Distributed By:

Integra LifeSciences Corporation

Plainsboro, NJ 08536 USA
Integra LifeSciences (Ireland) Limited
IDA Business and Technology Park
®
Sragh
Tullamore, County Offaly, Ireland
© 2009 Integra LifeSciences Corporation.
All Rights Reserved. Printed in Ireland

945103104ILS, Rev. A
Ultrasonic Surgical Aspirator Service Manual

CUSA EXcel® Ultrasonic Surgical Aspirator Service Manual

OPERATE WITH CONFIDENCE™

Radionics® MAYFIELD® Auragen™ Ruggles™ CUSA® OSV II® DuraGen Plus® Camino®
Stereotaxy Stabilization Brain Mapping Instruments Tissue Ablation CSF Management Duraplasty NeuroCritical Care

Integra LifeSciences Corporation

Integra LifeSciences
311 Enterprise Corporation
Drive • Plainsboro, NJ 08536
311 Enterprise
Customer Service USA and Canada: Drive • •Plainsboro,
800.997.4868 NJ (Outside
609.936.5400 08536 USA) • 888.980.7742 (Fax)
USA and Canada 800.997.4868www.Integra-LS.com
• (Outside USA) 609.936.5400 • (Fax) 888.980.7742
www.Integra-LS.com
Camino, CUSA, CUSA Excel,Camino,
DuraGenCUSA,
Plus, DuraGen Plus, Integra NeuroSciences,
Integra NeuroSciences, OSV II,are
OSV II, and Radionics andregistered
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are registered trademarks
of Integra of Integra
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Corporation Corporation
or its subsidiariesor in
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subsidiaries.
United States and/or other countries.
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Auragen, Operate
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subsidiaries.
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MAYFIELD is is a
a registered trademark of
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©2008
©2009 Integra
Integra LifeSciences
LifeSciences Corporation. All Rights
Corporation. All rights reserved.
Reserved.Printed
Printedininthe
theUSA.
USA.NS2073-10/08
NS408-06/09

USEnglishCover_Update_April09_18x12.indd 1 7/17/09 10:02 AM

Service Manual

CUSA EXcel® Ultrasonic Surgical

Aspirator System
Preface
This manual and the equipment it describes are for use only by qualified medical
professionals trained in the particular technique and surgical procedure to be
performed. It is intended as a guide for servicing the CUSA EXcel® ultrasonic
surgical aspirator only.

Caution
Federal (USA) law restricts this device to sale by or on the order of a physician.

Equipment covered in this manual

CUSA EXcel® ultrasonic surgical aspirator with 23 kHz and 36 kHz handpieces.
The CUSA EXcel® Ultrasonic Surgical Aspiration System Service Manual
consists of two parts—the text (part 1 of 2) and a Schematics Supplement (part 2
of 2), which contains the schematics.
Trademark acknowledgements
CUSA EXcel, TissueSelect, MacroTip, MicroTip, PrecisionTip, CEM, and Force
FX are trademarks of Integra LifeSciences Corporation or its subsidiaries.
Ajax® is a registered trademark of the Colgate-Palmolive Company.
Comet® is a registered trademark of Procter & Gamble.
Torque Seal® is a registered trademark of Organic Products Co.
Manufactured by
Integra LifeSciences (Ireland) Limited
IDA Business & Technology Park
Sragh
Tullamore, CO Offaly, Ireland

Distributed by
Integra LifeSciences Corporation
Plainsboro, NJ 08536, USA
800-997-4868
© 2009 Integra LifeSciences. All rights reserved. Contents of this publication
may not be reproduced in any form without the written permission of Integra.

Patent Information
One or more of the following U.S. patents and corresponding foreign patents
cover the CUSA EXcel system
4634419 4734964 4747820 4827911 4846790
4881761 4921476 4931047 4988334 5015227
5190517 5312329 5421829 5466020 6083191
6214017 6256859 6499358 6602227 6654999
D438952

Additional patents pending.

0086

ii CUSA EXcel Ultrasonic Surgical System Service Manual

 About This Manual
The service manual describes the CUSA EXcel ultrasonic surgical aspirator. It
presents the CUSA EXcel as a system that includes a console, handpieces, and
accessories:
• Descriptions of the system, its functions, specifications, and theory of
operation
• Step-by-step instructions on how to unpack, install, maintain, calibrate, and
troubleshoot the system
• Step-by-step instructions on how to replace specific components
• Parts lists, board layouts, and schematics.

Organization
We have organized this guide to introduce the safety issues, the system, and its
functions. After safety and the system, the guide gives instructions for unpacking
the system, then describes its components, technical specifications, and theory of
operation. The next sections tell you how to check out, maintain, troubleshoot,
replace parts, and calibrate the system. A schematics supplement includes printed
circuit board (PCB) layouts and schematics.

CUSA EXcel Ultrasonic Surgical System Service Manual iii

 Conventions Used in this Guide
Warning
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

Caution
Indicates a hazardous situation which, if not avoided, may result in minor or moderate
injury.

Notice
Indicates a hazard which may result in product damage.

Important
Indicates an operating tip or
maintenance suggestion.

iv CUSA EXcel Ultrasonic Surgical System Service Manual

Table of Contents
Preface 1-ii
About This Manual 1-iii
Organization 1-iii
Conventions Used in this Guide 1-iv
List of Figures 1-xiii
List of Tables 1-xv

Section 1. Service Personnel Safety

Safety Information 1-1
Warnings, Cautions, and Notices 1-1
General 1-2
Introduction 1-2
Unpacking and Installing the CUSA EXcel System 1-2
Console Components 1-2
Technical Specifications 1-2
Checkout Procedures 1-2
Maintaining the CUSA EXcel System 1-3
Troubleshooting 1-4
Replacement Procedures 1-4
Calibration 1-5
Repair Policy 1-5

Section 2. Introduction
For Your Information 2-1
Overview 2-2
Fragmentation 2-2
Tip Motion 2-2
Cooling 2-2
Irrigation 2-3
Aspiration (Suction) 2-4
Handpieces 2-5
Wide Variety of Tips 2-5

Section 3. Unpacking and Installing the CUSA EXcel Surgical

Aspirator System
The Responsibility of the Manufacturer 3-1
Unpacking the CUSA EXcel System 3-2
Tools You Will Need 3-2
Unpacking Procedure 3-2
Preparing the CUSA EXcel Console for Use 3-8

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual v

 Replacing the Power Connector 3-9

Section 4. Console Components

For Your Information 4-1
Console Overview and Structural Features 4-2
I.V. Pole 4-3
Control Panel 4-3
Arm and Arm Housing 4-3
Housing for Irrigation Pump Head and Suction Pinch Valve 4-3
Console Body 4-3
Shelf for Suction Canister 4-3
Casters 4-3
Control Panel 4-4
Alerts 4-5
Lap Mode, Prime, Test, and Status Buttons 4-5
Displays 4-5
Status Indicators 4-7
Setpoint Adjustment Buttons 4-7
Console Body Front Panel 4-8
Handpiece Connector Receptacle 4-8
Suction Pinch Valve 4-9
System Power Switch 4-9
Irrigation Pump Head 4-9
Contamination Guard 4-9
Retaining Bail for Suction Canister 4-9
Console Body Side Panel 4-10
Control Panel 4-11
Rotation Lock Handle 4-11
Housing for Irrigation Pump Head and Suction Pinch Valve 4-11
I.V. Pole 4-11
I.V. Pole Release Button 4-11
Arm and Arm Housing 4-11
Arm Release Tab 4-11
Cooling Water Reservoir 4-11
Console Body Rear Panel 4-12
Speaker 4-13
Volume Control 4-13
Footswitch Connector Receptacle 4-13
AC Main Switch 4-13
Fuses 4-13
Footswitch 4-13
AC Power Cord 4-15
Equipotential Grounding Lug 4-15

vi CUSA EXcel Ultrasonic Surgical Aspirator System Service

 Label 4-15
Cord Wraps 4-15
Storage Compartment 4-15
Symbols on the Control Panel 4-16
Other Features 4-17
Filling the Cooling Water Reservoir 4-17
Raising/Lowering the Arm 4-17
Rotating the Control Panel 4-18
Adjusting the Tone Volume 4-18
Adjusting the I.V. Pole 4-19

Section 5. Technical Specifications

Console Dimensions 5-2
CUSA EXcel Console 5-2
Footswitch 5-2
Console Subsystems 5-2
Ultrasonic 5-2
Fluidic System 5-3
Electrical Requirements 5-3
Input Power Source 5-3
Power Cords 5-3
Low Frequency Leakage 5-4
Duty Cycle 5-4
Environment 5-4
Standards and IEC Classifications 5-5
Class I Equipment (IEC 601-1) 5-5
Type BF Applied Part Equipment (IEC 601-1) 5-5
IPX - 8 (IEC 529, UL60601) Footswitch 5-5
Electromagnetic Interference 5-6
System Power Off / Standby 5-6
Pinch Point in the Suction Pinch Valve 5-6
Fuse Replacement 5-6
Footswitch Symbols 5-6
Voluntary Standards 5-7
Statutory and Regulatory Requirements 5-7
EMC Compatibility 5-7
Handpieces 5-12
Nominal Frequencies 5-12
Dimensions 5-12
Tip Specifications 5-12
23 kHz 5-13
36 kHz 5-14

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual vii

 Section 6. Principles of Operation
How the Handpiece Works 6-2
Electromechanical Operation 6-2
Fragmentation 6-3
Cooling 6-3
How the TissueSelect Feature Works 6-4
Inherent Tissue Selectivity 6-5
Increasing Tissue Selectivity 6-5
TissueSelect Reduces Reserve Power to the Tip 6-6
Benefits of TissueSelect 6-8
A Common Misunderstanding of the Amplitude Setting 6-9

Section 7. Circuit Theory

For Your Information 7-1
Display Board 7-2
General Description 7-2
Fundamentals of Operation 7-2
Detailed Circuit Description 7-3
Machine Control Board 7-4
Introduction 7-4
Irrigation Pump 7-4
Suction Pump 7-4
Cooling Pump 7-6
Suction Valve 7-6
Amplitude Control 7-6
Valve Controls 7-7
Power Control Input and Output Signals 7-7
Voltage Regulators 7-8
Interface Connectors 7-8
Ultrasonics Board–Ultrasonic Generator 7-8
Fundamentals of Operation 7-8
The Main Frequency Loop 7-9
Bandpass Filter (BPF) 7-9
AGC/Error Amplifier Circuit 7-10
Phase Compensator 7-11
Driver Stage 7-11
Feedback Signal 7-12
Bias Circuitry 7-12
Frequency Selection Circuitry 7-12
Ultrasonics Board–Other Circuits 7-13
Audible Alert and Operation Indicator 7-13
Valve Drivers 7-13

viii CUSA EXcel Ultrasonic Surgical Aspirator System Service

 Power and Other Signal Connections 7-13
System 24 V Power Supply Board 7-13

Section 8. Checkout Procedures

Inspections 8-1
Footswitch 8-1
Power Cord 8-2
Power On Verification 8-2
Handpiece Test (Optional) 8-2

