DAC U11 and power
to sequentially select each byte of the waveform amp U12:B with Q3. Controlling the level of this
and to reload its own count modulus at the DC voltage thereby sets the tone volume. A2Q2
beginning of each waveform. The selected byte that can be controlled by the base voltage.
of the waveform is then parallel-loaded into shift
register U26, where it is serially-shifted out to the 3.1.4 Controller Software
buffer U22 one bit every 50 nanoseconds. U25 is
configured as a modulus 8 counter that controls The behavior of the Controller is a function of
the parallel loading of the shift register U26 and the custom program residing in the 27C256
increments the lower waveform address counter EPROM memory. Since the 27C256 is a device
(U23 & 24). Both the loading and incrementing with a custom program, it must only be replaced
occur on the rising edge of the 20 MHz clock with a suitably programmed part. Most failures of
when /SRLOAD (U25-11) goes low and then this part may be traced to mishandling, particu-
high. larly due to static discharge or to a secondary fail-
ure resulting from application of excessive voltage
to the circuit, as may occur if a voltage regulator
fails.

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However, since undetected failure of 27C256 11. Verify that the contents of program memory
could escalate a minor failure to a serious con- in all locations where the program resides is intact
sequence in the O.R. environment, the 27C256 using a 16-bit cyclic redundancy check.
program is equipped with many fail detection and
shutdown features. Further, an independent exter- 12. Verify that the contents of the calibration data
nal circuit (the Watchdog Timer) guards against a is intact using a 16-bit cyclic redundancy check.
malfunctioning 27C256 or CPU operation. This
safety system is discussed in the following over- 13. Verify that the contents of the preset data is
view of the 27C256 program. intact using a 16-bit cyclic redundancy check.

3.1.4.1. Software Initialization and Test 14. Enable RF output relays and pass control to
Functions the working program.

The following list of software functions begins at Failure of any of the above self-tests will result
Power On Reset or by a manual reset performed in the end of program executions, and a display
by an internal CAL switch. The following initial- of “HLP” on the Cut display. An error tone is
ization sequence must be successfully executed sounded to alert the operator and the “HLP”
before the main working program can be entered. code is displayed on the Coag Power Level dis-
play. Refer to Table 4.7 for a list of HLP codes
1. Initialize outputs to relays and indicators. and their possible causes.

2. Initialize all data memory locations for the 3.1.4.2. Working Program Functions
working program.
The main program loop is executed continuously
3. Load the contents of the Non-volatile by calling the working subroutines and refreshing
EEPROM into working RAM space and verify the CPU Watchdog Timer on each pass through
the validity of it’s values. the loop.

4. Verify the microprocessor Watchdog Timer is Bipolar, hand control, foot switch, and return
functioning correctly and that it can control RF electrode inputs are monitored for changes. The
shutdown. validity of the input conditions are checked.
The following conditions are considered illegal
5. Display 8s on all numeric indicators, illumi- requests and result in a pulsing operator error
nate all status indicators and sound four tones for tone.
operator verification.
• More than one simultaneous activation request.
6. Verify that the RF circuitry is operating.
• Any activation request other than bipolar with
7. Verify that the Return Monitor circuits are the Return Fault indicator ON.
working.
In the case of an illegal hand/foot request, the last
8. Verify that the AC Line voltage is within oper- valid request is the one honored. Other operator
ating limits. actions that can result in a pulsing operator error
tone are multiple or stuck key press, or attempt-
9. Verify that no shorts exist in the hand/foot ing to increase or decrease power levels beyond
controls. the machine limits.

10. Verify that internal data memories are func-

tioning properly and without crosstalk.

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The current condition of the hand/foot controls 3.1.5.1 Keyboard

and the keyboard are continuously monitored.
When a valid request to change mode or power A membrane switch panel is integrally mounted
level is received, the displays are updated to reflect in the display. The switches form a 5x3 matrix
the change. When a valid request for RF activity which is scanned by PIA U10 and debounced in
is received, the following sequence is performed. software.

1. The appropriate RF indicator lamp and tone 3.1.6 Power Amplifier

are activated.
The Power Amplifier (PA) is a hybrid cascode
2. The requested accessory output relay is closed. amplifier made up of four high voltage bipolar
transistors and a low voltage power Mosfet. Refer
3. The current limit fail-safe is set. to Schematic 4.6. Bipolar transistors Q1-Q4 are
connected in parallel, with their emitters con-
4. The power setting is used to retrieve waveform nected together through resistors R17-R20. That
and amplitude parameters from the calibration combination is then connected to the drain of
memory which are then sent to the RF drive cir- Q5. This combination makes up a fast, high-volt-
cuits. age amplifier that can be controlled by the com-
bination of the dc voltage VBASE, and the fixed
5. RF output is enabled via /RFEN. amplitude, variable pulse width signal, BGATE.

Self-tests are continuously performed during In the OFF condition, BGATE is near ground,
operation to ensure the integrity and reasonable- turning off Q5 so that no drain current can flow.
ness of hardware and software operation during Thus no base or emitter current can flow in the
the working program execution. Failure of these bipolar transistors. Turn-on commences with
tests will result in a safe end-to-program execu- BGATE rising rapidly to turn on the MOSFET,
tion (RF drive and all relays are disabled). A forcing its drain low. Since the capacitors con-
display of HLP on the Cut power levels and a 1 nected to the bases of the bipolar transistors are
KHz tone alerts the operator to the condition. charged up, this results in a large pulse of base
The appropriate error code is displayed on the current flowing in from the bipolar transistors
Coag Power level. Q1-Q4, quickly turning them on and delivering
power to the output circuitry.
3.1.5 Display Hardware
After turn-on, Q5 will be conducting hard and
The Sabre 2400 display uses LED and incandes- the bipolar transistors will draw collector current
cent lamp segment technology. Three HV5708 in proportion to their base current, which in turn
drive chips (U19, U20, and U21) each contain is controlled by VBASE.
a 32 bit shift register, latch and segment drive
function. Each lamp segment is turned on or off Turn-off commences with BGATE quickly drop-
corresponding to a logic one or zero on a drive ping to nearly 0 V, shutting off Q5 and effectively
line. Each drive line is then buffered by a section disconnecting the bipolar transistors' emitters
of one of the ULN2004A buffers on the display from the circuit. Collector current then flows
board (A-7). The three HV5708 chips may be out of the bipolar transistors' bases into the base
considered as a 96 bit shift register driving a 96 capacitors until all of the charge stored in the
bit latch. A 96 bit data stream of display data bipolar transistors during turn-on is washed out.
(DISDATA) is downloaded to the shift registers Then the bipolar transistors completely shut off,
serially by clock DISCLK after which the data is ceasing power transfer to the output circuitry.
transferred to the latch sections by signal DISLE.
At power on reset, all HV5708 drive chips are
blanked during the reset period by a reset driver
ULN2003 (U13-F).

3-7
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The collector voltage may rise to many times the 3.1.7 RF Output Section
value of the RF supply voltage RFSUP after turn
off. Since the emitters are now disconnected, the CAUTION: Because of the high peak-to-peak
collector-base voltage can take on the highest amplitudes of these waveforms, use oscillo-
value which that junction will sustain with little scope probes that can withstand 2 KVpp mini-
chance of second-breakdown. The base bypass mum for cut, 10.0 KVpp minimum for coag,
capacitors, are sized to ensure that they can and 500 Vpp minimum for bipolar.
absorb all of the stored turn-off charge without
allowing Q5’s drain voltage to approach its break- Refer to Figure 4.6 for the schematic diagram.
down limit. Further, this charge is now available RF output power may be supplied through one
to charge the base on the next cycle, thereby sig- of two RF isolation transformers, as selected by
nificantly reducing the net current drain from the the relay, K4. When deenergized, K4 connects the
VBASE supply. power amplifier collector bus to the Monopolar
output transformer, T3, which is resonated by
Each bipolar transistor base has its own current C27 and C28 and damped by the chassis mount-
control network which is driven from a common ed resistor A5R1. The secondary of T3 is capaci-
VBASE supply. Each collector and each base is tively coupled by C26 and C29 to the return
separately fused, allowing a failed part to dis- monitor circuit, and via high-voltage reed relays,
connect itself from the circuit without seriously to the user selected monopolar active accessory
affecting performance. Voltage snubbing net- connectors. An auxiliary single-turn T3 secondary
works protect BGATE, VBASE, and the power supplies a replica of the power amplifier collector
MOSFET drain from being damaged in the event voltage to the VSENSE circuit. This rectifies and
of any transistor failure. This limits the extent of peak-detects this signal for use by the control cir-
failure damage. Each collector is equipped with a cuitry to limit output voltage.
diode which allows the voltage on the output bus
to swing negative with respect to ground, as it When K4 is energized, it disconnects T3 and
does in all monopolar modes of operation at suf- supplies the bipolar output transformer, T1, with
ficiently high power and load resistance. power from the power amplifier. The primary of
T1 is resonated by C62 and is damped by A5R1.
In Cut modes, BGATE is a fixed frequency rect- This transformer is designed to meet the particu-
angular pulse and VBASE is varied from about lar requirements of bipolar electrosurgery which
0.3 to +8.5 Vdc to control output power. The are characterized by much lower impedances and
same is true in Blend except that BGATE is fur- permissible voltages than those in monopolar
ther modulated to produce dead time with no operation. Its secondary is capacitively coupled
output. to the appropriate output connectors. Output
waveforms under various conditions are shown in
Bipolar Coag Mode uses a fixed VBASE and var- Figure 3.3.
ies the number of pulses per cycle period to con-
trol output power. See Figure 3.2 for representa-
tive BGATE drive waveforms.

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3.1.8 Aspen Return Monitor (A.R.M.) the center tap of T4 primary. The voltage on the
Circuitry and Software center tap is the average of the two collector volt-
ages, so it appears as a full-wave rectified sine
The A.R.M. Circuit converts the electrical resis- wave with a peak amplitude of one-half that on
tance appearing in the return electrode circuit either collector. Inductor L1 helps hold the cur-
into a digital value which can be processed by the rent fed to T4 constant regardless of these voltage
microprocessor. Software processes use this value variations, while C65 serves as a bypass to limit
to determine when a RETURN FAULT condi- the noise conducted from the A1 PWB up the
tion exists. The Resistance Indicator is also driven VARM line to the A2 PWB.
by software to indicate the value of the measured
DUAL FOIL resistance in the 10 to 150 ohm The A.R.M. oscillator is a dc-to-ac power con-
range. Portions of this function are implemented verter, with its major losses appearing as resis-
on the A2 Micro/Control PWB, Figure 4.4, and tors in parallel with the resistance of the return
on the A1 Power PWB, Figure 4.6. electrode circuit, RLOAD, transformed up through
T4 and T5. In effect, the A.R.M. oscillator trans-
The A.R.M. Circuitry on the A1 PWB comprises forms RLOAD into an equivalent dc resistance,
an oscillator section and an isolation section. RIN, appearing at the VARM input to the cir-
The isolation section employs a shielded toroi- cuit. Thus when RLOAD is very high, as when no
dal transformer, T5, to couple the impedance connection is made to the Return Electrode jacks,
presented at return electrode plate plug, A1J9 to RIN is maximum, allowing the VARM voltage to
the A.R.M. oscillator, while isolating that circuit rise to +2.3 - 3.0 Vdc.
from the effects of applied RF electrosurgical cur-
rent and voltage. Capacitors C55 and 56 split the When RLOAD falls into the 10 to 150 ohm range
return current evenly between the two legs, thus normally encountered with a properly applied
minimizing the RF voltage appearing across T5 dual-foil electrode, RIN also drops and VARM
windings. T5 also acts to step up the return cir- falls into the 1.0 to 2.5 V range. If RIN is very
cuit impedance by about 10:1. The shield serves low, as when a single foil electrode is connected,
to prevent the RF stray magnetic field generated VARM drops to about +0.8 Vdc. Resistors R51
by the monopolar output transformer, T3, from and R52 serve to set a lower limit to the resis-
interfering with the A.R.M. circuitry during RF tance applied across T4's secondary. Without this
activation. lower limit, the effective short circuit presented by
a single foil return electrode would reduce the Q
The A.R.M. oscillator generates a low-power sin- of the 37 KHz tuned circuit to the point that the
ewave voltage of about 36 KHz. This frequency oscillator would behave erratically. Thus VARM
is determined by the inductance of T4 in paral- varies directly with the resistance appearing in
lel with the capacitance presented by C52-54, the return electrode circuit. The relationship is
and that of C55 and C56 reflected through T5. essentially logarithmic, with increases in VARM
Transistors Q14 and Q15 are cross-coupled via becoming vanishingly small as RLOAD rises above
R49 and R50, so that when one transistor is con- 1000 ohms. This means that VARM will change
ducting, the other is fully turned off due to lack by a nearly constant voltage for a given percent-
of base drive. The conducting transistor turns off age change in RLOAD anywhere in the 10 to 150
at the next zero-crossing of the sinusoidal voltage ohm range. The balance of the A.R.M. Circuitry
on the primary of T4. This allows its collector resides on the A2 Controller PWB, Figure 4.4.
voltage to rise and thus provide base current to Diode D11 is a +1.235V regulator whose output
the other transistor to turn it on. In operation, voltage appears across the 2.49K resistor R21,
the collector voltages appear like half-wave recti- thus driving a constant current of 0.5 mA to the
fied ac, with each collector 180 degrees out of VARM line. R23 and C23 act as a low-pass noise
phase with the other. filter. U15:B is connected as a noninverting ampli-
fier with a gain of 2 to amplify the filtered VARM
The A.R.M. oscillator is powered by a constant voltage to 2VARM and is an input to the analog to
0.5 mA dc current driven from the A2 PWB via digital converter U16.
the VARM signal line. This current feeds into