Section 9. Maintaining the CUSA EXcel System

For Your Information 9-1
Recommended Maintenance Schedule 9-2
Clean the CUSA EXcel Console 9-3
Clean the Sterilizer Case 9-3
Maintain the Handpiece 9-3
Clean the Handpiece 9-4
Lubricate the Handpiece Connector O-Rings 9-5
Replace the Handpiece Connector O-Rings 9-5
Recalibrate the Handpiece 9-5
Maintain the Tip Torquing Set 9-6
Clean the Tip Torquing Set 9-6
Check the Torque on the Tip Torquing Wrench 9-6
Store the CUSA EXcel System and Accessories 9-7
CUSA Console 9-7
Handpiece 9-7
Footswitch 9-7
CEM Nosecone 9-7

Section 10. Troubleshooting

For Your Information 10-1
Troubleshooting Safety 10-2
User Troubleshooting 10-2
Responding to Alerts 10-3
General Troubleshooting 10-6
Engineer Troubleshooting 10-15
Guidelines 10-15
Flowcharts 10-15
No Power 10-16
Handpiece Alarm 10-17
Footswitch Alarm 10-18
Cooling Water Alarm 10-19

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual ix

 Low Suction 10-20
Low Irrigation 10-22
Vibration Alarm 10-23

Section 11. Replacement Procedures

For Your Information 11-2
Console Covers 11-3
Open the Left Cover 11-4
Open the Right Cover 11-4
Open the Rear Cover 11-4
Re-install the Left Cover 11-5
Re-install the Right Cover 11-5
Re-install the Rear Cover 11-5
System 24 Volt Power Supply 11-6
Remove the System 24 Volt Power Supply 11-6
Install the System 24 Volt Power Supply 11-6
Ultrasonics and Machine Control Printed Circuit Boards 11-8
Remove the Ultrasonics PCB 11-8
Install the Ultrasonics PCB 11-11
Remove the Control Panel Assembly 11-13
Remove the Machine Control PCB 11-14
Install the Machine Control PCB 11-14
Install the Control Panel Assembly 11-15
Control Head Components 11-15
Remove the Control Panel Assembly 11-17
Remove the Machine Control PCB 11-18
Remove the Control Panel Overlay 11-18
Remove the Display PCB 11-18
Install the Display PCB 11-19
Install the Control Panel Overlay 11-20
Install the Machine Control PCB 11-20
Install the Control Panel Assembly 11-20
Suction Control Valve 11-21
Remove the Suction Control Valve 11-21
Install the Suction Control Valve 11-27
Suction Pump and Controller Card 11-29
Remove the Suction Pump 11-29
Install the Suction Pump 11-34
Ready for Suction Pump Controller Card Replacement 11-35
Remove the Suction Pump Controller Card 11-36
Install the Suction Pump Controller Card 11-37
Suction Pinch Valve 11-38

x CUSA EXcel Ultrasonic Surgical Aspirator System Service

 Remove the Irrigation Pump Bezel 11-38
Remove the Suction Pinch Valve 11-38
Install the Suction Pinch Valve 11-40
Install the Irrigation Pump Bezel 11-40
Irrigation Pump Head and Gear Motor 11-41
Remove the Irrigation Pump Bezel 11-41
Remove the Irrigation Pump Head 11-41
Install the Irrigation Pump Head 11-42
Remove the Irrigation Pump Gear Motor 11-43
Install the Irrigation Pump Gear Motor 11-45
Replace the Irrigation Pump Bezel 11-45
Handpiece Flow Sensor 11-46
Remove the Handpiece Flow Sensor 11-46
Install the Handpiece Flow Sensor 11-48
Cooling Water Pump Tubing 11-49
Tools and Materials 11-49
Remove the Cooling Water Pump Head 11-49
Install Tubing and Re-Assemble the Cooling Water Pump Head 11-50
Cooling Water Reservoir O-Rings 11-50
O-Rings on the Cooling Water Reservoir Connectors 11-51
Fuses 11-52

Section 12. Calibration

For Your Information 12-1
Tools/Equipment Needed for Calibrations 12-2
DC Bias Power Supply 12-2
Suction Pump 12-3
Motor for the Cooling Water Pump 12-3
Set Up 12-3
Procedure 12-3

Section 13. Repair Policy

Return Equipment for Service 13-2
Obtaining a Return Authorization Number 13-2
Returning the Console 13-2
Returning the Handpiece 13-9
Returning Circuit Boards 13-9
Ordering Replacement Parts 13-9
Integra Service Center 13-9

Section 14. Service Parts Lists

Ordering Replacement Parts 14-1

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual xi

 Replacement Parts 14-2
Handpiece Cooling 14-2
Irrigation 14-2
Miscellaneous 14-3
Power 14-3
Suction 14-4
Electronic Parts 14-4
Miscellaneous Spare Parts 14-8

Appendix A. Warranty

xii CUSA EXcel Ultrasonic Surgical Aspirator System Service

List of Figures
Figure 2-1. The pre-aspiration holes and threads on tips 2-3
Figure 2-2. The three handpieces in the CUSA Excel system 2-5
Figure 4-1. Console structural features 4-2
Figure 4-2. Control panel features 4-4
Figure 4-3. Control panel features (continued) 4-6
Figure 4-4. Console body—front view 4-8
Figure 4-5. Console body—view of the right side 4-10
Figure 4-6. Console—rear view 4-12
Figure 4-7. Console—rear view (continued) 4-14
Figure 4-8. Control panel symbols 4-16
Figure 6-1. The handpiece components 6-2
Figure 6-2. Reserve power vs. TissueSelect settings 6-7
Figure 6-3. Reserve power vs. amplitude setting 6-9
Figure 7-1. The display organization on the control panel 7-3
Figure 9-1. Cleaning the handpiece with a soft cloth 9-4
Figure 9-2. Replacing the handpiece connector o-rings 9-5
Figure 11-1. Right and left sides of the console 11-3
Figure 11-2. The wiring harness on the system 24 volt power supply 11-7
Figure 11-3. Cables on the ultrasonics PCB assembly 11-9
Figure 11-4. The ultrasonics PCB fan assembly connections 11-10
Figure 11-5. Plugging the adapter for the syphon valve cable assembly into the
connector at J6 on the ultrasonics PBC 11-11
Figure 11-6. Disconnecting control panel assembly cables 11-13
Figure 11-7. Removing the Machine Control PCB from the control panel
assembly 11-14
Figure 11-8. The layers of control head components 11-16
Figure 11-9. Disconnecting control panel cables 11-17
Figure 11-10. Disconnecting the 50-pin ribbon cable and removing the Machine
Control PCB 11-19
Figure 11-11. Removing the Display PCB from the control head assembly 11-19
Figure 11-12. Removing the ends from the suction pump chamber 11-23
Figure 11-13. Removing the suction pump enclosure from the console 11-23
Figure 11-14. Disconnecting the suction tube at the contamination guard 90°
elbow 11-24
Figure 11-15. Disconnecting the suction tube from the left end of the suction
control valve 11-24

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual xiii

 Figure 11-16. Pulling the strain relief bushing away from the manifold bracket 11-25
Figure 11-17. Removing the manifold bracket from the console 11-25
Figure 11-18. Removing the suction control valve from the manifold bracket 11-
26

Figure 11-19. Removing the suction hose and clamp from the suction control
valve 11-27
Figure 11-20. Removing the suction tube and clamp from the “T” fitting 11-30
Figure 11-21. Pulling the split bushing away from the manifold bracket 11-30
Figure 11-22. Disconnecting cables from the suction pump to the suction pump
controller card 11-31
Figure 11-23. Removing the suction tube and strain relief bushing from the
suction pump and its wires 11-33
Figure 11-24. Removing the suction pump from its bracket mount 11-33
Figure 11-25. Attaching the suction pump motor to its mounting bracket, making
sure to center the pump on the bracket 11-34
Figure 11-26. Removing the cable clamps and screws from the suction pump
controller card 11-36
Figure 11-27. Removing the irrigation pump bezel 11-39
Figure 11-28. Removing the suction pinch valve 11-39
Figure 11-29. Removing the irrigation pump bezel 11-41
Figure 11-30. Removing the irrigation pump head 11-42
Figure 11-31. Disconnecting the irrigation pump gear motor from the control card
11-43

Figure 11-32. Replacing the gear motor/pump head coupler on the motor drive
shaft 11-44
Figure 11-33. Replacing the handpiece flow sensor 11-47
Figure 11-34. Removing the end bell and tubing from the cooling water pump
head 11-50
Figure 11-35. O-rings on cooling water reservoir connectors 11-51

xiv CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

List of Tables
Table 3-1. Wire colors 3-9
Table 5-1. Tip Specifications—23 kHz 5-13
Table 5-2. Tip Specifications—36 kHz 5-14
Table 6-1. On-off intervals for TissueSelect 6-6
Table 6-2. Fragmentation performance vs. TissueSelect settings 6-8
Table 7-1. Irrigation pump voltage steps 7-4
Table 7-2. Suction pump voltage steps 7-5
Table 7-3. Cooling pump voltage steps 7-6
Table 7-4. Handpiece amplitude control voltages 7-6
Table 9-1. Routine maintenance tasks 9-2
Table 9-2. Torque values for the torque wrench 9-7
Table 11-1. Cable connections on the ultrasonics PCB 11-8
Table 11-2. Ultrasonics PCB fan assembly connectors 11-10
Table 11-3. Cable connections on the ultrasonics PCB 11-12
Table 11-4. Procedures to access control panel components 11-16
Table 11-5. Suction pump cable connections to the controller card 11-31
Table 11-6. The suction pump controller card cable to the ultrasonics PCB 11-
36
Table 11-7. Suction pump cable connections 11-37
Table 11-8. Irrigation pump control card connections 11-45
Table 11-9. Fuse values 11-52
Table 14-1. Handpiece cooling replacement parts 14-2
Table 14-2. Irrigation replacement parts 14-2
Table 14-3. Miscellaneous replacement parts 14-3
Table 14-4. Power replacement parts 14-4
Table 14-5. Suction replacement parts 14-4
Table 14-6. Printed circuit board spares 14-4
Table 14-7. Ultrasonics board parts—resistors 14-5
Table 14-8. Ultrasonics board parts—diodes 14-5
Table 14-9. Ultrasonics board parts—FETs 14-6
Table 14-10. Ultrasonics board parts—integrated circuits 14-6
Table 14-11. Ultrasonics board parts—connectors 14-7
Table 14-12. Ultrasonics board parts—miscellaneous 14-8

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual xv

Notes

xvi CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 1

Service Personnel Safety

1

In this section:

• Safety information
• Warnings, Cautions, and Notices, organized by section.

Safety Information
The safe and effective servicing of ultrasonic surgical equipment depends to a
large degree on factors solely under the control of the service person. There is no
substitute for a properly trained and vigilant service staff. It is important that you
read, understand, and follow the procedures supplied with this ultrasonic
equipment.

Warnings, Cautions, and Notices

Before servicing the CUSA EXcel console or handpieces, it is important that you
read, understand, and follow the instructions and the warnings, cautions, and
notices supplied with it. It is also important that you read, understand, and follow
the instructions for any other equipment used to install, test, adjust, or repair the
CUSA EXcel system.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 1-1

Warnings, Cautions, and Notices

General
Caution
Federal (USA) law restricts this device to sale by or on the order of a physician.

Notice
Operating the console outside the specified voltage ranges may cause damage to the
power supply.

Introduction
Caution
Read all warnings, cautions, notices and instructions provided with the CUSA EXcel
system before servicing it.

Read the instructions, warnings, cautions, and notices provided with the CUSA EXcel
handpieces before servicing them.

To avoid injury to surgical personnel, keep fingers away from the suction pinch valve.

Unpacking and Installing the CUSA EXcel System

Caution
To prevent the ramp from falling and causing injury, be sure to hold the ramp in the up
position while cutting the corrugated tab that secures it to the carton.

Console Components
Caution
To avoid injury to surgical personnel, keep fingers away from the suction pinch valve.

Technical Specifications
Warning
Explosion Hazard Do not use the CUSA EXcel system in the presence of flammable
anesthetics or any potentially explosive or flammable atmosphere.

Caution
To avoid injury to surgical personnel, keep fingers away from the suction pinch valve
while powering the unit on or off, activating vibration, or using fast flush.

Checkout Procedures

1-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Warnings, Cautions, and Notices

Caution
Do not allow the handpiece tip to contact anyone or anything during tip activation.

Service Personnel Safety

Contact may result in patient injury, user injury, or handpiece tip damage.

Notice
To avoid product damage, NEVER hold the handpiece in your hand while using the
torque wrench to tighten or loosen the tip.

Maintaining the CUSA EXcel System

Warning
Electric Shock Hazard Always unplug the CUSA system before cleaning.

Notice
Do not rub, press, or touch any panels with solvents; caustic, corrosive, or abrasive
cleaning or disinfectant compounds; or other materials that could scratch the panels. Do
not use a betadine-based solution; it will cause discoloration.

Do not allow fluids to enter the chassis.

Do not clean the sterilizer case with abrasives. Product damage will result.

Product damage will result if you do not follow these notices when cleaning the
handpiece:
• Do not immerse the handpiece cable electrical connector in liquid.
• Do not use ultrasonic or automated cleaners.
• Do not use chlorinated substances such as bleach solution.
• Do not clean the handpiece with abrasives such as Ajax, Comet, or steel wool.

Product damage will result if you do not follow these notices when cleaning the Tip
Torquing Set.
• Do not use ultrasonic or automatic washers.
• Do not autoclave.
• Do not use chlorinated substances such as bleach solution.
• Do not clean with abrasives such as Ajax, Comet, or steel wool.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 1-3

Warnings, Cautions, and Notices

Troubleshooting
Warning
Electric Shock Hazard Do not touch any exposed wiring or conductive surface while
the system is disassembled and energized. Never wear a grounding strap when working
on an energized system.

Electric Shock Hazard Take appropriate precautions (such as the use of isolated tools
and equipment; use of the “one hand rule,” etc.) when taking measurements or
troubleshooting the system.

Do not activate vibration or the CEM handswitching nosecone while using the tip cleaner.
Tip damage, user injury, electrical shock, or any combination of these effects may occur.

Notice
Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.
When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

Replacement Procedures
Warning
Electric Shock Hazard Only trained biomedical engineers and technicians are
authorized to service the CUSA EXcel system.

Electric Shock Hazard Do not touch any exposed wiring or conductive surface while
the CUSA EXcel system is disassembled and energized. Never wear a grounding strap
when working on an energized CUSA system.

Electric Shock Hazard Take appropriate precautions (such as the use of isolated tools
and equipment; use of the “one hand rule,” etc.) when taking measurements or
troubleshooting the CUSA EXcel system.

High Current Hazard Do not touch the ultrasonics PCB heat sink while the
CUSA EXcel system is energized. The heat sink is isolated from ground, and can deliver
very high current, resulting in injury.

1-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Warnings, Cautions, and Notices

Notice
If you plan to connect the handpiece for activation, ensure that an I.V. set is available to

Service Personnel Safety

supply cooling irrigation solution to the handpiece tip. Otherwise, damage to the tip and/
or handpiece may result.

Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.

When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

When installing a new power supply, use the same screws and washers removed from the
previous power supply. A too-long screw will damage the power supply.

To avoid product damage, do not remove the jumper cable or the connector at J4.

To avoid product damage, remove the ESD wrist strap before connecting cables to the
Machine Control PCB.

To avoid product damage, when handling the suction pump controller card, do not turn
the three white adjustment dials designated as current limit (R13), max speed (R12), and
min speed (R11).

Calibration
Warning
High Current Hazard Do not touch the ultrasonics PCB heat sink while the
CUSA EXcel system is energized. The heat sink is isolated from ground, and can deliver
very high current, resulting in injury.

Repair Policy
Caution
To prevent the ramp from falling and causing injury, be sure to hold the ramp in the up
position while stapling the corrugated tab that secures it to the crate.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 1-5

Notes

1-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 2

Introduction
2

In this section:

• Overview
• Fragmentation
• Irrigation
• Aspiration (Suction)
• Handpieces
• Wide variety of tips.

For Your Information

Caution
Read all warnings, cautions, notices, and instructions provided with the CUSA EXcel
system before servicing it.

Read the instructions, warnings, cautions, and notices provided with the CUSA EXcel
handpieces before servicing them.

This section presents the CUSA EXcel system general information; what it is,
what it does, and (generally) how it works.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 2-1

Overview

Overview
The CUSA EXcel system is an ultrasonic surgical aspirator that allows a surgeon
to remove tissue—selectively and with precise control—from the body. It
performs three functions:
• Fragmentation
• Irrigation
• Aspiration (suction).
All three functions may occur at the same time.
The CUSA EXcel system includes the following components:
• The console:
 The console body houses electronics, pumps, and other parts that make the
system work.
 The control panel allows the user to control the system.
• The handpiece is the handheld surgical device that actually touches the
patient.
• Accessories include a variety of items; for example, manifold tubing, a large
selection of tips, a tip torquing base and torque wrench, and a sterilizer case.

Fragmentation

Tip Motion
Fragmentation occurs when the vibrating tip interacts with tissue. As the tip
begins to move toward tissue, it accelerates, impacts the tissue, then penetrates
the tissue. The acceleration, impact, and penetration produce a combination of
direct mechanical forces and hydrodynamic pressures that burst cells.
For more information on how the handpiece works, refer to Section 6, Principles
of Operation, in this manual.

Cooling
The high frequency vibration generates heat. To reduce the heat, the CUSA EXcel
system includes a closed, recirculating cooling water system. This system pulls
water from a cooling water reservoir, through a tube in the handpiece cable,
through the handpiece, and through a return tube in the handpiece cable to the
cooling water reservoir. Cooling water flows at 35 to 50 cc/min.
As it passes through the handpiece, the water removes heat. Normal handpiece
temperature, in sustained heavy use, remains at about 40° C (104° F).
Use distilled water for the cooling water system because it does not contain
natural minerals, chemical additives, or organic materials that are present in tap
water. Any of these impurities in tap water can cause problems within the cooling
water system.

2-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Irrigation

Irrigation
Sterile irrigation fluid flows from an I.V. set (bottle or bag and I.V. administration
tubing) to a variable speed peristaltic pump:
• The pump moves fluid at 1 to 10 cc/min; default flow is 3 cc/min. Adjustment
buttons (blue up/down arrows on black buttons at the bottom of the irrigation
display column on the control panel) allow you to increase or decrease the
irrigation flow.
• The pump can also accelerate to a Fast Flush speed, pumping at 25 to 30 cc/
min. The Fast Flush pedal on the CUSA EXcel system footswitch activates
the Fast Flush feature.
The pump pushes the fluid through the manifold irrigation tubing to a flue, a
sleeve surrounding the vibrating tip. As the irrigation fluid passes through the
flue, it cools the tip.
When the fluid reaches the distal end of the tip, as much as 99% of it passes
through two pre-aspiration holes in the tip, eliminating fluid pooling on the sterile
field and continually clearing the suction system. The fluid that does not pass

Introduction
through the pre-aspiration holes irrigates the surgical site and suspends
fragmented tissue.
Figure 2-1.
The pre-aspiration holes and threads Pre-aspiration Hole (2)
on tips

Threads

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 2-3

Aspiration (Suction)

Aspiration (Suction)
A vacuum pump in the console body provides up to 660 mm (26 in.) mercury
maximum vacuum at sea level. Adjustment buttons (green up/down arrows on
black buttons at the bottom of the aspiration display column on the control panel)
allow you to increase or decrease the suction from 10 to 100% in 10% increments.
The suction, which produces an air stream moving toward the vacuum pump,
pulls irrigation fluid, fragmented tissue, and other materials through the distal end
of the surgical tip. From the tip, the aspirated materials pass through the manifold
suction tubing into the suction canister. From the suction canister, the air stream
continues to flow through a contamination guard that filters any remaining
particulate matter or moisture, preventing them from entering the vacuum pump.
A suction pinch valve on the front of the console opens when the system is on and
closes to stop suction in the following cases:
• When priming the irrigation system
• When pressing the Fast Flush pedal
• In Run Status, when you release the Vibration pedal. In this case, the pinch
valve closes for about one second, then re-opens.
• In Lap Mode, when you release the Vibration pedal. This suction stoppage
prevents depletion of the pneumoperitoneum.