3-9
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Figure 3.1 shows the approximate resistance vs. In Dual Foil Mode, the Resistance Indicator will
number of illuminated bars in the resistance indi- be illuminated to indicate pad resistance in the
cator. If no bars are lit, then the resistance is less range of 10 to 150 ohms. At just over 10 ohms,
than approximately 10 ohms, if 10 bars are lit, the two left bars are illuminated. As VARM
the resistance is greater than approximately 150 increases, additional bars are illuminated in pro-
ohms. It is not possible for just 1 or 9 bars to be portion to VARM, progressing to the right, until
lit. the resistance approaches 150 ohms, where eight
bars are illuminated. When resistance exceeds 150
150 ohms, all ten bars are illuminated. Whenever a
Return Fault condition exists, all illuminated bars
130
will flash, but resistance is still displayed as above.
RESISTANCE (OHMS)

110
In Dual Foil Mode, the microprocessor declares
90 a Return Fault if RLOAD is less than 10 ohms or
greater than 150 ohms. If VARM is within the
70
allowed range, then the Return Fault Indicator
50
will turn off when the Monitor Set Key is
pressed, and the present value of VARM is stored
30 for reference. A new Return Fault will be declared
if pad resistance rises about 20% above this stored
10 value or goes out of the allowed range.
2 4 6 8
RESISTANCE BARS
A rise of approximately 20% over the resistance
FIGURE 3.1 of a Return electrode in full contact with a patient
indicates significant electrode detachment. A
The VARM voltage is read by channel #0 of the Return Fault declared in this case will NOT auto-
analog to digital converter (A2U16) to an accu- matically be cleared if the patient resistance drops
racy of 10mv. This voltage is directly proportional back to near the stored value. The Monitor Set
to pad resistance and is used by the program to Key must again be pressed to register the staff's
test and display the pad resistance value. This satisfaction that the electrode attachment is safe
value is then processed along with the VARM val- before turning off the alarm.
ues for 10 and 150 ohm return circuit resistances
stored in the EEPROM during the last pad cali- Because patients’ and return site resistances vary
bration to evaluate the current. over a considerable range, it is not safe to assume
that any in-range resistance indicates safe elec-
The Return Fault process works on a 50-point trode attachment. For example, a poorly placed
(0.6 sec) minimum average VARM value. If electrode on a well-perfused site can show the
Single Foil Mode is selected, the microprocessor same resistance as a safely attached electrode on
will declare a Return Fault when VARM indicates adipose tissue. Yet the poorly placed electrode
that pad resistance is 10 ohms or greater. The could still result in a burn due to low contact
Resistance Indicator is always dark in this mode. area. The clinical staff is responsible for the final
judgement of safe return electrode placement.

3-10
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3.1.9 Isolated Handswitching/Footswitching The secondary winding T2-8 and T2-7 combine
with D16 and C59 to produce an isolated dc
The circuit for the handswitched accessories are voltage. When the bipolar hand switch is closed,
electrically isolated using both magnetic and opti- the emitter of Q16 is pulled to the return of it's
cal coupling. Refer to Schematic 4.7. A 90 KHz isolated power supply, turning Q16 on. With
oscillator, A1U2, generates a 20% duty-cycle rect- Q16 turned on, current flows through the LED
angular wave drive to the FET transistor A1Q6, of the optocoupler U10, turning its output tran-
which drives the resonant primary circuit of a sistor on. This results in /BIP-H going low, and
toroidal isolation transformer, T2. The energy signalling the microprocessor that the handswitch
coupled to the secondary windings is rectified is on. C60 bypasses any RF currents around the
and filtered to produce an isolated 3 to 4 Vdc bipolar accessory switch. R53, R54,and R63 bias
source for each of the three separate RF output Q16 to prevent the circuit from turning on when
circuits (BIPOLAR, H1, and H2). The bipolar the impedance presented by the output switch
hand switch continuity detector will be used as an is >1000 ohms. This decreases the possibility of
example, since all sections are identical. accidental activations if blood or saline seep into
the switch. International units use similar circuits
(see Schematic 4.7) to provide footswitch isola-
tion.

3-11
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Figure 3.2 Waveform Generator Output

A1TP1 is the BGATE signal, A2TP23 is the GATE signal.

Note: The lower trace in each oscillogram is A2TP14 and is used as the trigger point source. Where there is
noticeable aliasing in the bipolar modes, an expanded view of the waveform is included for clarity.

3-12
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Figure 3.2 Waveform Generator Output

3-13
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Figure 3.3 RF Output Waveforms

3-14
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Figure 3.3 RF Output Waveforms

3-15
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Figure 3.3 RF Output Waveforms

3-16
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Maintenance
Section 4.0

4.1 GENERAL MAINTENANCE Slide the Top Cover forward and lift its front
INFORMATION edge. The Top Cover can be held open vertically
by sliding the Rear Support Bracket Slots onto
This section contains information useful in the the top edge of the Base Assembly. See Figure
maintenance and repair of the Sabre 2400. While 4.2. To close the Top Cover, lift it upward until
the unit has been designed and manufactured to the Support Bracket Slots are free and then lower
high industry standards, it is recommended that it onto the Base Assembly. Reengage the Front
periodic inspection and performance testing be Closure Pins into the Base Assembly slots before
performed to ensure continual safe and effective replacing the rear screws.
operation.
4.2.1 Power PWB Assembly A1
Ease of maintenance was a primary consideration
in the design of the Sabre 2400. Maintenance To gain access to the circuit side of the A1
features of this unit include microprocessor aided Assembly, remove 10 cable connectors (11 con-
troubleshooting aids and push button calibration, nectors on -003 & -015 models). Remove 4 sock-
built in fault detection, circuit simplicity, circuit et head fasteners from the Heatsink. Remove one
protection, use of common parts, easy access to socket head fastener from the PWB, and the two
circuitry while the unit is operational, and fused nylon hex nuts from the PWB. Don't remove fas-
power transistors. These features coupled with the teners from the diagonal brace. Note that there
warranty, local support, loaner equipment, fac- is a nylon push-on standoff at the rear of the A1
tory support, toll free phone service to the factory PWB assembly. Carefully lift the PWB off the
and available factory training ensure the user of a standoff, then lift the A1 Assembly straight up
minimal maintenance effort with extensive sup- and out of the A5 Base Assembly. Verify all cable
port available. connections when reinstalling this Assembly.

4.2 ASSEMBLY BREAK DOWN & PARTS 4.2.2 Micro Controller PWB Assembly A2
ACCESS
>WARNING< To gain access to the circuit side of the A2
HAZARDOUS VOLTAGES ARE PRESENT Assembly, remove 4 cable connectors. Remove
ON INTERNAL COMPONENTS. three #6 hex nuts clamping the voltage regula-
BE SURE THAT THE UNIT IS tors to the cover. Rotate the clamps away from
TURNED OFF AND THE POWER the voltage regulators. Remove 4 socket head
PLUG IS DISCONNECTED BEFORE fasteners from the PWB. Lift the PWB Assembly
DISASSEMBLY. from the A4 Cover Assembly. Replace the 3 volt-
age regulator pads when reinstalling. Use Loctite
The Sabre 2400 opens into a Base Assembly #222 on all fasteners when reinstalling. Torque
and a Top Cover Assembly. To gain access to the the hex nuts to 5 inch pounds, +1/-0. Verify all
internal parts remove the two Phillips head screws cable connections after reinstalling.
on the Rear Panel. Refer to Figure 4.1.

4-1
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4.2.3 Display PWB Assembly A7 4.5 PERIODIC PERFORMANCE

TESTING
To gain access to the component side of the
A7 Assembly, remove three cable connectors. The Sabre 2400 should be performance tested
Remove four socket head fasteners holding the at least every six months. Every unit is supplied
PWB to the A3 Control Panel. Carefully lift the with a serialized Production Test Data Sheet that
A7 Assembly away from the A3 Control Panel. tabulates the results of the factory tests that were
Reverse this process when reassembling. Use performed on the unit. This data is supplied so
Loctite #222 on all fasteners when reinstalling. that it may be used as a reference for subsequent
tests. Recommended periodic performance tests
4.3 CLEANING are listed in the following sections.

The interior of the unit may be vacuumed or When comparing your RF output current read-
blown out as required. The exterior of the unit ings to those on the Test Data Sheet, bear in
may be cleaned by wiping it with a cloth that mind that most RF ammeters may read an error
has been dampened (not dripping) with a mild up to 3% of full scale. This means an actual cur-
detergent such as Windex® or Formula 409®. rent of 0.60A may register on a 1A meter any-
Windex® is the registered trademark of the where from 0.57 to 0.63A.
Drackett Products Company. Formula 409® is
the registered trademark of the Clorox Company. 4.5.1 Chassis Ground Integrity

4.4 PERIODIC INSPECTION Equipment:

Volt-Ohmmeter, Simpson 260 or equivalent
The Sabre 2400 should be visually inspected at
least every six months. This inspection should Procedure:
include checks for: Connect the ohmmeter between the earth ground
prong of the power plug and the footswitch con-
• Damage to the power cord. nector. Confirm less than 0.1 ohm resistance.
• Damage to the power plug.
• Tightness of the power plug. 4.5.2 Displays, Alarms, Commands
• Proper mating and absence of damage to the
patient connectors. Preliminary checks of the items listed below
• Obvious external or internal damage to the appear in Section 2.3.
unit.
• Accumulation of lint or debris within the unit • Return Fault Alarm
or heatsink. • Mode Indicator Lamps
• Control Panel punctures or dents • Sound Tones and Volume Control
• Hand control/Forceps Operation
• Foot switch Operation
• Resistance Indicator
• Return Fault Indicator
• Power Indicators

Equipment:
2 Hand controls, Single and Dual Foil Return
Electrodes, Foot switches, Jumper Wire

Procedure: See Section 2.3.

4-2
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4.5.3 Output Power unit's return electrode jack and the foot switch
controlled active jack.
Equipment:
2. Perform the monopolar power tests indicated
Monopolar Foot switch in Table 4.1 depending on the value of the load
Bipolar Foot switch resistor used.

0-1.5A RF Ammeter as a minimum. The most 3. Disconnect the RF ammeter and load resistor
accurate RF current measurements will result from the unit.
when read on the upper 50% of the meter scale.
A set of meters including 150mA, 250mA, 4. Use test leads to connect the RF ammeter in
500mA, 1.0A and 2.0A are recommended. series with the 50W resistor and the unit's blue
Bipolar Accessory Jacks.
300, 400, or 500 ohm 250W noninductive resis-
tor 5. Perform the bipolar power tests indicated in
Table 4.1 depending on the value of the load
50, 100, or 125 ohm 50W noninductive resistor resistor used.
Return Electrode Adapter Plug (shorting)
Note: The RF output power level checks of Table
Bovie #12 Adapter Plug 4.1 correct for the load regulation characteristics
3 test leads, 1m max. length of the Sabre 2400. This results in output cur-
rent levels that may be different from the power
Procedure: setting when the P=I2*R calculation is done
1. Use test leads to connect an RF ammeter in at other than the rated load. Refer to the Load
series with the 250W resistor and one of the Regulation Curves in Section 1 for details.

Mode Power Output Power Output

Setting Current (mA) Setting Current (mA)

Monopolar
Pure Cut
300 ohms 300 949-1040 150 671-741
400 ohms 300 822-908 150 619-684
500 ohms 300 730-806 150 564-623

Blend Cut
300 ohms 180 739-812 90 520-574
400 ohms 180 634-700 90 489-539
500 ohms 180 562-620 90 449-496

Coag
300 ohms 120 596-659 60 417-461
400 ohms 120 520-574 60 368-406
500 ohms 120 465-513 60 329-363

Bipolar
50 ohms 50 949-1040 25 671-741
100 ohms 50 592-653 25 425-469
125 ohms 50 514-567 25 360-397

Table 4.1 RF Output Power Checks

4-3
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4.5.4 RF Leakage 3. Set the unit for full power Standard Coag and
Bipolar Coag. Connect the 200 ohm nonreactive
Equipment: resistor in series with the 250 mA RF ammeter,
and a common earth ground (the footswitch con-
0-250 mA RF Ammeter nector shell will suffice). One at a time, connect
this series combination to each RF output termi-
200 ohm 10 W Noninductive Resistor nal indicated in Table 4.2, and activate the unit
using the corresponding command. Confirm that
Patient Plate Adapter Plug no meter readings exceed the specified maximum.
Hand control coag activations are accomplished
Bovie #12 Adapter Plug by connecting a jumper between the lower black
jack and the red jack of the desired hand switch-
2 - Test leads, 1 m max. length able accessory jack.