Caution
To avoid injury to surgical personnel, keep fingers away from the suction pinch valve.

When the System Power Switch is off, the suction pump remains off and the
suction pinch valve remains closed. A button on the front of the suction pinch
valve allows you to open the valve manually.

2-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Handpieces

Handpieces
The CUSA EXcel system includes three handpiece configurations:
• 36 kHz, straight (smaller handpiece, black body, blue connector)
• 23 kHz, straight (gray body, green connector)
• 23 kHz, angled (gray body, green connector)
Figure 2-2.
The three handpieces in the
CUSA EXcel system 23 kHz
Straight

36 kHz
Straight 23 kHz
Angled

Introduction
Wide Variety of Tips
You can use a wide variety of tips with the CUSA EXcel handpieces. Tips vary in
inside diameter, length, and shape (straight or curved). For complete information
on the tips that are available for each handpiece, refer to Appendix A, Tip
Specifications, in the CUSA EXcel Ulstrasonic Surgical Aspirator System User’s
Guide.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 2-5

Notes

2-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 3

Unpacking and Installing

3

the CUSA EXcel Surgical Aspirator

System

In this section:

• The responsibility of the manufacturer

• Unpacking the CUSA EXcel system
• Preparing the CUSA EXcel console for use:
Replacing the power connector.

The Responsibility of the Manufacturer

Integra is responsible for the safety, reliability, and performance of the
CUSA EXcel system only under the following circumstances:
• The person unpacking and installing the unit follows the installation and setup
procedures in this manual.
• Authorized persons perform assembly operations, re-adjustments,
modifications, or repairs.
• The electrical installation of the relevant room complies with local codes and
regulatory requirements.
• You use the equipment in accordance with the Integra instructions for use.
For warranty information, refer to the Preface section of this manual.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 3-1

Unpacking the CUSA EXcel System

Unpacking the CUSA EXcel System

The CUSA EXcel system arrives in a corrugated cardboard crate strapped to a
wood shipping pallet. The corrugated cardboard crate has several components:
• A bottom, larger section contains the CUSA EXcel console and foam packing
cushions.
• A tray, inserted into the top of the crate and supported by the top of the crate
walls, contains the footswitch, contamination guards (2), service manual,
inservice kit, and dust cover.
• A lid covers the crate/tray assembly.

Tools You Will Need

• Utility knife
• Pliers (optional).

Unpacking Procedure
1. Cut the vertical bands on
the shipping crate. Remove
the bands.
Note: Save the box edge
protectors for use when
shipping the system.

2. Lift the lid and the tray from

the crate.

Remove the contents from

the tray, then put the tray
aside.

3-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Unpacking the CUSA EXcel System

3. Cut and remove the

horizontal bands on the
crate.
Note: Save the box edge
protectors for use when
shipping the system.

4. Remove the three plastic clips that hold the crate closed. (If the clip is
especially tight, you may need to use pliers for this step.) Refer to the
following figure.
a. Inside the clip, grasp the two horizontal bars near the locking retainer (on
the right side of the clip).
b. Squeeze the bars toward each other to release them from the locking
retainer.
c. Pull the bars toward you. They should swing outward.

d. Pull the tab at the bottom of the clip to remove the clip from the carton.

the CUSA EXcel Surgical

Unpacking and Installing

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 3-3

Unpacking the CUSA EXcel System

5. Open the crate.

6. Cut the corrugated tab that

secures the ramp to the
carton. Cut as close as
possible to the staples that
hold the tab to the ramp;
you may want to use the tab
again.

Caution
To prevent the ramp from falling and causing injury, be sure to hold the ramp in the up
position while cutting the corrugated tab that secures it to the carton.

7. Lower the ramp.

3-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Unpacking the CUSA EXcel System

8. Lift the corrugated carton

walls off the pallet.

9. Remove the four interlocking foam pieces from the foam cushion around the
console (refer to the following figure).

Remove the right and left foam cushions from the console.

the CUSA EXcel Surgical

Unpacking and Installing

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 3-5

Unpacking the CUSA EXcel System

10. Cut the vertical band on the

clear plastic bag, then
remove the bag from the
console.

11. The rear casters have direction locks that keep the wheels rolling in one
direction; the front casters have brake locks that, when locked, prevent the
wheels from rolling (refer to the following figure).
a. Unlock the front casters by lifting the lock lever upward.

b. Check the rear casters to be sure that, if locked, they will allow the console
to roll toward the ramp.

3-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Unpacking the CUSA EXcel System

12. Roll the console down the

ramp. If the rear casters are
unlocked, be sure that you
do not allow the console to
roll off the side of the ramp.

13. Unlock the control arm

release tab, then remove the
U-shaped foam cushion
from under the control
panel.

Put the box edge protectors and all foam packing materials into the clear plastic
bag for storage. Save all shipping components. You will need them if you need to
return the console to Integra. In fact, it is very important that you use the proper

the CUSA EXcel Surgical

Unpacking and Installing
materials and the proper packing procedures to ship the console. If, in Integra’s
judgement, you fail to use the proper packing procedures or if you use improper
packaging materials to return the console, you may void the warranty on this
system. For more information on packing the console for shipping, refer to
Section 13, Repair Policy, in this guide.
Inspect all contents for damage that may have occurred during shipping. If any
damage has occurred, notify Integra immediately to arrange repair or replacement
of damaged parts. For more information on how to arrange repair or replacement,
refer to Section 13, Repair Policy.
If you have any questions about the contents of these cartons, contact the Integra
Service Center nearest you, or your Integra representative.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 3-7

Preparing the CUSA EXcel Console for Use

Preparing the CUSA EXcel Console for Use

The CUSA EXcel console is shipped in one carton with the following items:
• Footswitch
• In-service kit
• Contamination guards
• User’s guide
• Sterilizable instruction pad: Assembling or Changing Tips on the Sterile Field
• Dust cover.
On the CUSA EXcel console, the following items are provided:
• Standard, three-prong, hospital grade power connector
• 95 to 120V, T10A, time delay fuses.

3-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Preparing the CUSA EXcel Console for Use

Replacing the Power Connector

If your facility’s power receptacles are not compatible with the standard connector
supplied on the CUSA EXcel system, install a different power connector
according to your institution’s policy.
Tools needed:
Slotted blade screwdriver
Procedure:
1. Remove the connector provided with the unit.

2. Attach the new connector, using the following chart:

Table 3-1.
Wire colors Wire Color Prong

green with yellow stripe safety ground

brown line/hot

light blue neutral

Important
Ensure that all electrical The power connector meets all requirements for safe grounding. Do not defeat its
installations comply with local purpose by using extension cords or three-prong-to-two-prong adapters.
codes and regulatory Periodically check the power cord for damaged insulation or connectors. Always
requirements. grasp cords by the connector; do not pull on the cord to remove the connector
from the wall receptacle.
If required by local regulations, connect an equipotential grounding cable to the

the CUSA EXcel Surgical

Unpacking and Installing
equipotential grounding lug on the rear of the CUSA EXcel console.

Notice
To avoid product damage, be sure to insert fuses that are appropriate to the power supply:
• 95 to 120 V, T10A, Time Delay (default)
• 220 to 240 V, T5A, Time Delay

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 3-9

Notes

3-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 4

Console Components
4

In this section:

• Console overview and structural features

• Control panel
• Console body front panel
• Console body side panel
• Console body rear panel
• Symbols on the control panel
• Other features.

For Your Information

This section presents the CUSA EXcel console. It begins with an overview of the
console, then describes each major console subsystem and its components. The
description includes an illustration and a brief sketch of the function each
subsystem or component serves.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-1

Console Overview and Structural Features

Console Overview and Structural Features

This drawing presents the front view of the CUSA EXcel console, with structural
features called out.
Figure 4-1. .
Console structural features

Control panel

I.V. pole

Arm

Housing for
irrigation pump head
and suction pinch
valve

Arm housing

Console body

Cooling water
reservoir

Shelf for suction

canister

Casters

4-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Overview and Structural Features

I.V. Pole
Attached to the right side of the console, it supports the sterile irrigation fluid
container. You can raise or lower the pole; you can also rotate the pole 90° in the
lower position.

Control Panel
Mounted on the arm, the control panel allows the user to control all system
functions. The next page presents control panel details.

Arm and Arm Housing

• Supports the control panel.
• Allows the control panel to pivot 135° to allow users to see the control panel
from most of the operating room.
• Adjustable—lifts to allow a CUSA Electrosurgical Module (CEM) generator
to sit on top of the console body, under the control panel.
The Arm Housing covers the arm attachment along the console body side panel.

Housing for Irrigation Pump Head and Suction Pinch Valve

The prominent black area at the top of the console body includes the following
features:
• The irrigation pump head and irrigation tube pathway (marked with blue
lines)
• The suction pinch valve and suction tube pathway (marked with a light green
line).

Console Body
The main body of the console unit contains the electronics, pumps, and other
working components. A later page presents console body details.

Shelf for Suction Canister

The shelf provides a place to put the hospital provided suction canister.

Casters
Console Components

Unlocked, both front and rear casters roll easily and rotate freely.
• Front casters have brake locks that stop the wheels from rolling.
• Rear casters have direction locks; when locked, casters remain fixed in one
direction.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-3

Control Panel

Control Panel
A slot in the rear of the control panel allows you to store the quick reference
guide.
Figure 4-2.Control panel features

Lap Mode button

Alerts (Red): Lap On indicator

Vibration
Footswitch
Handpiece Test button
Cooling Water Prime button Status button

Displays
(Green LED
columns and values)

4-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Control Panel

Alerts
All alerts are red. When lit, the alerts indicate the following:
Alert Alert: An alert condition exists.

Vibration: Amplitude is out of range.

Footswitch: Connector not plugged into its receptacle on the console rear panel.

Handpiece: Connector not plugged into its receptacle on the console.

Cooling Water: Cooling water problem in the system.

Lap Mode, Prime, Test, and Status Buttons

To activate Lap Mode, Prime, or Status, press the button once; to deactivate the
function, press the button again. To activate Test, press the button once; it
automatically deactivates when the test is complete.
Lap Mode: Selects the Laparoscopic mode of operation—the system provides no
suction to the handpiece until you activate the Vibration pedal.
When you activate the Lap Mode, the system turns on the Lap On indicator light.
Prime: Automatically increases irrigation rate to 25 to 30 cc/min to pump
irrigation fluid to the tip. A timer turns Prime off after approximately one minute.
Test: Verifies the handpiece is working properly by automatically increasing tip
amplitude to 100%, then decreasing it to 0%—all within 4 seconds.
Status: Toggles the status between Standby and Run.

Displays
Green light emitting diodes (LEDs) show user adjusted setpoints for Aspiration,
Irrigation, and Amplitude:
• Not Activated: One LED illuminates to show the setpoint value
• Activated: All LEDs up to and including the setpoint value light up.
For TissueSelect, “Std” (standard) is the first setpoint value; “++++” is the highest
setpoint value.
Console Components

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-5

Control Panel

Figure 4-3.
Control panel features (continued)

Status indicators:
Run (Green)
Standby (Amber)
Wait/Cooling Water (Amber)

Setpoint adjustment buttons

(Up/Down Arrows):
Aspiration (Green)
Irrigation (Blue)
Amplitude (Orange)
TissueSelect (Yellow)

4-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Control Panel

Status Indicators
To change from Standby to Run, or from Run to Standby, press the Status button.
Run: A green LED illuminates to show when the system is in Run status.

Standby: An amber LED illuminates to show when the system is in Standby

status.
Wait: An amber LED illuminates in the following circumstances:
• Flashing – Immediately after turning on ( | ) the System Power Switch, the
system automatically fills the handpiece with cooling water
• Flashing – Immediately after turning off ( ) the System Power Switch, the
system automatically drains handpiece cooling water
• Continuous – When any alarm condition exists
• Continuous – When in Prime mode.
Cooling Water: An amber LED illuminates in the following circumstances:
• Immediately after turning on ( | ) the System Power Switch, the system
automatically fills the handpiece with cooling water.
• Immediately after turning off ( ) the System Power Switch, the system
automatically drains handpiece cooling water.

Setpoint Adjustment Buttons

Marked with Up/Down arrows, these buttons allow you to adjust the setpoint
values:
Aspiration (Suction): 10 increments; linear scale of 10 to 100%; default value is
100%.
Irrigation: 10 increments; linear scale of 1 to 10 cc/min; default value is 3þcc/min.

Amplitude: 10 increments; linear scale of 10 to 100%; default value is 10%.

TISSUESelect: 5 increments from std (standard operation) to ++++. TissueSelect

interrupts continuous vibration for specified times:

Setting On-Time Off-Time

Std continuous 0 ms*

+ 40 ms 10 ms
++ 30 ms 10 ms
+++ 20 ms 10 ms
++++ 10 ms 10 ms
Console Components

*1 ms = 1 millisecond = 1 one-thousandth of a second

Push a button once for a single change in setpoint value. Holding down the button
changes a setpoint value by only one setting (you get no additional setpoint value
changes by holding down the button).

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-7

Console Body Front Panel

Console Body Front Panel

Figure 4-4.
Console body—front view

Handpiece
connector
receptacle

Suction pinch valve

Irrigation pump head

System power
switch

Contamination guard

Retaining bail for

suction canister

Handpiece Connector Receptacle

This receptacle allows you to connect the handpiece to the console. It is on the left
side (as you face the front panel) of the console.

4-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Body Front Panel

Suction Pinch Valve

Caution
To avoid injury to surgical personnel, keep fingers away from the suction pinch valve.

When closed, the valve pinches off suction flow to the handpiece:
• When priming the irrigation system
• When pressing the Fast Flush pedal
• In Run Status, when you release the Vibration pedal. In this case, the pinch
valve closes for about one second, then re-opens.
• In Lap Mode, when you release the Vibration pedal. This suction stoppage
prevents depletion of the pneumoperitoneum.
The suction pinch valve default position (system off) is closed. If the System has
been running, when you turn the Power Switch off, the suction pinch valve
remains open until the drain cycle has finished, then closes. A button on the front
of the suction pinch valve allows you to open the valve manually.

System Power Switch

Turning this switch on ( | ) activates all system components and begins filling the
handpiece with cooling water. Turning this switch off ( ) activates the cooling
water drain cycle. When the system has drained water from the cooling water
system (about one minute), it automatically deactivates all system components.

Irrigation Pump Head

A latch rotates from right to left to open the pump head, and from left to right to
close. When open, it allows you to place irrigation tubing into the peristaltic
pump. Closed, the pump head holds irrigation tubing against the peristaltic pump.

Contamination Guard
Important
The guard is hydrophilic and Protects the vacuum pump from particulate matter and moisture in the suction
becomes blocked when wet. stream. It is necessary to replace the contamination guard every six months or
when it becomes blocked.

Retaining Bail for Suction Canister

The bail holds the suction canister in place on the shelf.
Console Components

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-9

Console Body Side Panel

Console Body Side Panel

Figure 4-5.
Console body—view of the right side

I.V. pole

Control panel

Rotation lock handle Arm

I.V. pole release

Housing (black) for button
irrigation pump head and
suction pinch valve
Arm housing

Arm release tab

Cooling water reservoir

release button

Cooling water reservoir

4-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Body Side Panel

Control Panel
Refer to pages 4-4 through 4-7.

Rotation Lock Handle

This handle releases the control panel, allowing it to swivel and lock into one of
four positions:
• Straight forward
• 45° right
• 45° left
• 90° left.

Housing for Irrigation Pump Head and Suction Pinch Valve

Refer to pages 4-2 and 4-3.

I.V. Pole
Refer to pages 4-2 and 4-3.

I.V. Pole Release Button

This button releases the I.V. pole, allowing you to raise it or lower it.

Arm and Arm Housing

Refer to pages 4-2 and 4-3.

Arm Release Tab

This tab releases a lock that holds the arm in three vertical positions.

Cooling Water Reservoir

This container holds cooling water to be continuously circulated through the
handpiece. The reservoir holds 1000 cc of distilled water.
A clear panel, which runs vertically up the side, allows you to see the water level
inside the reservoir.
Console Components

The reservoir also includes fittings that snap into receptacles inside the Arm
Housing on the console side panel. The fittings and receptacles automatically
connect the reservoir to the cooling water system.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-11

Console Body Rear Panel

Console Body Rear Panel

Figure 4-6.
Console—rear view

Speaker

Volume control

Footswitch
connector receptacle

AC main switch

Fuses (2)

Footswitch
Integra LifeSciences (Ireland) Limited
IDA Business and Technology Park
Stragh, Tullamore, County Offaly, Ireland

4-12 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Body Rear Panel

Speaker
The speaker sounds an audible tone when an alert condition exists and when
vibration is active.

Volume Control
This potentiometer allows you to adjust the active vibration audible tone. You
cannot adjust the alert tone.

Footswitch Connector Receptacle

This receptacle allows you to connect the footswitch to the console.

AC Main Switch
This switch controls the flow of AC power to the CUSA EXcel system. It does not
activate the system; instead, it allows power to flow from the wall receptacle to
the System Power Switch.
Once the AC Main Switch is On ( | ), you can leave it On even when you unplug
the system from the wall receptacle.

Fuses
These protect the system from electrical overloads. Refer to Section 11,
Replacement Procedures for instructions on replacing the fuses.

Footswitch
The footswitch has two pedals in a base, and allows you to activate two functions:
• Ultrasonics/vibration: Right pedal (orange), when pressed, activates vibration at
the tip. When you release the pedal, vibration stops.
• Fast Flush: Left pedal (blue), when pressed, increases the irrigation rate to
25 to 30 cc/min. It also closes the Suction Pinch Valve, stopping suction. When
you release the pedal, irrigation returns to the setpoint value and suction
resumes.
Console Components

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-13

Console Body Rear Panel

Figure 4-7.
Console—rear view (continued)

Storage compartment

Cord wraps

Integra LifeSciences (Ireland) Limited

IDA Business and Technology Park
Stragh, Tullamore, County Offaly, Ireland

Serial number, model number, and Equipotential AC power cord

agency approval label grounding lug

4-14 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Body Rear Panel

AC Power Cord
Connects power to the system from the wall receptacle.

Equipotential Grounding Lug

If you are using a CEM generator, the grounding lug allows you to connect
ground from the CEM generator to the CUSA EXcel console.

Label
The label shows the console serial number, model number, and agency approvals.

Cord Wraps
The unit has two cord wraps. These are brackets that allow you to hang two coils
of cord on the back of the unit, keeping the cords safely out of the way.

Storage Compartment
This area, which includes one interior shelf, allows you to store a footswitch and a
manual.

Console Components

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-15

Symbols on the Control Panel

Symbols on the Control Panel

Some symbols appear on the control panel. The following list shows each symbol
and its meaning.
Figure 4-8.
Control panel symbols

Vibration amplitude out of range

Footswitch failure or footswitch not connected

Handpiece failure or handpiece not connected

Cooling water:
Alert (red, left side of the control panel)—failure

Wait (amber, right side of the control panel)—system is circulating cooling water
through the handpiece or draining the handpiece

On On/selected

Lap Laparoscopic mode

4-16 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Other Features

Other Features
The CUSA EXcel console offers other convenient features:
• Easy-to-fill cooling water reservoir
• Adjustable arm height
• Rotating control panel
• Adjustable audible tone
• Adjustable I.V. pole.
The next portion of this section tells you how to use these features.

Reservoir release button Filling the Cooling Water Reservoir

To remove the cooling water reservoir,
1. Press the cooling water reservoir release button (just above the reservoir) on
the arm housing to release the fittings inside the housing.
2. Slide the reservoir toward the rear of the console.
To fill the reservoir,
1. Gently open the rubber lid on the reservoir top.

2. Fill the reservoir with 1000 cc distilled water (to the line).

3. Close the rubber lid on the reservoir top.

To attach the cooling water reservoir, slide it into the slot on the console side
Limited
(Ireland) Park
Ireland
Offaly,
Technology
LifeSciences
and
County
Integra
Business
IDA Tullamore,
Stragh,

panel until it snaps into place.