3 - Test leads, 10 cm max. length 4. This measurement applies only to Sabre 2400
P/N’s 60-5600-003 and 60-5600-015. Measure
Wooden table approximately 1 m from floor. A1 C67 and C68 in circuit resistance to confirm
a value greater than 20M ohm resistance. Temp-
Procedure: orarily disconnect A1-J11 and measure RF leak-
age from the Foot Active with Foot Coag activa-
1. Ensure that the unit is fully assembled and all tion and confirm that RF leakage increases with
fasteners are tight. the connector disconnected. Reconnect A1-J11
when finished.
2. Place the meter and resistors on the table so
that they are at least 0.5m away from the unit >WARNING<
under test and any other conductive surface. HAND CONTROL ACTIVATIONS
SHOULD BE KEYED USING 3'' OR LESS
WELL INSULATED JUMPER(S). USE OF
AN INSULATING ROD TO INSERT THE
JUMPER IS ADVISED TO PREVENT RF
BURNS.

MEASURED OUTPUT ACTIVATION MAXIMUM

TERMINAL COMMAND LEAKAGE (mA)

RETURN ELECTRODE FOOT COAG 100

RETURN ELECTRODE LEFT HAND CONTROL COAG 100
RETURN ELECTRODE RIGHT HAND CONTROL COAG 100
RETURN ELECTRODE BOTH HAND CONTROL COAG 100
FOOT ACTIVE FOOT COAG 100
BIPOLAR TOP FOOT BIPOLAR 20
BIPOLAR BOTTOM FOOT BIPOLAR 20

Table 4.2 RF Leakage to Ground Tests

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4.5.5 RF Leakage from Inactive Outputs >WARNING<

Equipment: Same as in Section 4.5.4 HAND CONTROL ACTIVATIONS

SHOULD BE KEYED USING 3'' OR LESS
Procedure: WELL INSULATED JUMPER(S). USE OF
AN INSULATING ROD TO INSERT THE
1. Set the unit for full power Standard Coag and JUMPER IS ADVISED TO PREVENT RF
Bipolar Coag. Connect the 200 ohm, nonreactive BURNS.
resistor in series with the 250 mA RF ammeter.
One at a time, connect that series combination CAUTION: To avoid destroying the meter, never
between the return electrode connector and each activate output terminal connected to the meter.
RF output terminal shown in Table 4.3, and
activate the unit using the corresponding com- 2. Disconnect the meter and resistor from the
mand. Confirm that no meter readings exceed the unit. Turn unit Power Switch OFF.
specified maximum. Hand control coag activa-
tions are accomplished by connecting a jumper
between the lower black jack and the red jack of
the desired hand switchable accessory jack.

MEASURED 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
BIPOLAR TOP FOOT BIPOLAR 20
BIPOLAR BOTTOM FOOT BIPOLAR 20

Table 4.3 RF Leakage for Inactive Outputs Test

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4.5.6 Line Frequency Leakage Table 4.4. With the meter scale set for ac mil-
livolts, the meter reading is equivalent to micro-
Equipment: (See UL 544 or ANSI/AAMI amperes.
HF-18)
2. Since the Sabre 2400 monopolar active outputs
Line Reversing Switch are disconnected by relays when the unit is not
activated, active-to-neutral leakage tests must be
Ground Switch performed with the unit activated in order to be
valid. To prevent RF current from affecting leak-
High Impedance Meter (Fluke 8000 A or equiva- age readings, set all controls to zero.
lent)
3. With all power controls set to 0, measure the
Frequency Compensation Network (1K resistor leakage current as in step 1 from each of the three
in parallel with the series combination of a 10 active output terminals to neutral (See Table
ohm resistor and a 0.15 uf capacitor.) 4.5) while that output is activated in Cut by the
appropriate foot switch or hand control jumper.
Procedure: Hand control cut activations are accomplished by
connecting a jumper between the lower black jack
1. With the frequency compensation network and the red jack of the desired hand switchable
connected across the voltage input terminals of accessory jack.
the meter, make the measurements indicated in

Leakage Line Case Test

Path Polarity Ground Limit

Bipolar-Neutral Normal Closed 5uA

Bipolar-Neutral Normal Open 5uA
Bipolar-Neutral Reversed Closed 5uA
Bipolar-Neutral Reversed Open 5uA
Return Electrode-Neutral Normal Closed 5uA
Return Electrode-Neutral Normal Open 5uA
Return Electrode-Neutral Reversed Closed 5uA
Return Electrode-Neutral Reversed Open 5uA
Chassis-Neutral Normal Open 40uA
Chassis-Neutral Reversed Open 40uA

Table 4.4 Unkeyed Line Frequency Leakage Tests

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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 5uA
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

4.5.7 Aspen Return Monitor (A.R.M.) Procedure:

Calibration Check
1. Disconnect all accessories from the Sabre 2400
This section describes the method to check the front panel.
calibration of the A.R.M. circuitry.
2. Power up the Sabre 2400 in the RUN
Equipment: Non-inductive Decade Resistance Mode. Select Dual Foil Mode and confirm that
Box (DRB) with attached dual foil return elec- Resistance Indicator has all 10 green bars flash-
trode cable. The DRB must be adjustable from 0 ing, the Monitor Set Key is flashing and that the
to 160 ohms in 1 ohm steps and accurate to 1%. Return Fault Indicator is illuminated.
A dual foil return electrode cable can be made by
cutting the cable and connector (2 to 3 feet from 3. Using the test cable, connect the DRB to the
the connector) from a dual foil return electrode, Return Electrode Jack.
and stripping the wires for connection to the
DRB. 4. Adjust the DRB until eight bars of the
Resistance Indicator are flashing.
NOTE: Some DRBs may present a brief open
circuit at the output terminals during switch 5. Carefully advance the DRB in 1 ohm steps
movement. This may cause the A.R.M. software until all 10 bars of the Resistance Indicator are
to calculate an erroneously high resistance read- flashing. Confirm that the DRB reads between
ing. This effect may be minimized by making 137 and 163 ohms.
DRB setting changes quickly. If the resistance
read during any of the following tests is above the
upper limit, repeat the test carefully stopping in
each 1 ohm step for at least 1 second.

4-7
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6. Set the DRB to 7 ohms and confirm that A special operational mode, called CAL Mode,
the Resistance Indicator is dark and the Return permits the EEPROM data to be updated to
Monitor is lit. compensate for circuit performance changes due
to aging or replacement of components. In CAL
7. Select Single Foil Mode. Confirm the Mode, the microprocessor guides the technician
Resistance Indicator stops flashing and the to simplify and expedite a complete and accurate
Return Monitor is not illuminated. calibration. A second function "dIA" may also be
selected in CAL mode. See sections 4.7.2 and
8. Increase the DRB in 1 ohm steps until an 4.7.3 for an explanation of its function.
audible Return Fault Alarm is sounded and the
Return Fault Indicator is lit. Confirm the DRB is NOTE: CAL Mode should not be used to per-
between 8 and 12 ohms. form routine calibration checks. Those tests are
better conducted in RUN Mode per Sections
9. Decrease the DRB setting in 1 ohm steps until 4.5.3 and 4.5.7. If the unit proves to be out of
the Return Fault Indicator goes dark. Confirm calibration, the possibility of a component failure
that the DRB reads from 1 to 4 ohms less than should be eliminated as the cause before recali-
the resistance read in Step 8. brating. Once the physical health of the unit as
been confirmed, then CAL Mode may be entered
10. Disconnect the DRB. This completes the to correct the calibration.
A.R.M. calibration test. If any readings were only
slightly out of range, first check the DRB with 4.6.1 CAL Mode General Information.
an accurate ohmmeter. If the DRB is accurate,
recalibrate the A.R.M. limits in CAL Mode. See CAUTION: Do not enter CAL Mode without
Section 4.6.4. If one or more readings were far first reading and understanding the follow-
from the mark, troubleshoot the A.R.M. circuitry ing material and ensuring that the necessary
before attempting recalibration. See Section equipment is on hand and accurate. Improper
4.7.6. calibration procedures can cause an otherwise
serviceable unit to become unusable until cali-
4.6 CALIBRATION AND ADJUSTMENTS bration is corrected.

The Sabre 2400 is calibrated without selecting • On initial entry to CAL Mode, a calibration
or adjusting components. Instead, calibration validity test is done. If the test passes, then all
factors necessary to compensate for unit-to-unit points in all modes are considered calibrated; if it
circuit variations are stored digitally in an electri- fails, ALL points are declared uncalibrated, and
cally erasable programmable read only memory the EEPROM is loaded with a set of nominal val-
(EEPROM) A2U4. This device contains the ues which will bring a properly functioning unit
VBASE drive vs. output power lookup tables for within range of its required calibration. The unit
each of the operational modes, and the VARM will be unserviceable until fully recalibrated.
values for the upper and lower allowable resis-
tance limits of the dual foil return circuit. • If nonmonotonicity is detected on exit from a
Calibration mode, a HLP-11 code is displayed,
The EEPROM contents remain intact for years and all of the calibration points for the nonmono-
with no power applied, and redundant hard- tonic operational mode are declared uncalibrated.
ware and software are used to prevent changing As with incomplete calibration, the menu selec-
EEPROM data in normal use. On every power tion for the affected mode will flash when the
up and during normal operation, the integrity of "SEL" Key is pressed again.
the EEPROM contents is validated using a Cyclic
Redundancy Check (CRC). Failure of the stored
EEPROM CRC to match the computed value
will result in declaration of a HLP-3 Fault code
and shutdown of all output.

4-8
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• After a fully calibrated mode is entered, making tered and calibration completed or corrected to
a change to any one calibration point will cause fix the problem.
all of the other points in that mode which have
not yet been checked to be declared uncalibrated. • When the “SEL” Key is pressed to exit a
Those points must then be calibrated prior to Calibration mode, the unit first checks for any
returning the unit to service. This precaution is uncalibrated points in that mode. If any exist,
taken on the assumption that if some part of the then a HLP-10 code is displayed. The values
circuitry has changed enough to justify adjust- of all of the points remain as they were at the
ment of one calibration point, then it is likely that time of exit, eliminating the need to repeat the
the other points have been affected as well. adjustments that were already made. An excep-
tion occurs when the selected load resistance is
• Each calibration point has fixed upper and changed. In that case, the entire section (C-C or
lower limits which will permit calibration of a bP) will go to it's uncalibrated state. Pressing the
healthy unit at nominal line voltage. It is not pos- “SEL” Key again will restore the menu, and the
sible to store a calibration value in the EEPROM menu display for the partly calibrated mode will
which falls outside that range. flash. The calibrated and uncalibrated status for
all points in that mode is preserved while in CAL
• The CAL Mode is entered by powering up Mode, so that when the mode is reentered, it is
while depressing the internal CAL switch, A2S1. necessary only to calibrate the flashing points to
Successful CAL Mode entry is signified by all dis- fully calibrate that mode.
play segments illuminating. This allows a careful
check of the display for missing segments. • CAL Mode is exited by turning the POWER
switch OFF. This operation should only be per-
• To proceed past the display check, press the formed AFTER returning to the main menu.
SEL key, then the CUT power window will
display "C-C", which is one of four available NOTE: If ANY of the modes in the menu are
mode selections. Any of the other modes may flashing, the calibration for that mode is invalid.
be selected sequentially by pressing the CUT Exiting CAL Mode in this condition will result in
Power Increase or Decrease keys. In some modes, an immediate EEPROM FAIL (HLP-3) alarm on
the COAG power window and/or the Bipolar powerup in RUN mode. Complete recalibration
power window will display an option applicable will then be required in order to return the unit
to that mode; these options are similarly select- to service.
able by pressing the Power Increase or Decrease
keys. Details of how to use each mode appear in • It's a good practice to be sure that all of the
following sections. The available CAL modes, menu modes show as calibrated (not flashing)
options and their uses are summarized in Table before departing CAL or entering Diagnostics
4.6. modes.