Reservoir
Raising/Lowering the Arm
It is possible to raise the arm that supports the control panel to allow a CEM unit
to sit on top of the CUSA EXcel console or to see the control panel more easily
over obstacles. A locking mechanism holds the arm at one of three positions:
normal (lowest position), 7.6 cm (3 in.) above normal, and 15.2 cm (6 in.) above
Arm release tab normal.
To adjust the arm position, follow these steps:
1. With one hand, press the release tab (rectangular) on the arm housing to
disengage the lock. Once you have disengaged the lock and started to move
the arm, it is not necessary to continue pressing the button.
2. With the other hand, grasp the arm and push gently up or down. A
counterweight balances the arm, making it easy to raise or lower.
Console Components

3. Continue to move the arm up or down until it reaches the next position at
which the lock engages. You will feel and hear the arm click into place in the
locked position.
Integra
IDA
Business

Stragh,
and
Technology
LifeSciences

Tullamore,
County
Offaly,
Limited
(Ireland) Park
Ireland

4. If you want to move the arm to another position, press the release tab again
and continue to push gently on the arm.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-17

Other Features

Rotating the Control Panel

The control panel rotates and locks into one of four positions:
• Straight forward
• 45° right
• 45° left
• 90° left.
To rotate the control panel from one position to another, do this:
1. Grasp the release handle located under the control panel, and pull the handle
forward.
2. While holding the handle in this position, rotate the control panel out of its
previous position, then release the handle.
3. Continue to rotate the control panel. At its next locking position, it will
automatically lock into place.

Adjusting the Tone Volume

The CUSA EXcel system includes an audible tone that sounds in two
circumstances:
• When you press the Ultrasonics pedal on the footswitch to activate tip
vibration
• When any alert activates.

Ultrasonics Tone
Volume Control
This tone (constant) sounds when you press the Ultrasonics pedal on the
footswitch. You can adjust its volume.
To adjust tone volume, rotate the stem on the volume control potentiometer
located just above and to the right of the footswitch connector receptacle on the
console rear panel:
• Volume up—clockwise
• Volume down—counterclockwise
Note: At its lowest volume, the ultrasonics tone is barely audible. You cannot turn
off the ultrasonics tone.
Limited
(Ireland) Park
Ireland
Offaly,
Technology
LifeSciences
and
County
Integra
Business
IDA Tullamore,
Stragh,

Alert Tone
This tone (on/off) sounds when an alert activates. You cannot adjust the volume
of the alert tone.

4-18 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Other Features

Adjusting the I.V. Pole

The I.V. pole, located at the top rear of the arm housing, adjusts to two locking
positions: down or up. A spring-loaded locking pin slides into a recessed area on
the pole to serve as a lock on the pole’s up/down motion. A button, located just
under the opening in which the pole rests in the arm housing, releases the locking
pin.
When in the down position, the pole also rotates approximately 90° allowing two
positions:
• Parallel to the console side
(position A)
• At a right angle to the side
(position B).
When in the up position, the
pole does not rotate. It remains
at position B. Notice that the
I.V. bag does not hang over the
console.
Position A
When a CUSA EXcel unit is Position B
shipped, the I.V. pole is in
position A.

Raise the Pole

To raise the I.V. pole, do this:

Important
Do not try to raise the pole from 1. Grasp the pole and rotate it to position B.
Position A. Do not try to rotate the
pole when it is in the upper 2. With one hand, hold the pole; with the other hand, press the button to release
position. the locking pin.
3. Raise the pole. As the pole clears its lower locking position, release the
button.
4. Continue to move the pole upward until it locks into position.

Lower the Pole

To lower the I.V. pole, do this:
1. With one hand, hold the pole; with the other hand, press the button to release
the locking pin.
2. Gently lower the pole. As the pole clears its upper locking position, release the
button.
Console Components

3. Continue to move the pole downward until it locks into position.

4. After the pole has locked into its lower position, you can rotate it to position
A.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 4-19

Notes

4-20 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 5

Technical Specifications
5

In this section:

• Console dimensions
• Console subsystems
• Electrical requirements
• Environment
• Standards and IEC classifications
• Handpieces
• Tip specifications.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-1

Console Dimensions

Console Dimensions

CUSA EXcel Console

Height 1.32 m (52 in.)

Width 55.88 cm (22 in.)

Depth 71.12 cm (28 in.)

Weight 95.3 kg (210 lb.)

Footswitch

Height 5.08 cm (2 in.)

Width 30.48 cm (12 in.)

Cable length 4.575 m (15 ft)

Console Subsystems

Ultrasonic

Nominal Frequencies 23 kHz

35.75 kHz

Maximum Tip Up to 355 microns for straight handpiece

Amplitudes (23 kHz)
Up to 183 microns for angled handpiece

Maximum Tip Amplitude Up to 210 microns

(36 kHz)

5-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Electrical Requirements

Fluidic System

Technical Specifications
Cooling System Cooling water flow is 35–50 cc/min

Irrigation Rate The irrigation rate display shows digits 1–10

The irrigation rate is approximately
1–10 cc/min, normal; 25–30 cc/min, Fast Flush

Suction System Up to 660 mm (26 inches) mercury at the pump

intake at sea level
The suction level will be lower at higher altitudes

Electrical Requirements

Input Power Source

Power Rating The CUSA EXcel system operates on one of the following
voltage ranges:
95 – 120 Volt (default)
220 – 240 Volt

Frequencies 60 Hz ± 2 Hz
50 Hz ± 2 Hz

Line fusing resides in fuse receptacles on the rear panel. The fuse values for 95–
120 volt operation are T10A; for 220–240 Volt operation, T5A. Refer to Section
11, Replacement Procedures, for instructions on replacing the fuses.

Power Cords

Cord UL listed 3-conductor

Connector Hospital grade, three-prong, 95–120 Vac connector

If a facility intends to use the CUSA EXcel system in an operating room with
another type of receptacle, the facility is responsible for replacing the connector
on the power cord. The replacement connector must be properly grounded.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-3

Environment

Warning
Explosion Hazard Do not use the CUSA EXcel system in the presence of flammable
anesthetics or any potentially explosive or flammable atmosphere.

Low Frequency Leakage

Enclosure leakage <300 µA

current

Patient leakage current <100 µA

Duty Cycle
Under maximum loading conditions, the CUSA EXcel console is suitable for
ultrasonics activation times of 10 minutes on, 5 minutes off.

Environment
Operating temperature 10° C (50° F) to 40° C (104° F)
range

Operating humidity 15 to 80%, relative humidity, non-condensing

range

Operating atmospheric 70 kPa to 106 kPa (10.15 to 15.38 psi)

pressure range

Storage and shipping -34° C (-29° F) to 65° C (149° F)

temperature

Storage and shipping 25 to 85% relative humidity, non-condensing

humidity

The system requires a minimum of one hour exposure at its operating temperature
range before you use it.

5-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Standards and IEC Classifications

Standards and IEC Classifications

Technical Specifications
ATTENTION
Consult accompanying documents.

DANGER
Explosion risk if used with flammable anesthetics.

EQUIPOTENTIAL GROUND
Connect equipotential ground cable here.

POWER ON
Applies power at the AC Main Switch and the System Power Switch.

POWER OFF
Removes power at the AC Main Switch.

PROTECTIVE EARTH GROUND

CAUTION
To reduce the risk of electric shock, do not remove the cover. Refer servicing to
qualified service personnel.

Classified with respect to electrical shock, fire, mechanical, and other specified
hazards only in accordance with UL60601-1 and CAN/CSA C22.2 No. 601.1.

Class I Equipment (IEC 601-1)

Accessible conductive parts cannot become live in the event of a basic insulation
failure because of the way in which they are connected to the protective earth
conductor.

Type BF Applied Part Equipment (IEC 601-1)

The CUSA EXcel console provides a high degree of protection against electric
shock, particularly regarding allowable leakage currents. It is type BF isolated
(floating) output.

IPX - 8 (IEC 529, UL60601) Footswitch

The CUSA EXcel footswitch includes protection against the effects of continuous
immersion in water.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-5

Standards and IEC Classifications

Electromagnetic Interference
The CUSA EXcel console minimizes electromagnetic interference to other
equipment used in the operating room. The system complies with the
requirements of IEC 801.
Note that other devices in the operating room may generate electromagnetic
interference. Use caution in locating equipment within the room to reduce the
electromagnetic interference.

System Power Off / Standby

When you turn off the System Power Switch, the system automatically drains
water from the cooling water system and deactivates other system components. It
also maintains power to the logic circuitry to monitor the System Power Switch
position.

Pinch Point in the Suction Pinch Valve

The suction pinch valve may pose a hazard during normal use.

Caution
To avoid injury to surgical personnel, keep fingers away from the suction pinch valve
while powering the unit on or off, activating vibration, or using fast flush.

Fuse Replacement
Indicates the location of the fuse holder on the rear panel.

Footswitch Symbols
The following symbols appear on the CUSA EXcel footswitch:
Activate vibration.

Activate fast flush (irrigation).

5-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Standards and IEC Classifications

Voluntary Standards
The CUSA EXcel system meets the following standards:

Technical Specifications
• UL 60601-1

• cUL/CSA Test requirements: (CSA 22.2, No. 601.1)

• IEC 601-1 Medical electrical equipment: General requirements for safety
• IEC 60601-1-2 Second edition
• CISPR11 Class A electromagnetic compatibility for industrial-process
measurement and control equipment: Emissions requirements
• ISTA Pre-Shipment Test Procedures, Project 2A.

Statutory and Regulatory Requirements

Class II Medical Device (Special Controls)

EMC Compatibility
Notice
The CUSA EXcel should not be used adjacent to or stacked with equipment other than
specified in the CUSA EXcel User Guide and Service Manual. If adjacent or stacked use
is necessary, the CUSA EXcel should be observed to verify normal operation in the
configuration in which it will be used.

The electrical surgical generator used with the CUSA EXcel intentionally applies RF
energy for diagnosis or treatment during activation. Observe other electronic medical
equipment in the vicinity during the CUSA EXcel activation for any possible adverse
electromagnetic effects. Ensure adequate separation of electronic medical equipment
based on observed reactions.

The use of accessories, other than specified in the CUSA EXcel User Guide and Service
Manual, may result in increased emissions or decreased immunity of the CUSA EXcel.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-7

Standards and IEC Classifications

Guidance and manufacturer's declaration - electromagnetic emissions

The CUSA EXcel is intended for use in the electromagnetic environment specified below. The customer or the user of the CUSA
EXcel should assure that it is used in such an environment.

Emissions test Compliance Electromagnetic environment -

guidance

RF emissions Group 1 The CUSA EXceI uses RF energy only

CISPR 11 for its internal function. Therefore, its RF
emissions are very low and are not likely
to cause any interference in nearby
electronic equipment.

RF emissions Class A The CUSA EXcel is suitable for use in all

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

5-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Standards and IEC Classifications

Guidance and manufacturer's declaration - electromagnetic immunity

Technical Specifications
The CUSA EXcel is intended for use in the electromagnetic environment specified below. The customer or the user of the CUSA
EXcel should assure that it is used in such an environment.

Immunity test IEC 60601 test level Compliance level Electromagnetic

environment - guidance

Electrostatic discharge (ESD) +/-6 kV contact +/-6 kV contact Floors should be wood,
IEC 61000-4-2 concrete or ceramic tile. If
+/-8 kV air +/-8 kV air
floors are covered with
synthetic material, the
relative humidity should be
at least 30%.

Electrical fast transient/burst +/-2 kV for power supply lines +/-2 kV for power supply Mains power quality
IEC 61000-4-4 lines should be that of a typical
+/-1 kV for input/output lines
commercial or hospital
+/-1 kV for input/output lines
environment.

Surge +/-1 kV differential mode +/-1 kV differential mode Mains power quality
IEC 61000-4-5 should be that of a typical
+/-2 kV common mode +/-2 kV common mode
commercial or hospital
environment.

Voltage dips, short <5% Ut (>95% dip in Ut) <5% Ut (>95% dip in Ut) Mains power quality
interruptions and voltage for 0,5 cycle for 0,5 cycle should be that of a typical
variations on power supply commercial or hospital
40% Ut (>60% dip in Ut) 40% Ut (>60% dip in Ut)
input lines environment. If the user of
for 5 cycles for 5 cycles
IEC 61000-4-11 the CUSA EXcel requires
70% Ut (>30% dip in Ut) 70% Ut (>30% dip in Ut) continued operation during
for 25 cycles for 25 cycles power mains interruptions,
it is recommended that the
<5% Ut (>95% dip in Ut) <5% Ut (>95% dip in Ut) CUSA EXcel be powered
for 5 sec for 5 sec from an uninterruptible
power supply or a battery.

Power frequency (50/60 Hz) 3 A/m 3 A/m Power frequency magnetic

magnetic field fields should be at levels
IEC 61000-4-8 characteristic of a typical
location in a typical
commercial or hospital
environment.

NOTE Ut is the a.c. mains voltage prior to the application of the test level.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-9

Standards and IEC Classifications

Guidance and manufacturer's declaration - electromagnetic immunity

The CUSA EXcel is intended for use in the electromagnetic environment specified below. The customer or the user of the CUSA
EXcel should assure that it is used in such an environment.

Immunity test IEC 60601 test level Compliance level Electromagnetic environment -
guidance

Portable and mobile RF

communications equipment should be
used no closer to any part of the CUSA
EXcel, including cables, than the
recommended separation distance
calculated from the equation applicable
to the frequency of the transmitter.
Recommended separation distance

Conducted RF 3 Vrms 3V d=1/2ÐP

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

NOTE 1 At a80MHz and 800MHz, the higher frequency range applies.

NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection
from structures, objects and people.

a. Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless) telephones and land mobile radios,
amateur radio, AM and FM radio broadcast and TV broadcast cannot be predicted theoretically with accuracy. To assess the
electromagnetic environment due to fixed RF transmitters, an electromagnetic site survey should be considered. If the measured
field strength in the location in which the CUSA EXcel is used exceeds the applicable RF compliance level above, the CUSA
EXcel should be observed to verify normal operation. If abnormal performance is observed, additional measures may be
necessary, such as reorienting or relocating the CUSA EXcel.
b. Over the frequency range 150kHz to 80MHz, field strengths should be less than 3 V/m.

5-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Standards and IEC Classifications

Recommended separation distances between portable and mobile RF communication equipment and the CUSA EXcel

The CUSA EXcel is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The

Technical Specifications
Customer or the user of the CUSA EXcel can help prevent electromagnetic interferences by maintaining a minimum distance
between portable and mobile RF communications equipment (transmitters) and the CUSA EXcel as recommended below,
according to the maximum output power of the communications equipment.

Separation distance according to frequency of transmitter (m)

Rated maximum output power 150 kHz to 80MHz 80MHz to 800MHz 800MHz to 2.5GHz
of transmitter (W) d=1.2ÐP d=0.5ÐP d=ÐP

0.01 .12 m 0.05 m 0.1 m

0.1 .38 m 0.16 m 0.32 m

1 1.2 m 0.5 m 1m

10 3.8 m 1.6 m 3.2 m

100 12 m 5m 10 m

For transmitters rated at a maximum output power not listed above, the recommended separation distance d in meters (m) can be
estimated using the equation applicable to the frequency of the transmitter, where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter manufacturer.

NOTE 1 At a80MHz and 800MHz, the separation distance for the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection
from structures, objects and people.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-11

Handpieces

Handpieces

Nominal Frequencies

23 kHz Straight 23 kHz

23 kHz Angled 23 kHz

36 kHz Straight 35.75 kHz

Dimensions

23 kHz Straight
Length 22.2 cm (8.74 in.)

Diameter 20.8 mm (0.82 in.)

23 kHz Angled
Length 22.2 cm (8.74 in.)

Diameter 20.8 mm (0.82 in.)

36 kHz Straight
Length 13.9 cm (5.47 in.)

Diameter 16.4 mm (0.65 in.)

Tip Specifications
The table on page 5-9 shows specifications for tips that attach to the 23 kHz
handpiece.
The table on page 5-10 shows specifications for tips that attach to the 36 kHz
handpiece.

5-12 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Tip Specifications

23 kHz
Table 5-1.

Technical Specifications
Tip Specifications—23 kHz

Length cm ID mm OD mm Amplitude (peak to peak) µm Weight

Tip [in.] [in.] [in.] [in.] (g)

Standard Tip 7.98 [3.140] 1.98 [0.078] 2.54 [0.100] Straight Handpiece: 3.54
287 to 355 [0.0113 to 0.0140]
Angled Handpiece:
112 to 163 [0.0044 to 0.0064]

MicroTip 9.22 [3.630] 1.57 [0.062] 1.93 [0.076] Straight Handpiece: 3.99
279 to 355 [0.0110 to 0.0140]
Angled Handpiece:
127 to 183 [0.005 to 0.0072]

Straight Extended 18.38 [7.238] 1.98 [0.078] 2.54 [0.100] Straight Handpiece: 16.15
Standard Tip 287 to 355 [0.0113 to 0.0140]
Angled Handpiece:
112 to 163 [0.0044 to 0.0064]

Curved Extended 18.38 [7.238] 1.98 [0.078] 2.54 [0.100] Straight Handpiece: 16.15
Standard Tip 287 to 355 [0.0113 to 0.0140]
Not compatible with angled
handpiece

MacroTip 7.95 [3.130] 2.64 [0.104] 3.18 [0.125] Straight Handpiece: 3.84
254 to 307 [0.0100 to 0.0121]
Angled Handpiece:
102 to 142 [0.0040 to 0.0056]

Laparoscopic Tip 30.14 [11.865] 1.98 [0.078] 2.54 [0.100] Straight Handpiece: 32.13
178 to 229 [0.007 to 0.009]
Not compatible with angled
handpiece

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 5-13

Tip Specifications

36 kHz
Table 5-2.
Tip Specifications—36 kHz

Length cm ID mm OD mm Amplitude (peak to peak) µm Weight

Tip [in.] [in.] [in.] [in.] (g)

PrecisionTip 5.64 [2.221] 1.14 [0.045] 1.45 [0.057] 191 to 210 [0.0075 to 0.0083] 1.37

Straight Extended 12.51 [4.924] 1.14 [0.045] 1.45 [0.057] 191 to 210 [0.0075 to 0.0083] 7.86
PrecisionTip

Curved Extended 12.51 [4.924] 1.14 [0.045] 1.45 [0.057] 191 to 210 [0.0075 to 0.0083] 7.86
PrecisionTip

MicroTip 5.28 [2.080] 1.57 [0.062] 1.93 [0.076] 175 to 193 [0.0069 to 0.0076] 1.30

Straight Extended 12.15 [4.783] 1.57 [0.062] 1.93 [0.076] 175 to 193 [0.0069 to 0.0076] 7.50
MicroTip

Curved Extended 12.15 [4.783] 1.57 [0.062] 1.93 [0.076] 175 to 193 [0.0069 to 0.0076] 7.50
MicroTip

Standard Tip 4.57 [1.800] 1.98 [0.078] 2.54 [0.100] 137 to 155 [0.0054 to 0.0061] 1.31

Straight Extended 11.44 [4.504] 1.98 [0.078] 2.54 [0.100] 137 to 155 [0.0054 to 0.0061] 7.48
Standard Tip

Curved Extended 11.44 [4.504] 1.98 [0.078] 2.54 [0.100] 137 to 155 [0.0054 to 0.0061] 7.48
Standard Tip

5-14 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 6

Principles of Operation
6

In this section:

• How the handpiece works

Electromechanical operation
Fragmentation
Cooling
• How the TissueSelect feature works
Inherent tissue selectivity
Increasing tissue selectivity
TissueSelect reduces reserve power to the tip
Benefits of TissueSelect
A common misunderstanding of the amplitude setting.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 6-1

How the Handpiece Works

How the Handpiece Works

The handpiece converts electrical energy to mechanical energy, resulting in
vibration in the handpiece, and from the handpiece through a connecting body to
a hollow titanium tip. When it contacts tissue, the tip fragments the tissue. The
conversion of electrical energy to mechanical energy generates heat; a cooling
system reduces the heat in the handpiece.
Figure 6-1.
The handpiece components

Irrigation
solution
Irrigation
connection

Suction Handpiece clip

Transducer
Handpiece
cable
Cooling
water out Cooling
water in Retainer
Handpiece Clip
housing

Electric coil
Vibrating tip

Flue

Electromechanical Operation
The CUSA EXcel console provides alternating current at 23 or 35.75 thousand
cycles per second (kHz) to the handpiece (the frequency depends on which
handpiece you connect to the console). In the handpiece, the current passes
through a coil, which induces a magnetic field. The magnetic field excites a
transducer of nickel alloy laminations, resulting in an oscillating motion in the
transducer laminated structure—vibration—along its long axis. The transducer
vibrates at 23 or 35.75 kHz.