• Although the points in a Calibration mode • The Diagnostics modes are removed from the
may be calibrated in any order, it's best to use a menu after RF is activated in either of the Power
sequence which ensures that calibration is com- Calibration modes. It is not possible to return to
plete before returning to the menu. the menu from either of the Diagnostics modes
without powering down.
• When calibration in a mode is completed sat-
isfactorily, pressing the “SEL” Key will save all
calibration changes and will return to the menu.
If the menu mode display for one of the three
Calibration modes is flashing, then one or more
points in that mode is uncalibrated or nonmono-
tonic. Pressing the “SEL” Key again will restore
the menu, from which the mode may be reen-

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4.6.2 Power Calibration General Information CAUTION: Before activating a newly selected
point, be sure that the tester range is at least
• The only equipment necessary to conduct as great as the displayed target current. Bear
power calibration is an electrosurgical output in mind that a unit which is far out of calibra-
power tester having load resistances of 300, 400 tion may deliver considerably more than the
or 500 ohm for Monopolar and 50, 100, or 125 target current.
ohms for Bipolar and an RF rms current indica-
tor capable of accurate measurements from 50 to • The Power Increase and Decrease keys are used
1000 mA. These units are commercially available to select the calibration points when the unit is
from a number of sources, or can be constructed not activated. When the highest calibration point
using 250 watt 3% or better noninductive resis- in a mode is displayed, the Power Increase key
tors and a selection of RF ammeters ranging from will have no further effect; the same is true for
150 mA to 1A full scale. the Power Decrease key when the lowest point is
displayed. This is useful in determining when a
• If the selected power calibration load resistance mode is fully calibrated.
is other than the rated load, target current will
deliver another power which takes into account • Each point is calibrated by activating the
Sabre 2400's typical load regulation characteristics unit, then using that mode's Power Increase or
in that mode. The actual load regulation curve for Decrease key to match the target point as close as
a particular unit may vary somewhat from typical, possible. It may not be possible to match the tar-
so the most accurate calibration is obtained when get exactly, but the setting which reads closest to
calibration is performed using the rated load. the target will be within the specified tolerance.
Satisfactory calibration is possible ONLY if the The most accurate current readings will appear on
calibration resistor option chosen and the actual the lowest RF current range which reads on scale.
load resistance used are the same.

MODE MODE USE OPTION 1 OPTION 1 USE OPTION 2 OPTION 2 USE

(CUT PWR) (COAG PWR) (BIPOLAR PWR)

C-C MONOPOLAR 300, 400, 500 SELECT LOAD A, P SELECT

POWER CAL RESISTANCE READOUT IN
FOR CAL AMPS OR POWER

bP BIPOLAR PWR 50, 100, 125 SELECT LOAD A, P SELECT

CAL RESISTANCE FOR READOUT IN
BIPOLAR CALIBRATION AMPS OR POWER

PAd ARM (PAD) BLANK

RESISTANCE
CALIBRATION

dIA DIAGNOSTICS 1 WATCHDOG NONE

TIMER CHECK
2 PSEUDO RUN MODE NONE
(DISABLES SOFTWARE
SHUTDOWN TO AID
TROUBLESHOOTING)
3 VIEW MODE 1-9 SEE TABLE 4.9
FOR DETAILS

Table 4.6 CAL Mode Options

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• It is only necessary to activate the unit for the 6. Press “SEL” to move into the actual calibration.
selected point to be considered calibrated. No The Power Windows will display the target value
actual adjustment is required, but the output cur- in amps or watts as determined above.
rent should still be measured and verified against
the target value. This eliminates unnecessary 7. Activate the unit and use the Power Increase/
“tweaking” if a point is adjusted correctly already. Decrease Keys next to the mode being activated
to set output to match the displayed target as
4.6.3 Output Power Calibration Procedure closely as possible. Deactivate when the best
match occurs.
Note: This procedure lists a complete power
calibration. It is possible to go directly to bipolar NOTE: Heating tends to change the gain of the
mode power calibration ("bP" in the display) if power amplifier slightly, so a slow change in load
desired by selecting that mode first. In general current may be noted while the unit is activated.
the complete calibration should be done. This is These errors may be minimized by allowing the
because whatever changed an output in one mode unit to cool for 15 to 20 seconds between acti-
requiring recalibration will likely affect the other vations. This phenomenon is not ordinarily a
mode. problem unless the unit is far out of calibration,
requiring extended activations in order to bring it
1. Remove the two screws at the rear of the unit in. In such cases, first perform a complete rough
to open the top cover. calibration. Let the unit cool for several minutes,
then repeat the calibration. Now the activation
2. Connect the output power tester to the Return time necessary to close in on final adjustments
Electrode jack and one of the active monopolar will be very brief.
RF output jacks, depending on how one wishes
to activate the unit. If possible, set the tester for 8. Press the Power Increase/Decrease Key to move
the rated load resistance, since this will yield the the target to the next calibration point. Repeat
most accurate calibration results. If this resistance steps 6 & 7 for Pure, Blend and Coag until all
is not available, the Sabre 2400 may be calibrated points are calibrated (no points are flashing).
using 300, 400 or 500 ohm loads.
9. When all monopolar points have been calibrat-
3. Connect the power plug to a source of AC ed satisfactorily, pressing the “SEL” key will store
power of the same frequency and within 1% of the updated values and restore the menu. The
the voltage specified on the nameplate. display will show a steady “C-C” if the calibration
has been completed properly, otherwise it will be
4. Press A2SW1 (marked CAL) on the micro/ flashing or show a HLP code.
control PWB, while turning on the unit's circuit
breaker. Successful entry to CAL mode is signi- 10. Disconnect the tester from the Monopolar
fied by all segments of the display lighting. outputs, and connect it to the Bipolar output
jacks. Set the tester up for the rated load of 50
5. Press “SEL”. The unit will then momentarily ohms if possible, otherwise select 100 or 125 for
display “CAL” and proceed to display “C-C” in output load resistance.
the Cut Power Window, either 300,400,or 500 in
the Coag Power Window, and “A” or “P” in the 11. Use the Cut Power Increase/Decrease Keys to
Bipolar Power Window. Use the Power Increase/ select “bP” in the Cut Power Window. Select the
Decrease to set your requirements. Example: same RF load as chosen above by using the Coag
Desired RF load is 500 ohms, and target display Power Increase/Decrease Keys, and select the
in Power. Press the Coag Power Increase Key target display mode as “A” for amps, or “P” for
to set “500” in the Coag Power Window, and Power in watts (in the Bipolar Power Window)
the Bipolar Power Increase Key to set “P” in the using the Bipolar Power Increase/Decrease Keys.
Bipolar Power Window. Press “SEL” to enter the Bipolar calibration mode.

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12. Activate the unit in Bipolar mode and use the 4. Press “SEL”. The unit will then momentarily
Bipolar Power Increase/Decrease keys to match display “CAL” and proceed to display “C-C” in
the target value. Deactivate the unit when the the Cut Power Window. Press the Cut Power
best match is reached. Increase/Decrease Keys to display “Pad” in the
window.
13. Press “SEL” and return to the menu. When
the point has been calibrated satisfactorily, press- 5. Press “SEL” to move into the actual calibra-
ing the “SEL” key will store the updated values tion. The Coag Power Window will display the
and restore the menu. The display will show a target value ohms to be connected to the Return
steady “bP” if the calibration has been completed Electrode jack. The Resistance Indicator will be
properly otherwise it will be flashing or show a lit with a corresponding number of bars. A flash-
HLP code. ing Resistance Indicator denotes an uncalibrated
point.
14. Check all modes (C-C, bP, and Pad) to deter-
mine none of them are flashing. If any are, cali- 6. Connect the selected resistance to the Return
brate that mode. Electrode jack. Wait a second or two, then press
the Monitor Set key to store the calibration value.
15. Turn the unit off, then on to confirm the unit
powers up normally and is ready for use. Replace 7. Use the Coag Power Increase or Decrease keys
the top cover screws. to select the other calibration point, connect the
new indicated resistance, pause and enter it as
4.6.4 A.R.M. Calibration (Pad) before.

This mode calibrates the Aspen Return Monitor NOTE: If an error tone is sounded when the
(A.R.M.) circuitry. The only equipment required Monitor Set key is pressed, then the calibra-
to complete A.R.M. Calibration are 10 and 150 tion point is out of range, and both points will
ohm resistances accurate to 5% or better. Power be declared uncalibrated. Check to ensure that
ratings are unimportant, but wirewound resistors the resistance has the value as displayed in the
should not be used. A means to connect the resis- Coag window and that it is well connected to the
tance between both pins of either of the Return Return Electrode. Then repeat calibration of both
Electrode jacks is also required. One can make values. Calibration was successful if the Resistance
a set of calibration resistors by cutting dual foil Indicator is lit steadily for both points.
return electrode plugs from the pad and soldering
the appropriate resistor to the plug. 8. Press the “SEL” Key to restore the menu and
save the new values.
1. Remove the two screws at the rear of the unit
to open the top cover. 9. Turn the unit off, then on to confirm the unit
powers up normally and is ready for use.
2. Connect the power plug to a source of AC
power of the same frequency and voltage speci- 10. Replace the top cover screws.
fied on the nameplate.

3. Press A2SW1 (marked CAL) on the micro/

control PWB, while turning on the unit's circuit
breaker. Successful entry to CAL mode is signi-
fied by all segments of the display lighting.

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4.7 TROUBLESHOOTING Upon fault detection, the program will branch

to an endless loop which displays a fault HLP
This section explains the troubleshooting aids code in the Monopolar Cut and Coag power
built in to the Sabre 2400 and provides a guide level displays. This loop takes /RFEN false, forces
to their use. Not all failures can be covered in a VBASE and the waveform generator output to
guide such as this, so the troubleshooter must zero drive condition and commands the relays to
by necessity understand the full operation of the open. Further, it ceases generation of Watchdog
unit. Read Section 3 for the description of system Timer strobes and redundantly disables the base
and circuit theory. and gate drive to the Power Amplifier. If the
Watchdog Timer detects a processor fault, it will
>WARNING< issue an interrupt to the processor, causing a
READ THE SAFETY SUMMARY branch to the same routine as above if the proces-
IN SECTION 1.1.4 BEFORE sor is healthy enough to respond; if not, RF will
TROUBLESHOOTING THE UNIT. still be disabled.

If trouble is suspected, perform a thorough visual Processor-controlled fault detection occurs exten-
inspection, looking for loose or burned com- sively on power-up and to a lesser extent, con-
ponents which may point to the source of the tinuously during operation. Each test is assigned
problem. Verify that all connections are clean and a unique HLP number to be displayed on the
seated properly and that soldered harness connec- Monopolar Coag Power Level Display. Refer to
tors are sound and not shorting. Check all wiring Table 4.7 for a complete list of HLP codes and
for evidence of mechanical damage. Check the their possible causes.
regulated and unregulated power supply volt-
ages. Improper supply voltages can produce a 4.7.2 Pseudo Run Diagnostics (dIA 2)
multitude of problems. Check that all mechanical
connections are secure. Check all fuses. Check the Armed with a good understanding of the Theory
operating instructions and see if the suspected of Operation in Section 3, one can make effec-
problem was actually designed to work that way. tive use of Pseudo Run Diagnostics (dIA 2) in
correcting any of the faults which result in HLP
4.7.1 HLP Codes alarms in Run mode.

The Sabre 2400 microprocessor is programmed Pseudo Run Diagnostics (dIA 2) is provided to
with a number of fault detection routines permit troubleshooting problems which cause the
designed to shut the unit down safely if a failure unit to lock up with a HLP code in RUN mode.
has occurred. This shutdown procedure will pro- Such failures can be in the current limit circuitry,
duce a HLP code that can help with the trouble- continuity detectors, or power amplifier, to name
shooting process. The following will further a few. These problems can be more effectively
explain the HLP codes and other troubleshooting diagnosed if the unit is made operational.
aids.

4-13
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Table 4.7 HLP Codes and Possible Causes

HLP Meaning When Performed Possible Causes

-1 Read/Write ability Initialization Faulty A2U3 (8031)

of 8031 internal and operation
memory is impaired.

-2 Program memory CRC Initialization Faulty A2U9 (27256)

check error. and operation Faulty A2U3 (8031)
Faulty A2U8 (74573)
Open or shorted Address, Control,
or Data buss lines.

-3 Calibration memory Initialization Calibration was

CRC check error and operation incomplete when exiting Cal mode.
Faulty A2U4 (X24C04)
Faulty A2U3 (8031)
Faulty A2U10 (8155)
Open or shorted address, Control,
or Data buss lines.

-4 Watchdog Timer Initialization WDT timing parts incorrect

pulse width is incorrect. Microprocessor frequency incorrect.
Faulty A2U1 (4538)
Faulty A2U3 (8031)
Faulty A2U6 (8255)
Faulty A2U2 (7400)

-5 RF PA supply Initialization Incorrect base voltage

and operation Incorrect gate drive
Shorted PA power transistor
Shorted PA power FET
A1 RVI shorted
A5BR1 disconnected
Shorted capacitor on RFSUP line
ISENSE circuit faulty
VSENSE circuit faulty
Open fuses(s) or transistor(s) in PA
Bipolar relay stuck closed
Faulty A2U3 (8031)

-6 Attempted entry into Initialization Faulty A2U3 (8031)

guarded memory location and Operation Faulty A2U8 (74573)
or CPU Failure Faulty A2U9 (27256)

-7 Watchdog Timer hardware Initialization Faulty A2U30 (7402)

does not disable RF Faulty A2U22 (74140)
drive.

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Table 4.7 HLP Codes and Possible Causes

HLP Meaning When Performed Possible Causes

-8 Detection of a shorted Initialization Shorted hand or foot control.

hand or foot control Faulty A2U6 (8255)
Shorted bypass caps on control lines.

-10 Incomplete Cal Cal Mode One or more power or ARM cal points not
calibrated on return to CAL menu.

-11 Non-monotonic Cal Mode Operator error when calibrating power

power calibration Faulty Waveform generator.
Faulty Base Voltage generator.
Faulty A2U4 (X24C04)

-13 Detection of shorted Initialization Key press at power up.

key. Shorted Keyboard.
Faulty A2U10 (8155)

-17 Low AC line Fail Initialization Faulty A2U16 (0838)

and operation. Faulty voltage sense CH2 (0838)
Inadequate AC mains

-18 High AC line Fail Initialization Faulty A2U16 (0838)

and operation. Faulty voltage sense CH2 (0838).
Excessive AC mains

-19 External RAM Fail Initialization Faulty A2U3 (8031)

Faulty A2U10 (8155)

-20 EEPROM defective Initialization and Faulty A2U4 (X2001)

Operation

-21 ARM circuit defective Operation Faulty A2U15 (LM358)

Faulty A2D11 (LM385)
Faulty A2U16 (0838)
Faulty ARM current source (TP12).
Faulty A1, Q14, 15

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In Diagnostics 2, the unit operates exactly as 4.7.3.1 Accessing Watchdog Timer

in normal RUN mode and will deliver RF to Diagnostics (dIA 1)
the output jacks, except the following software
routines which detect hardware faults are not To enter diagnostics 1, enter the CAL MODE per
executed: section 4.6.1 then select “dIA” in the Cut window
by pressing the Cut Power I in Decrease Key.
• Microprocessor internal RAM validity The menu will display dIA 1. Press the “SEL” key
• Calibration EEPROM CRC validity again.
• Power Amp Overcurrent Protection
• ARM Circuit failure detection Since this mode is useful only with the /RLYEN
• Hand, Foot or Keyboard activation on flag in the reset state, “dIA” will not appear in
Power-Up. the menu once RF has been activated in any of
the power calibration modes. On the other hand,
The routine that checks for the Program EPROM if a faulty WDT is detected on initial entry to
CRC validity will still be active. CAL MODE, Diagnostics 1 will be automatically
entered, bypassing the menu, since proper calibra-
CAUTION: If any of those failures exist, the tion may be impossible if the WDT is faulty.
microprocessor will not shut the system down
or display a HLP code. One should be pru- The menu cannot be restored from this mode.
dent in deciding whether or not to enter this When work is complete, exit CAL Mode by pow-
mode without first attempting to identify the ering down. This mode has no effect on the
fault while powered down. EEPROM, so the calibration and CRC are
unchanged.
As an example of the above note, if there is a
problem with the Power Amplifier which causes it 4.7.3.2 dIA 1 Mode Selection
to draw excessive current, say a shorted FET, then
activating the unit can allow the fault current to An indication of the currently selected mode
flow for the duration of the activation. This may appears in the Bipolar Power window. Modes are
result in damage to other components which had selected round robin fashion by using the Coag
previously been spared by the microprocessor's (righthand) foot switch to step up to the next
fast response to overcurrents in RUN mode. The higher mode, and the Cut treadle to step down.
time saved by not first performing an ohmmeter Table 4.8 lists the available modes.
test of the FET will be lost in identifying and
replacing parts damaged by the undetected over- If the WDT is operating normally the Return
current. Monitor Lamp will appear as shown in Table 4.8
until Lockup Mode 4 is selected and then either
4.7.3 Watchdog Timer Troubleshooting Late Mode 2 or Early Mode 3 is selected. After
that, the Return Monitor Lamp should be bright
This section contains help in troubleshooting the in all modes. This indicates that the WDT has
Watchdog Timer on the Controller PWB A2. effectively locked up, as it should.

A faulty Watchdog Timer (WDT) will cause the 4.7.3.3 Troubleshooting with Diagnostics 1
microprocessor to stop generating the WDSTR
signal in RUN mode. Troubleshooting this circuit Since the WDT timing accuracy and ability to
is difficult without that signal, and setting up an interrupt RF output are verified by the micro-
external generator and connecting it to the circuit processor on every power up, there is no need to
is time-consuming. recheck these parameters periodically. The only

4-16
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DISPLAY MODE WDSTR PERIOD RYLEN RETURN MONITOR ERROR

1 Normal 25.0 mS Unaffected Dark

2 Late 38.0 mS Unaffected Flashing
3 Early 15.0 mS Unaffected Bright
4 Lockup 25.0 mS Set Dark*

*on initial entry to Mode 4

Table 4.8 dIA 1 Modes

feature not checked automatically is lockout, at 300W. The VDAC voltage at 300W will vary
which is extremely reliable due to its simplic- from unit to unit, the important factor is that the
ity. If the unit declares a HLP-4 error in RUN voltage changes in small increments.
mode, then the timing is incorrect. Select Late
Mode 2 to observe timing of both WDT one-shot Next monitor A2TP6 and repeat the above proce-
stages at their test points. Stage 1 should go high dure. Confirm that TP6 voltage increases from no
for 16-20 mS after each WDSTR, and Stage 2 more than 0.4V at 0W to approximately 5.0Vdc
should run from 32-36 mS. Slight timing errors at 300W. If it fails to do so, check that VSENSE
are most likely due to a faulty timing resistor or and ISENSE are both less than 0.6V (this is true
capacitor. Failure of the pulses to respond at all only if the PA fuses have been removed). Confirm
are more indicative of an IC failure. that A2D2, D3, and D8 are good.

A HLP-7 indicates that the WDT did not shut Confirm that A2U12 pin 3 is approximately
down RF when Stage 2 timed out. This may be 3.42Vdc.
caused by failure of any of the components carry-
ing the WFAIL signal to the WFG and VBASE Other problem sources could be one of the resis-
circuits. tor divider chains in the BVG, a bad RFEN or
WFAIL signal. Also check that the other com-
Most WDT faults can be diagnosed in ponents in the BVG chain are correct and func-
Diagnostics 1 using a simple logic probe, but tional.
an oscilloscope will yield better timing measure-
ments. The general health of the WDT can be If the BVG performs correctly as tested so far, and
confirmed with no instruments simply by observ- the Power Amplifier and Waveform Generator
ing the behavior of the Return Monitor Lamp in both test good, proceed with the following test.
the various modes.
Turn off the unit, confirm that RFSUP has
4.7.4 Base Voltage Generator Troubleshooting dropped to less than 15 Vdc, and replace
the fuses in the PA. Reenter dIA 2 and select
Remove all collector and base fuses on the A1 Monopolar Blend. Monitor A2TP7 (VSENSE)
Power Board Assembly before checking a suspect and slowly increase the power setting on the
Base Voltage Generator (BVG). Enter the dIA front panel. When functioning correctly, TP7
2 mode (see Section 4.6). Check that A2U11 is will increase with power setting up to about 4
producing the proper VDAC voltage at pin 2. Vdc. At that point, there should only be a slight
Do this by selecting the Monopolar Pure Cut increase in TP7 voltage. If TP7 fails to increase
mode, and increasing the power setting from 0 to towards 4V, do not proceed with this test; find
300W. Monitor the pin to see that VDAC goes the failed components and repair them.
from approximately 5.0 Vdc at 0W to 2.8 Vdc

4-17
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After successful testing of the VSENSE circuit, likely cause. Check the A1T5 shield lid for
connect a 300 ohm 250W load resistor to the good electrical and mechanical contact with the
unit's RF outputs. Select Monopolar Pure Cut shield cup, and capacitors A1C55 and C56 for
and slowly increase the power setting while proper value and connection. Also check bypass
monitoring TP8. The dc voltage at TP8 should capacitors A1C65, A2C27 and low pass filter
increase as power increases, but should not exceed capacitor A2C23.
4.2 volts at full power.
If the Resistance Indicator vs. resistance test fails,
Units that have passed the troubleshooting steps check 2VARM at A2TP13 with 10 and 150 ohms
so far should be checked for properly oriented connected to the Return Electrode Jacks. With
diodes, mismarked resistors, and correct divider 10 ohms connected, 2VARM should be +0.88 to
voltages. If the unit has passed these BVG checks, 0.98 Vdc and with 150 ohms, it should be +1.89
then the problem is likely elsewhere. to 2.18 Vdc. 2VARM should also be twice the
voltage at VARM (A2TP12). If this test passes,
4.7.5 Waveform Generator Troubleshooting then the trouble is most likely in the A2U15, one
of the resistor values, or A2D11.
Remove the base and collector fuses from the
Power Board Assy before checking a suspect If the VARM vs. resistance test fails, check the
Waveform Generator (WFG). Enter the dIA dc current source U15 and D11, by connecting
2 mode (see Section 4.6.1.) Check that a 10.0 a dc milliammeter from A2TP12 to ground. The
MHz clock appears at A2U25 pin 12. Select a meter should read from 0.47 to 0.53 mA. Read
power setting and mode that corresponds to the the dc voltage across D11. It should be approxi-
photos in Fig. 3.2 and confirm the waveforms are mately 1.235 Vdc.
similar to that at TP23 (use TP14 to trigger the
oscilloscope to get comparable results). If they are If VARM test reads near zero and the dc current
not, suspect one of A2U23-U27 or U29 as being is low, check for a short circuit in the harness,
bad. Another problem could be in the waveform shorted bypass capacitors, or shorted transistors
select lines WV0-WV7. A1Q14 or Q15.

4.7.6 Aspen Return Monitor (A.R.M.) With the Return Electrode Jacks open-circuited,
Troubleshooting check the waveforms on the A.R.M. oscillator
collectors, A1Q15 or Q14. They should appear
The overall functionality of the A.R.M. cir- as half-wave rectified sine waves with a frequency
cuitry may be checked by selecting DUAL of 34.5 - 38.1 KHz. If the frequency is too high,
FOIL in Run Mode and connecting an accurate A1C53-C56 may be open. If the circuit is not
decade resistance box or selected resistors to the oscillating and VARM is 0.6 - 0.8 Vdc, check the
Return Electrode Jack on the output panel. If feedback resistors A1R49 and R50, transformer
the Resistance Indicator vs. resistance appears A1T4 for opens or shorts and transistors A1Q14
to match Figure 3.1, then the circuitry may be and Q15 for opens. If the circuit is oscillating
assumed to be operating properly. at the correct frequency but VARM does not
respond to resistance changes, check the cir-
If this test passes, but the unit still declares a cuitry from the secondary to A1T4 to the Return
Return Fault in operation with the ESU activat- Electrode jacks for shorts or open circuits.
ed, interference from electrosurgical current is the

4-18
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4.7.7 RF Amplifier Troubleshooting 2. Remove the screw and compression washer

from the transistor being removed. Slightly bend
The first step in troubleshooting a Power the transistor away from the heatsink to make
Amplifier (PA) is to remove all PA collector and desoldering easier.
base fuses (check the fuses as you remove them
and note if any of them are blown). This will pre- 3. Desolder and remove transistor.
vent possible secondary failures in the PA due to
overload. 4. Bend leads of the new transistor to fit in their
appropriate holes, and to allow the transistor
Use a DVM in the diode check position to check body to lie flat against the heatsink. Be sure to
for shorted bipolar power transistors, power check positioning with the screw securing the
Mosfets, and snubbing networks. Check to see transistor in place before soldering transistor.
that diodes are functional. Check RFSUP TP-
8 for approximately +140 Vdc and U2-6 for 5. Be sure to install the insulator pad. No thermal
+8Vdc with power on. compound is necessary, but the mating surfaces
of the transistor, insulator and heatsink should be
Check the Base Voltage Generator and Waveform clean. Replace any insulator which is torn, punc-
Generator for proper function before proceeding. tured or dirty.
If everything checks this far, enter dIA 2 (See sec-
tion 4.6.1) and select Monopolar Pure Cut from 6. Ensure that the body of the transistor is flat
the front panel. Confirm that A1TP1 looks like against the heatsink before tightening screws.
the waveform of Fig. 3.2 Photo 2. This ensures a maximum heat transfer and longer
transistor life, and minimizes cutting of the insu-
Turn off the power to the unit, confirm that lator pad.
RFSUP has dropped below 10Vdc and replace
the base fuses. Reenter dIA 2 and select 7. Install the compression washer and tighten
Monopolar Pure Cut from the front panel. Use the screws to 4-6 pound inches. Excessive torque
an oscilloscope on the drain of A1Q5 (TP6) to may cause the insulator pad to be cut, destroy-
confirm that the power Mosfets are switching ing its dielectric strength and shorting RFSUP to
properly. ground.

If the unit has passed all tests to this point, it will 8. Clean solder connections and replace the
be necessary to replace the fuses to troubleshoot assembly into the unit, tighten all fasteners and
further. Proceed with caution! reconnect all harnesses.

4.7.8. Power Amplifier Transistor

Replacement

All bipolar power transistors A1Q1-Q4 may be

replaced singly without replacing the entire set.
Calibration should be checked after transistor
replacement. When replacing the power transis-
tors:

1. Remove the entire Power Board/Heatsink

Assembly for easy access to the bottom of the
PWB. See Section 4.2.1 for detailed instructions.

4-19
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4.8 VIEW MODE (dIA 3) To ensure prompt service, please include the fol-
lowing information with your order or request:
Diagnostics 3 mode allows the monitoring of
internal software variables as an analog voltage Model Number
presented at Test Point #5. Each variable rep- Serial Number
resents an 8-bit number (0-255) as an analog Number Reference Designator and
voltage (0 to 4.98V) or 19.531 mV/bit. To enter Description of Part
diagnostics 3, enter the “SEL” key. The menu will CONMED Part Number (if known)
display dIA 1. Using the Coag up key select dIA Quantity Desired
3, then press the “SEL” key again. The variable Mailing or Shipping Address
selected for output at Test Point #5 is a number Preferred Shipping Means (if any)
1 thru 8 which appears in the Bipolar window. Purchase Order Number (if applicable)
The number may be raised or lowered using the Your Name
Foot Coag treadle to raise or the Foot Cut treadle
to lower. See Table 4.9 for a chart of the number If you are returning a unit, obtain a Return
code and it's meaning. Authorization Number from CONMED Tech
Services. This number should be marked on the
4.9 PARTS ORDERING INFORMATION outside of the carton.

To obtain replacement parts or additional infor-

mation regarding your unit, write or phone:

MAIL:
CONMED Corporation
310 Broad Street
Utica, New York 13501

PHONE: (315) 797-8375

1-800-448-6506 Toll Free
or contact your CONMED distributor.

# Variable (output at TP-5) Description

1 Tone Volume Amplitude of Tone Volume Set.

2 Limit The set value at which the current limit detect circuitry
will trip (HLP-5).
3 Return Monitor Value The A.R.M. value.
4 RF Current The actual RF amplifier current value.
This value is compared with Limit.
5 Line Value The AC Line Voltage.
6 Expanded Line Value The AC Line value used for Line compensation.
7 Line Compensation Value The Line compensation modifier controlling V Base.
8 Relay and Current Limit The Value of the delay timer (useful for
Delay Timer power-on scope triggering).
9 RF Current (Peak) The peak RF amplifier current value after the switch was
depressed to activate RF. (Note: The peak value will be
retained when the switch is released. When the switch is
depressed, the peak value will be reinitialized to zero to
obtain new peak values.)

Table 4.9 View Mode (dIA 3)

4-20
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4.10 REPLACEABLE PARTS

The following is a list of replaceable parts available from CONMED Corp. See Section 4.9 for ordering
information. Many of the more common parts are available from local electronic suppliers. Not all parts are
used on all assembly versions. Refer to schematics for details.

Ref. Des. Part Number Description

ASSEMBLY: Power Board (A1), 61-4705

BR1 62-0258-005 RECTIFIER, KBL01 BRIDGE

C1, 2 62-3314-003 CAP, 820uF 200V ELEC
C3 62-1677-007 CAP, 1.0uF 250V MET PE
C4,6,21,65 62-0267-002 CAP, 0.10uF 50V 20% CERAMIC
C5 62-0268-002 CAP, 47uF 63V ELEC.
C7 62-3314-001 CAP, 4700uF 35V ELEC
C8,9,36,38,40 62-0267-003 CAP, 0.33uF DIP CER
C10 62-3314-008 CAP, 4700uF 16V ELEC
C11,13,15,17 62-2844-001 CAP, 1.0uF 50V MET PE
C12,14,16,18,25 62-1677-008 CAP, 0.1uF 400V 10% PE
C20 62-1677-009 CAP, MET PE
C22,24,30-34,37,39,41, 62-0267-001 CAP, 0.01uF 50V 20% CER
44,46,49,51,61
C23 62-1677-001 CAP, 0.022uF 250V 20% MET POLY
C26,C29 62-1676-003 CAP, 1.5 nF 2000V 10% PP
C27,C28 62-1675-001 CAP, 5.6 nF 2500V 5% PP
C35,42,47,59,66 62-0268-001 CAP, 10uF, 16V 20% ELECT.
C43,45,48,50,55,56,60 62-1677-004 CAP, 0.33 uF 100V 10% MET POLY
C52 62-0267-004 CAP, 100pF DIP CER
C53,54 62-1677-005 CAP, 0.22 uF 100V 10% MET POLY
C62 62-1675-003 CAP, 2.7 nF 2000V 5% PP
C63,64 62-1676-002 CAP, 10 nF 1600V 10% PP
C67 62-1678-002 CAP, 180pF 6KV 20%
C68 62-1678-001 CAP, 150pF 6KV 20%
D1 62-4861-001 DIODE, P6KE12A
D2-5,12 62-1683-001 DIODE, MUR4100E
D6,11,13-16 62-0290-002 DIODE, 1N914B
D7 62-1687-001 DIODE, 1N5355A 18V
D8 62-4865-001 DIODE, 1N5401
D17 62-0292-004 DIODE, ZENER, 1N5221B
D18 62-0292-001 DIODE, ZENER, 8.2V
DS1 62-4056-001 LED, RED
F1,3,5,7 62-4866-004 FUSE, 3/8A, 2AG
F2,4,6,8 62-4643-046 FUSE, 2.5A, 5x20
J1, 4-7 62-3598-001 HEADER, STR. PIN
J2 62-4857-001 CONNECTOR, 50 PIN
J3 62-4248-006 CONNECTOR, 6 PIN
J8 62-2845-005 HEADER, 6 PIN
J9 62-3598-003 HEADER, STR. PIN, GOLD
J10 62-2845-001 HEADER, 2 PIN
K1-3 62-3473-003 RELAY, REED
K4 62-0638-003 RELAY, SPDT 12V
L1 62-4178-001 INDUCTOR 20mH
L2 62-1093-001 INDUCTOR 3.5mH
Q1-4 62-4773-003 TRANSISTOR, NPN, PWR, HI V PLASTIC
Q5 62-4242-004 TRANSISTOR, N-CH PWR FET 60V

4-21
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Ref. Des. Part Number Description

ASSEMBLY: Power Board (A1), 61-4705 (continued)

Q6 62-4242-003 TRANSISTOR, IRF510

Q7-16 62-4239-001 TRANSISTOR 2N3904
R2 62-4243-001 RES, CER, 0.1 5W 5%
R3,4,30,33,36,39,42, 62-0364-039 RES, 100 1/4W 5% CF
45,48,55,66-68
R5 62-0367-039 RES, 100 2W 5%
R6 62-0364-050 RES, 300 1/4W 5%
R7 62-0364-057 RES, 560 1/4W 5%
R8 62-0364-063 RES, 1K 1/4W 5%
R9 62-0364-048 RES, 240, 1/4W, 5%
R10-13 62-1693-002 RES, 3.3 3W 5%
R14 62-0364-043 RES, 150, 1/4W, 5%
R15 62-0364-016 RES, 11 1/4W 5%
R17-20 62-1693-001 RES, 0.33 3W 5%
R21 62-0364-066 RES, 1.3K 1/4W 5%
R23 62-0365-061 RES, 820 1/2W 5% CF
R24,27 62-0364-081 RES, 5.6K 1/4W 5% CF
R25 62-0364-052 RES, 360 1/4W 5% CF
R26 62-0366-078 RES, 4.3K 1W 5%
R28,29,31-32,34,35, 62-0364-068 RES, 1.6K 1/4W 5%
37,38,40,41,43,
44,46,47,53,54
R49,50 62-0364-104 RES, 51K 1/4W 5% CF
R51,52 62-0364-025 RES, 27 1/4W 5%
R56-63 62-0364-055 RES, 470 1/4W 5% CF
R64 62-3859-001 RES, 10K 5W 5%
R65 62-4609-002 RES, 27K 2W 5% CF
R69 62-0364-003 RES, 3.3 1/4W 5%
R70 BI05-0081 RES, 1 5W 5% (-004 Assembly ONLY)
R70 62-1693-005 RES, 0.47 3W 5% Power Oxide (-005 ONLY)
RV1 62-4594-004 VARISTOR, 17 VAC
TP1-15,17,18 62-2725-001 TEST POINT
T1 61-4764-003 TRANSFORMER, BIPOLAR
T1 61-4764-001 TRANSFORMER, BIPOLAR
T2 61-4870-002 TRANSFORMER, CONT. DETECT, -001 ASSY
T2 61-4870-001 TRANSFORMER, CONT. DETECT, -002 ASSY
T3 61-4887-001 TRANSFORMER, MONOPOLAR
T4 62-4177-001 TRANSFORMER, OSCILLATOR
T5 61-4176-004 TRANSFORMER, ISOLATION
U1 62-1709-001 IC, DSOO26 DUAL DRIVER
U2 62-0301-001 IC, NE555 TIMER
U3-10 62-4238-001 IC, OPTOISOLATOR OPTI 1264A
XF1,3,5,7 62-0295-003 FUSE CLIP
XF2,4,6,8 62-0295-002 FUSE CLIP
N/A 62-4704-001 PWB, Sabre 2400 POWER
N/A 62-0274-001 SEALANT, RTV
N/A 62-4240-001 STANDOFF, NYLON WIRE 1"
N/A 62-0260-001 CABLE TIE 0.085 WIDE
N/A 62-0260-002 CABLE TIE 0.190 WIDE
N/A 62-3429-003 INSULATOR PAD, TRANSISTOR
N/A 62-4765-001 HEATSINK, Sabre 2400
N/A 62-4286-002 INSULATOR CLAMPS
N/A 62-1575-004 SCREW, #6 SOCKET HEAD CAP
N/A 62-4766-001 BRACE, PWB
N/A 62-4768-001 BRACKET, MOUNTING
N/A 62-4878-007 SCREW #4-40x1/2" SOCKET HEAD CAP
N/A 62-4901-001 WASHER #4 COMPRESSION

4-22
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Ref. Des. Part Number Description

ASSEMBLY: Micro/Control Board (A2), 61-4796

C1,4,6-12,15,16,21-22 62-0267-002 CAP, 0.1uF 50V CERAMIC

24-27,29-31,45-48,64,66-68,74
C2,3 62-2844-001 CAP, 1uF 50V PE
C14,71,75,80,86 62-0268-001 CAP, 10 uF 16V ELEC.
C17,38,40-44,49-56,58 62-0267-001 CAP, 0.01uF 50V CERAMIC
C18,23,39,57,63,69,70,72 62-0267-003 CAP, 0.33uF 50V CERAMIC
C65 62-1355-002 CAP, 33pF 50V CERAMIC
C73 62-0268-011 CAP, 22uF 6V ELEC.
C76 62-0267-004 CAP, 100pF 50V CERAMIC
C85 62-1355-003 CAP, 0.047uF 50V
C87 62-1854-001 CAP, 10uF 16V TANT
D2,3,5,8,9,15-19 62-0289-001 DIODE, 1N4148
D4,10 62-0565-001 DIODE, 1N4004
D6 62-1687-002 DIODE, 1N5371B
D7 62-4854-001 DIODE, LM336Z-5.0
D11 62-0964-001 DIODE, LM385-1.2Z
D14 62-0292-002 DIODE, ZENER 1N5245
J1,2,5 62-4857-001 HEADER, 50 PIN DIN W/LATCH
J8 62-2860-001 HEADER, 9 PIN RT ANGLE
Q2 62-4859-001 TRANSISTOR, TIP120
Q3 62-4852-001 TRANSISTOR, MPS6724
Q4 62-4853-001 TRANSISTOR, VN0116N3
Q5 62-4239-001 TRANSISTOR, 2N3904
Q6 62-1696-001 TRANSISTOR, NPN HIREL, LM395
R1 62-0961-314 RESISTOR, 18.2K 1/4W 1% MF
R2 62-0961-340 RESISTOR, 34.0K 1/4W 1% MF
R3 62-0961-185 RESISTOR, 825 1/4W 1% MF
R4,10,11,15,17,24,26 62-0961-222 RESISTOR, 2.00K 1/4W 1% MF
R5 62-0961-464 RESISTOR, 665K 1/4W 1% MF
R6,34 62-0961-391 RESISTOR, 115K 1/4W 1% MF
R7,66 62-0364-039 RESISTOR, 100 1/4W 5% CC
R12,35,52 62-0364-081 RESISTOR, 5.6K 1/4W 5% CC
R13,14 62-0961-254 RESISTOR, 4.32K 1/4W 1% MF
R18 62-0364-027 RESISTOR, 33 1/4W 5% CC
R19,51 62-0364-056 RESISTOR, 510 1/4W 5% CC
R20 62-0364-079 RESISTOR, 4.7K 1/4W 5% CC
R21 62-0961-231 RESISTOR, 2.49K 1/4W 1% MF
R22,29,39 62-0364-063 RESISTOR, 1K 1/4W 5% CC
R23 62-0961-289 RESISTOR, 10.0K 1/4W 1% MF
R25 62-0961-288 RESISTOR, 9.76K 1/4W 1% MF
R27 62-0961-204 RESISTOR, 1.30K, 1/4W, 1%, MF
R28 62-0364-060 RESISTOR, 750 1/4W 5% CC
R30-33 62-0961-277 RES, 7.50K 1/4W, 1%, MF
R36,67 62-0364-087 RES, 10K 1/4W, 5% CC
R45,46 62-0961-318 RES, 20.0K, 1/4W, 1%, MF
R47,48 62-0364-071 RES, 2.2K, 1/4W, 5%, CC
R50 62-0364-049 RES, 270 1/4W, 5%, CC
R65 62-0364-049 RES, 270 1/4W, 5%, CC
R68,69 62-0364-039 RES, 100 1/4W 5% CC

4-23
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Ref. Des. Part Number Description

ASSEMBLY: Micro/Control Board (A2), 61-4796 (continued)

RN1,3 62-2861-003 RES, 4.7K, 10PIN SIP

RN2 62-2861-008 RES, 4.7K, 11 PIN SIP
RN4 62-2861-006 RES, 1.0K 6 PIN SIP
RN5 62-2861-005 RES, 4.7K 6 PIN SIP
RN6,7 62-2861-007 RES, 100 8 PIN SIP
RN8 62-2861-009 RES, 22K 4 PIN SIP
SW1 62-4855-001 SWITCH, SPST N.O. MOM
TP1-15,19-25 62-2725-001 TEST POINT
U1 62-1370-001 IC,CD4538
U2 62-4847-001 IC, 74HCTOO
U3 62-2569-002 IC, MICROCONTROLLER, 8 BIT, 80C31
U4 62-3466-004 IC, X24C04 512 x 8 EEPROM
U6 62-3457-001 IC, 8255-2
U7 62-1714-001 IC, 74LS138
U8,29 62-4848-001 IC, 74HCT573
U9* 61-4797-001 IC, Sabre 2400 CONTL PROGRAM EPROM
U9* 61-4797-002 IC, Sabre 2400 Program EPROM HI ISO
U10 62-4606-001 IC, 8155-2
U11 62-4849-001 IC, MAX500BCPE
U12 62-3394-001 IC, LM324
U13,14 62-1374-001 IC, ULN2003
U15 62-1362-001 IC, LM358
U16 62-4850-001 IC, ADC0838ACN
U17 62-1716-002 IC, 74HCT74
U19,20,21 62-4851-002 IC, HV5308 32 CHAN SRL/PARL
U22 62-4253-001 IC, 74S140
U23,24,25 62-1711-001 IC, 74LS163
U26 62-4254-001 IC, 74LS166
U27* 61-4792-001 IC, Sabre 2400 WAVEFORM PROGRAM EPROM
U30 62-1715-001 IC, 74LS02
U50 62-4258-002 IC, LTC1232
VR1 62-4603-003 VOLTAGE REG, 5V, 5%, LT1086 CT-5.0
VR2 62-0417-005 VOLTAGE REG, 12V 5%, 7812
XU3,6,10 62-1377-009 SOCKET, 40 PIN DIP
XU9,27 62-1377-008 SOCKET, 28 PIN DIP
XU19-21 62-4858-001 SOCKET, 44 PIN SQUARE
Y1 62-1718-002 IC, 20 MHZ OSCILLATOR
N/A 62-3429-002 INSULATOR PAD, TRANSISTOR
N/A 62-4795-001 PWB, MICRO/CONTROLLER

*When ordering replacement EPROMs, please specify the REV level of the existing EPROM and the part
number and REV level of the A2 Assembly. Upgraded EPROMs will be supplied only on request and only
if they are compatible with REV level of your A2 PWB.

4-24
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Ref. Des. Part Number Description

ASSEMBLY: Control Panel (A3), 62-4908

A3 62-4908-001 CONTROL PANEL

ASSEMBLY: Cover (A4), 61-4930 (Not available as a complete assembly.)

A2 61-4796-001 ASSY, A2 MICROPROCESSOR PWB

A2 61-4796-002 ASSY, A2 MICROPROCESSOR PWB
A3 62-4908-001 CONTROL PANEL
A7 61-4913-001 A7 DISPLAY ASSEMBLY
N/A 62-4781-001 CABLE, FLAT RIBBON, A2
N/A 62-7032-001 BRACKET, RIGHT
N/A 62-7032-002 BRACKET, LEFT
N/A 62-4926-001 BUMPER, RUBBER
N/A 62-4286-001 INSULATOR CLAMP, TO220
N/A 62-0649-002 LOCTITE #222
N/A 62-1575-002 SCREW, 6-32 X .25 SOCKET HD CAP
N/A 62-4772-001 SEAL GASKET
N/A 62-0343-002 #6 KEP NUT
N/A 62-0342-004 #6 NUT
N/A 62-1752-001 WIRE BRAID
N/A 62-1575-004 SCREW 6-32 X .38 SOCKET HD CAP
N/A 62-4774-001 TOP COVER

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Ref. Des. Part Number Description

ASSEMBLY: Base (A5), 61-4775 (Not available as a complete assembly.)

A1 61-4770-002 LED AMP/OUT/HEATSINK ASSY.

A1 61-4770-003 LED AMP/OUT/HEATSINK ASSY.
A1 61-4770-004 LED AMP/OUT/HEATSINK ASSY. IEC HI ISO
A5BR1 62-0257-001 BRIDGE RECTIFIER 400V, 25A
A5CB1 62-0645-004 CIRCUIT BREAKER, THERMAL, 5A
A5CB1 62-0645-005 CIRCUIT BREAKER, THERMAL, 10A
A1P3 62-4193-006 CONNECTOR, RECEPTACLE, 600V, 6 POS.
A1P1 62-3682-003 CONNECTOR,.156,HOUSING W/LOCK,3PIN
A5W1 61-4780-001 HARNESS, FOOTSWITCH, Sabre 2400
A6 61-4173-003 OUTPUT PANEL ASSY., Sabre 2400
A1P10 62-1389-001 PLUG (.100)
A5W2 62-4274-002 POWER CORD, ASSY, Sabre 2400
A5R1, A5R2 62-0362-005 RESISTOR, 200 OHM, 50W, 1%
A5R3 62-0362-006 RESISTOR, 5K OHM, 50W
A5SP1 62-0333-001 SPEAKER, 2 1/2'', 100 OHM
A5W2 62-0327-006 STRAIN RELIEF 5R17-2, RT. ANGLE
A5TB1 62-4168-006 TERMINAL STRIP, 6 POSITION
A5T1 62-3858-001 TRANSFORMER, Sabre 2400 POWER
A5T1 62-3858-002 TRANSFORMER, POWER UL/CSA
N/A 62-4767-001 BASE, Sabre 2400, DOMESTIC
N/A 62-0260-001 CABLE TIE, 3.5''
N/A 62-1707-002 CLAMP, FLAT CABLE, 3'' X 1''
N/A 62-3682-201 CONNECTOR, TERMINAL 18-24 AWG
N/A 62-1388-001 CRIMP TERMINAL
N/A 62-0337-002 FOOT, PLASTIC, 5/8'' BLACK
N/A 62-4786-001 HANDLE, ROUND, Sabre 2400
N/A 62-0259-001 MOUNT, CABLE TIE
N/A 62-0753-003 NUT, HEX NYLON, #63-32
N/A 62-0343-001 NUT, KEPS #4-40
N/A 62-0343-004 NUT, KEPS #20-32
N/A 62-0343-002 NUT, KEPS #6-32
N/A 62-4814-001 SCREW, #10-24 X 1/2'', SELF TAPPING
N/A 62-0377-005 SCREW, #6-32 X 3/8, BHS
N/A 62-0383-004 SCREW, #6-32 X 5/16 FHS
N/A 62-4172-003 SCREW, #6-32 X 3/8, SBHC
N/A 62-4287-003 SCREW, #8-32 X 3/8, BH
N/A 62-4878-004 SCREW 4-40 SKT, 5/16
N/A 62-4878-008 SCREW 4-40 SKT, 5/8
N/A 62-0274-001 SEALANT, RTV
N/A 62-2820-003 SPACER, PWB, 3/4''
N/A 62-4884-001 TAPE, PTFE #60
N/A 62-0287-009 TERMINAL, 1/4'' RING, BLUE
N/A 62-0288-005 TERMINAL, FEMALE 16-14 AWG, BLUE
N/A 62-0076-002 TERMINAL, FEMALE MOLEX 02-09-1111
N/A 62-0272-001 THERMAL COMPOUND
N/A 62-0649-002 THREAD SEALANT, LOCTITE 222
N/A 62-0339-003 TUBING, PVC-105 .263
N/A 62-0339-005 TUBING, PVC-105 .438
N/A 62-0622-002 WIRE, HIGH VOLTAGE #22, 10KV
N/A 62-0436-005 WIRE, 18 AWG, STRANDED, BLUE
N/A 62-0436-002 WIRE, 18 AWG, STRANDED, BROWN
N/A 62-2967-002 CONNECTOR IEC, SIDE FLANGE
N/A 62-0436-006 WIRE, 18 AWG, STRANDED, GRAY
N/A 62-0436-004 WIRE, 18 AWG, STRANDED, YELLOW
N/A 62-0436-008 WIRE, 18 AWG, STRANDED, BLK
N/A 62-4427-006 WIRE, 24 AWG, STRANDED, ORG/WHT
N/A 62-0620-005 HEAT SHRINK TUBING 1/8" BLK
N/A 62-5362-001 SPACER, 3/4" ROUND

4-26
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Ref. Des. Part Number Description

ASSEMBLY: Output Panel (A6), 61-4173

A1P4-7 62-3682-201 CONNECTOR, 0.156, TERMINAL TIN

A1P6 62-3682-004 CONNECTOR, 0.156, HSG, 4PIN
A1P9 62-3682-202 CONNECTOR, .0156 TERMINAL GOLD
A1P4,P7 62-3682-003 CONNECTOR, 0.156, HSG, 3PIN
A1P5,P9 62-3682-002 CONNECTOR, 0.156, HSG, 2PIN
J1,2,4,5 62-0304-002 BANANA JACK, BLK
J3,6 62-0304-001 BANANA JACK, RED
J7 62-0085-001 SPRING CLIP
J8 62-0801-001 CONNECTOR, PHONE JACK
J9-1,-2 62-4342-001 CONTACT, POST, .093 DIA. X #4-40
J10,12 62-0304-004 BANANA JACK, BLU
J11 62-3749-001 JACK, BANANA, MINIATURE, BLK
N/A 62-0260-001 CABLE TIE
N/A 62-4101-001 COVER WHEEL (WITH SELECTOR WHEEL)
N/A 62-0418-006 LOCK WASHER INT TOOTH, 1/4"
N/A 62-5107-001 LOCK WASHER INT TOOTH, 3/8"
N/A 62-0418-008 LOCK WASHER INT TOOTH, 5/16"
N/A 62-0343-001 NUT, KEPS #4-40
N/A 62-4109-001 OVERLAY, OUTPUT PANEL
N/A 62-3729-001 PANEL, OUTPUT (WITH SELECTOR WHEEL)
N/A 62-4196-001 RETAINING RING, EXTERNAL, 3/16
N/A 62-4197-001 RETAINING RING, EXTERNAL, 3/32
N/A 62-4404-001 SCREW, TYPE B SELF TAP, #4, PAN HD
N/A 62-0370-001 SCREW, #6x3/8 SELF-TAPPING
N/A 62-0314-001 SOLDER LUG, #6
N/A 62-4164-001 SPRING, TORSION
N/A 62-0649-004 THREAD SEALANT, TYPE 425
N/A 62-0339-003 TUBING, PVC-105
N/A 62-4198-001 WASHER, SPRING, 1/4
N/A 62-0470-002 WIRE, 22 AWG, BLK
N/A 62-0470-004 WIRE, 22 AWG, BRN
N/A 62-0470-006 WIRE, 22 AWG, ORG
N/A 62-0470-005 WIRE, 22 AWG, RED
N/A 62-0622-002 WIRE, HIGH VOLTAGE #22
N/A 62-3729-002 PANEL OUTPUT (NO SELECTOR WHEEL)
N/A 62-5237-001 OVERLAY, PANEL (NO SELECTOR WHEEL)

4-27
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Ref. Des. Part Number Description

ASSEMBLY: Display Board (A7), 61-4913

C1,2 62-0267-003 CAP, 0.33uF 50V CERAMIC

I1,3,5,7,8,10,16,17,19 62-1361-001 DISPLAY, LED 7 SEG, CA, RED
I2,6 62-1360-002 LAMP, LED LIGHTBAR, YEL
I4 62-1643-001 LAMP, INCAND, 14V, YEL
I9,18 62-1643-002 LAMP, INCAND, 14V, BLU
I11,14 62-1360-001 LAMP, LED LIGHTBAR, RED
I12,15 62-1360-003 LAMP, LED LIGHTBAR, GRN
I13 62-3462-001 DISPLAY, LED BARGRAPH 10X, GRN
P1,2 62-4921-001 HARNESS, RIBBON, 50 COND, PWB/DIL
R1,2,5,6 62-0364-046 RES, 200, 1/4W, 5%, CC
R3,4 62-0364-056 RES, 510, 1/4W, 5%,CC
RN1-RN6, RN9-RN11 62-3463-006 RES. NET, 8X390 16 PIN DIP
RN7,8 62-2861-002 RES. NET, 5X200, 6 PIN SIP
U1-U12 62-1374-002 IC,DRIVER, ULN2004
N/A 62-4912-001 PWB, DISPLAY A7, Sabre 2400 LED
N/A 62-2772-001 CONN, SOCKET STRIP, 10 PIN

ASSEMBLY: Footswitch Harness (A5W1)

A1P8 62-1389-005 CONNECTOR, PLUG, 6 PIN

A5J1 62-0279-001 CONNECTOR, 4 PIN
A5J2 62-0279-002 CONNECTOR, 3 PIN
E1,2 62-0314-002 GROUND LUG, #4
N/A 62-0260-001 CABLE TIE, 3.5''
N/A 62-1388-001 TERMINAL, CRIMP
N/A 62-0339-004 TUBING, PVC 105/0
N/A 62-0620-003 TUBING, 3/32'' HEATSHRINK
N/A 62-0431-001 WIRE, 22 AWG BUS
N/A 62-4427-002 WIRE, #24 TWISTED BLK/WHT
N/A 62-4427-007 WIRE, #24 TWISTED BLK/YEL/BLU

ASSEMBLY: Miscellaneous

N/A 60-5601-002 MANUAL

N/A 62-4783-001 CARTON, Sabre 2400 SHIPPING
N/A 62-4784-001 INSTAPAK, Sabre 2400 TOP
N/A 62-4787-001 INSTAPAK, Sabre 2400 BOTTOM
N/A 62-4287-004 SCREW, 8-32X1/2, BHPH
N/A 62-0343-002 NUT, KEPS, 6-32

4-28
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Figure 4.1 Rear Panel Screw Locations

COVER ASSEMBLY
COVER SCREWS - REMOVE TO OPEN

MONOPOLAR
FOOTSWITCH

BIPOLAR
FOOTSWITCH

US PATENT NOS. 4,569,345 - 4, 617,927 -

4,848,335 - 4,961,739 AND PAT.PEND.

IDENTIFICATION LABEL
BASE ASSEMBLY

4-29
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Figure 4.2 Subassembly Locations

A3 CONTROL PANEL
A7 DISPLAY BOARD ASSEMBLY
ASSEMBLY

A2 CONTROLLER
ASSEMBLY

A4 COVER ASSEMBLY

A5T1 TRANSFORMER A1 POWER BOARD

ASSEMBLY

A5 BASE ASSEMBLY

A6 OUTPUT PANEL
ASSEMBLY

4-30
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Figure 4.3 Power Board Assembly

NOTE: This layout is for models 60-5600-002, -004 & -005 only.
See Figure 4.6 for -003 and -015 versions.

C1 REPLACE FUSES R10

AS MARKED
C11

3/8 A 250 V
C12
F1
Q1
B

D2 C
F2

E
C2
2.5 A 250 V R17

C13
R11

3/8 A 250 V

1 3 F3 C14
2.5 A 250 V
J3 F4
Q2
B

C3 C
D3

E
D8 R18
4 6

TP14

GND R8
1 2 3 4 5 6 2 1 TP15
J8
C65

C30

C24

C31

C34

C33

C32

J10 GND R2 RV1

2 50 R7 R15 G
R9 D7
C36 R30 Q7 D
TP1 BGATE
E

R56 J2
B

R12 S
R29
EC

R28 Q8 R3 D6 Q5
U3 R66 1 49 C5 R21 C15
B

C38 R33 A C R27

R64
E C

TP7 U1
C37

R32 Q9
R57 K E R65 GND
R14
B

D1

R31 U4 R67 R26 +11UNREG C16

C

C40 R58 A C TP4 DS1 TP9 C4 R4 R6 C6 3/8 A 250 V

TP13
C39

C10 B
R36 +12 VBASE F5
K E C9 TP3 F6
R35 U5 R68 C7 +22UNREG /GATE
R24 D17
A C R5 C
R34 D13 TP10
C41

U2
C35 T2-10 K E D18 C8 E
D11 BR1
R69 R23 2.5 A 250 V Q3
T2-9 TP12 TP5 R19
TP17 FRET C21 C66 GND D4
VARM TP18
C20 1
2 TP8
L1 C22 RLYSUP RFSUP
Q6
2 T2-1 C17
G K4
C52 C53 R25 T2-2 C25 R13
D
C23 3 3/8 A 250 V
R51 S
B 12 11 T4
R49

T5-2
E C 4
Q14 1 T5-1
2 F7 C18
T5-4 D12 5 J1 B
Q15 T5-3 T3-3 T3-4 TP6
8 DRAIN
R50

C E
7 1 2 3 C
R52 T5 C62 F8
B
5 6 C54 K3-2 K3-3 A1 OUTPUT/POWERAMP ASSEMBLY
61-4705 E
K2-2 K2-3 REV D5 Q4
C44 C46 TP11
GND C49 C51 T1-2
K1-2 K1-3 R20
C

C
E

T2 T3-1
2.5 A 250 V

C27 C28 T3-2 T1-1 T1

TP2
COLL

T3
U6

U7

U8

U9
K

K
A

Q10 Q12 Q13

Q11
R48
R42

E E E
E
CB C C CB
C43 B B C48
T1-3
R45

R47
R46
R39

R41
R40

J5
R38
R37

R44
R43

C50

T1-4
C45
D14

D15

C42 C47 2 1
T2-4

R61
R62

T2-6
R59
R60

C29 C61
T2-5
C E
T2-3

3 3 T3-6 C59
U10
2 C60
2 1 2
2
2
1
E
J7 J4 Q16
B
R55

R63

A K C
T2-8
T3-5 D16
T2-7
C26

4 3 2 1
R53

R54

C56 C55
J6
T5-5
3 3 3 T5-6

J9

K1 K2 K3 1 2
C64 C63

4-31
4-32
R

49 1 49 1 D15 D16 D17

* * * *

D18
J8
1
J1 50 2 J2 50 2 RN6 RN7

U19 U20 U21

C10
D19

J6 RN8

REV
1
R66

TP25 1 2 3 4

U10
GND

C29 1 RN2

CAL
C30 C39

A2 MICRO/CONTRL ASSY
C31 R34
1

61-4796-
SW1
U9

C47
/DDAT C18 R33
TP20 RN4

U7
R30

U22
C8

TP19 R32 TP2 WDTIMER R2

C2
C3

/DCLK

R29
U30
R31
TP15 /GOFF R1
C9

C66
TP3
U8

R13
/WFAIL

U17
U1
TP14 R68 R6 C85

C45
/CNTRLD ISENSE
C6

TP8

U29
14 8 Q3 R35 R12 R36
TP22
C E
/RESET
C1
U50

D8
B
U3

C46
U12
C64

C63

Y1
C4

R48 R19 1 RN1

Q5

C22
1 7

U14
R69 C76 R15

C25
C65 C E
U4
C11

R10 R50
R46 R28 R7
B
D5

TP5
Figure 4.4 Micro/Controller Board Assembly

U27
R45 R18 D9
R39

C48
C12

C67
U25
D3
TP1

TP13
R65
U2

R11 RN5 R51

U6

+5VREF

GATE
1

2VARM
C7

R3
R4

C24
R5

U15
U16
D2

U24
U26
TP7 1 RN3

C23
C26

TP23
R47 C15
U13

VSENSE
R24 C17
D11

R67
R20

C68
U11
C41

R25
C43

C38

R14
C44

U23
A C86 D14
C21

K R21 R26 C16

C58 C42

C87 A R17
D4 D7

C27
C56

TP9
C53

C75
C49
C50
C51
C52
C54
C55

TP24 R22 R27 C57 +22UNREG

TP6 C14 +12V
R23 VARM Q2 TP10
GND TP12 VBASE B C E C69
2 50
D10

C70

C71
R52

C72
C73
3 2 1 C80 C E B 3 2 1

VR1 TP11 J5 1 49 C74 C40 Q6 VR2

+5V

R67 IS MOUNTED ON CIRCUIT SIDE IF BOARD

IS REVISION "A" OR "B". RESISTOR IS ON COMPONENT
SIDE IF BOARD IS REVISION "C" OR GREATER.
SEE CIRCUIT SIDE FOR CURRENT REVISION LEVEL OF BOARD.
 50 30
C1
20 4 50 30 20 4
U12

C2
P1 P2
47 31 21 1 47 31 21 1
U10

U1 RN1
RN11

1 1

R3
I11 I14
I4 I9 R4 1 1 I18
U2 RN2 I15 I19
U4 RN4 I12
I1 I3 I5 I7 I8 I10 I16 I17
R5

1
U8

U7
R6
U11

1 1 1 1 1 1 1 1
U3 RN3
U5 RN5 U6 RN6
I13
U9

I6
RN10

I2
1 1
RN7 RN8
RN9

R1 R2
SABRE A7 DISPLAY ASSY
61-4913-001 REV__
R

Figure 4.5 Display Board Assembly

4-33
 R

Figure 4.6 Power Board Assembly

NOTE: This layout is for models 60-5600-003 & -015 only.
See Figure 4.3 for -002, -004 and -005 versions.

C1 REPLACE FUSES R10

AS MARKED
C11

3/8 A 250 V
C12
F1
Q1
B

D2 C
F2

E
C2
2.5 A 250 V R17

C13
R11

3/8 A 250 V

1 3 F3 C14
2.5 A 250 V
J3 F4
Q2
B

C3 C
D3

E
D8 R18
4 6

R70 TP14 R8
1 2 3 4 5 6 GND
2 1 TP15
J8
C65

C30

C24

C31

C34

C33

C32

J10 GND RV1

2 50 R7 R15
R2 G
R9 D7
C36 R30 Q7 D
TP1 BGATE
E

R56 J2
B

R12 S
R29
EC

R28 Q8 R3 Q5
U3 R66 1 49 C5 R21 D6 C15
B

C38 R33 A C R27

R64
E C

TP7 U1
C37

R32 Q9
R57 K E R65 GND
R14
B

D1

R31 U4 R67 R26 +11UNREG R4 C16

C

C40 R58 A C TP4 DS1 TP9 C4 R6 C6 3/8 A 250 V

TP13
C39

C10 B
R36 +12 VBASE F5
K E C9 TP3 F6
R35 U5 R68 C7 +22UNREG /GATE
R24 D17
A C R5 C
R34 D13 TP10 TP8
C41

U2 RFSUP
C35 T2-10 K E D18 C8 E
D11
R69 R23 2.5 A 250 V Q3
T2-9 TP12 TP5 BR1 R19
TP17 FRET C21 C66 GND D4
VARM
C20
L1 C22
Q6
1 2
G
T2-1 TP18 1 4 C17
C52 C53 R25
D T2-2 RLYSUP K4 R13
C23 3/8 A 250 V
R51 S C25
B 12 11 T4
R49

T5-2 D12
E C J1
Q14 1 T5-1
2 F7 C18
T5-4 1 2 3
2 3 5 B
Q15 T5-3 TP6
8 TP2
T3-3 DRAIN
R50

C E COLL
7 C
R52 T5 T3-4 C62
B
5 6 C54 K3-2 K3-3 F8
C28 C27 E
TP11 K2-2 K2-3 T3-2 D5 Q4
C44 C46
C49 C51 T1-2
GND
K1-2 K1-3 T3-1 A1 2.5 A 250 V R20
T2 OUTPUT/POWERAMP ASSEMBLY
C

C
E

61-4705- REV T1-1

T1

T3 C61
U6

U7

U8

U9

C E

J11
K

K
A

1
Q10 Q11 Q12 Q13
R42

E E E E 2 1
C C
C B C
B B B A K
C43
R45
R44
R43

T1-3
R48
R47
R46

J5 U10
R39

R41
R40

C50
R38
R37

D15 C47
T2-6 C48 T1-4
C45
D14

C42 T2-5 R62

2 1
T2-4

R61
R59
R60

3
2
C68
1 2
T2-3

3
J4 T3-6 L2 C59
2
2 2 R55 C60
1
C67 E
2 J7 T3-5 Q16 B
R63

C
T2-8

T2-7 D16

C26 4 3 2 1
R53

R54

J6
T5-6 T5-5
3 3 3 C55
C29

J9
C56
K1 K2 K3 1 2
C64 C63

4-34