6-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 How the Handpiece Works

The transducer transmits vibrations through a metal connecting body to an

attached surgical tip. The frequency of vibration remains the same at the tip (23 or
35.75 kHz), but the amount of motion (amplitude) at the tip varies: Lower
frequency, greater amplitude; higher frequency, smaller amplitude.
Amplitude also varies with the transducer/connecting body/tip configuration:
Handpiece angle reduces tip amplitude.
A small feedback coil in the handpiece generates a signal (voltage) that is
proportional to the amount of motion in the transducer. The console uses the
feedback signal to adjust the power sent to the handpiece. For example, if the
transducer motion decreases due to resistance from tissue, the feedback signal
decreases. As the feedback signal decreases, the console increases power to the
handpiece to return transducer motion to normal value.

Fragmentation

Principles of Operation
Fragmentation occurs when the vibrating tip interacts with tissue. As the tip
begins to move toward tissue, it accelerates, impacts the tissue, then penetrates the
tissue. The acceleration, impact, and penetration produce a combination of direct
mechanical forces and hydrodynamic pressures that burst cells.

Cooling
The high frequency vibration generates heat. To reduce the heat, the CUSA EXcel
system includes a closed, recirculating cooling water system. This system pulls
water from a cooling water reservoir, through a tube in the handpiece cable,
through the handpiece, and through a return tube in the handpiece cable to the
cooling water reservoir. Cooling water flows at 35 to 50 cc/min.
As it passes through the handpiece, the water removes heat. Normal handpiece
temperature, in sustained heavy use, remains at about 40° C (104° F).
Use distilled water for the cooling water system because it does not contain
natural minerals, chemical additives, or organic materials that are present in tap
water. Any of these impurities in tap water can cause problems within the cooling
water system.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 6-3

How the TissueSelect Feature Works

How the TissueSelect Feature Works

TissueSelect is a feature that allows the surgeon to maintain a high fragmentation
rate while increasing selectivity and control at the surgical site.
Fragmentation occurs when the vibrating tip interacts with tissue. As the tip
begins to move toward tissue, it accelerates, then impacts and penetrates the
tissue. The acceleration, impact, and penetration produce a combination of direct
mechanical forces and hydrodynamic pressures that burst cells.
Several variables affect the fragmentation rate. Most are functions of the
CUSA EXcel system:
• Stroke (tip excursion—the total distance the tip travels)—greater stroke
results in greater fragmentation rate.
• Suction
 Suction has two functions:
(1) It draws tissue toward the vibrating tip and creates a tip/tissue
coupling effect.
(2) It removes irrigation and fragmentation debris from the surgical site.
 If there is no suction or low suction, coupling does not occur, resulting in
minimal tissue fragmentation and increased tissue temperature.
• Tip acceleration—produces the peak forces and pressures that fragment
tissue.
• Tip cross-sectional area at the tip-tissue contact site.
These variables also affect tactile feedback—what the surgeon’s hand feels when
using the handpiece.

6-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 How the TissueSelect Feature Works

Inherent Tissue Selectivity

With all other variables remaining constant, the tip does not fragment all tissue
types equally effectively. Another variable—tissue strength—affects
fragmentation rate.
• “Low strength” tissues (easiest to fragment) include the brain and most
organs. Older, partially dried tissues are also easy to fragment. “High
strength” tissues (most difficult to fragment) include vessel structures,
tendons, ligaments, healthy skin, and organ capsules.
• Strength increases and fragmentation rate decreases with tissue containing
greater collagen, elastin, or both (collagen type, quantity, and organization
affect cell structural quality).
Tissue strength also affects tactile feedback. The surgeon can feel a difference
between the tip contacting low-strength tissue and the tip contacting high strength
tissue. As the tip works through low strength tissue, the surgeon feels a smooth,
rhythmic sensation from the handpiece. When the tip contacts high strength

Principles of Operation
tissue, it feels like it is “bouncing off” the tissue. Also, the smooth, rhythmic
sensation becomes rougher. To avoid fragmenting high strength tissue, the
surgeon must apply less pressure to the tip or move the tip away from the tissue.
To continue fragmenting high strength tissue, the surgeon must manually apply
more pressure.
However, the surgeon may not always recognize the difference in tactile feedback
quickly enough, or react quickly enough, to avoid damaging vital structures,
particularly those with a tissue strength similar to the tissue being fragmented.
The CUSA EXcel system can help the surgeon when dissecting near vital
structures.

Increasing Tissue Selectivity

It is possible to increase the inherent selectivity resulting from variations in tissue
strength while maintaining stroke amplitude, tip acceleration, and suction. This
increase in selectivity results from reducing the reserve power that drives the tip.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 6-5

How the TissueSelect Feature Works

The CUSA EXcel ultrasonic generator delivers electrical power (which is directly
related to the acoustic power present at the tip, which results in fragmentation) to
the handpiece. You can think of the power delivered to the handpiece in three
terms:
• Initial power—the quantity of power necessary to drive the tip vibration in air;
that is, no contact with tissue.
• Reserve power—the power necessary to maintain tip vibration under load (in
contact with tissue). When the tip encounters load, a feedback loop in the
system senses the additional load and provides additional reserve power to
maintain tip vibration.
• Maximum power—the greatest power output the console can provide.
Maximum power is the sum of initial and reserve power.

TissueSelect Reduces Reserve Power to the Tip

The TissueSelect feature increases both the inherent selectivity and the tactile
feedback of the vibrating tip by reducing the reserve power the ultrasonic
generator provides to the handpiece.
How does it reduce the power? One of the variables of power consumption is
time: reduce time, reduce power consumed. To reduce power consumption, the
ultrasonic generator reduces the time that it provides electrical power.
Specifically, rather than providing power continuously, it provides power at
measured on-off intervals:
Table 6-1.
On-off intervals for TissueSelect
Setting On-Time Off-Time

Std continuous 0 ms*

+ 40 ms 10 ms

++ 30 ms 10 ms

+++ 20 ms 10 ms

++++ 10 ms 10 ms

*1 ms = 1 millisecond = 1 one-thousandth of a second

6-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 How the TissueSelect Feature Works

Power decreases as on-time decreases.

Figure 6-2.
Reserve power vs. TissueSelect
settings

TissueSelect Setting (100% Amplitude)

Principles of Operation
At a 100% Amplitude setting, as TissueSelect settings increase, on-time and
reserve power decrease.
The TissueSelect feature offers five settings from “std” (standard—least selective)
to ++++ (most selective). The std setting selects continuous power, resulting in
ample reserve power. The ++++ setting selects the least power.

Standard Operation
Power is continuous. The ultrasonic generator provides ample reserve power;
more than is necessary to drive stroke amplitude under heavy load:
• The tip fragments “softer” tissue easily.
• The tip fragments “stronger” tissue, but with more difficulty (slower, requires
more surgeon pressure).

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 6-7

How the TissueSelect Feature Works

TissueSelect Operation
Power is interrupted. The ultrasonic generator provides less reserve power to the
handpiece:
• The tip still fragments “softer” tissue easily.
• But, when it encounters “stronger” tissue, the power the tip receives is no
longer enough to fragment the tissue. The tip stalls.
At increased selectivity settings (+ to ++++), suction and the tip cross-sectional
area remain the same, and stroke amplitude and tip acceleration decrease slightly:
Table 6-2.
Fragmentation performance vs.
TissueSelect settings
Setting Fragmentation Rate

Std and + maximum

++ and +++ slightly decreased rate, increased tissue

selectivity and tactile feedback

++++ slowest rate, maximum selectivity and

tactile feedback

Benefits of TissueSelect
The TissueSelect feature presents several benefits:
• Maintains fragmentation ability.
• Reduces (automatically) fragmentation rate.
• Provides maximum tissue selectivity.
• Gives surgeon superior tactile feedback.
• Gives surgeon greater control and precision when dissecting near delicate
structures.

6-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 How the TissueSelect Feature Works

A Common Misunderstanding of the Amplitude Setting

It has been common practice to decrease the amplitude setting when encountering
critical structures. The reasoning behind this practice is that the lower amplitude
setting results in slower fragmentation rate and greater selectivity, thus greater
control to help avoid damage when dissecting near the critical structures. Look at
this reasoning more carefully.
True: Decreasing the amplitude setting also decreases the fragmentation rate.
True: Because the fragmentation rate is slower, the surgeon has a little more time
to move the tip away from a critical structure before damaging it; therefore, the
surgeon seems to have greater selectivity and control.
False: The surgeon gains greater selectivity, thus greater control and precision
when dissecting near critical structures.
Why does the decrease in amplitude not give greater selectivity and control?
Decreasing the amplitude does not greatly affect the reserve power.

Principles of Operation
Figure 6-3.
Reserve power vs. amplitude setting

Decreasing the amplitude leaves plenty of reserve power.

When the tip contacts critical structures, it still has more than enough power to
fragment them if the surgeon applies pressure or prolongs the tip-tissue contact.
Therefore, decreasing the amplitude setting gives the following results:
• Reduced fragmentation ability
• Reduced fragmentation rate
• Little increase in selectivity
• Little reduction in reserve power.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 6-9

Notes

6-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 7

Circuit Theory
7

In this section:

• Display board
• Machine control board
• Ultrasonics board–ultrasonic generator
• Ultrasonics board–other circuits
• System 24 V Power Supply board.

For Your Information

When reading the descriptions in this section, refer to the Schematics Supplement
to view schematics.

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-1

Display Board

Display Board

General Description
The display board contains the user information displays and user input buttons
for the unit. User input buttons control the following settings and functions:
• Settings:
 Amplitude
 Aspiration
 Irrigation
 TissueSelect.
• Functions:
 Status (run or standby)
 Lap
 Test
 Prime.
The display board also includes four fault indicators (alerts):
• Vibration
• Footswitch
• Handpiece
• Cooling water.
The PCB is a single, four-layer circuit board. It includes both through-hole and
surface-mount parts due to space constraints on the board and the quantity of
parts. The buttons and electronics provide bi-directional data communication with
the machine control board via a 50-pin ribbon cable.

Fundamentals of Operation
The display board, the fundamental user interface for the system, both receives
and displays information to the user. Figure 7-1 shows the display organization.

7-2 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 Display Board

Figure 7-1.
The display organization on the
control panel

Due to the quantity of LEDs, space restriction, and heating considerations, FET
switches connected to a multiplexing display driver (Maxim 7218) drive the
displays. A resistor in series with the LED light bar limits current through the
LEDs. A P-channel FET sources the voltage to the resistor and LED light bar
series combination. An N-channel FET sinks the current to ground from the LED
light bars. The outputs of the 7218 display driver control the gates of the FETs.
To reduce the number of display drivers and the quantity of logic code, a coded
map identifies each individual LED light bar location so that a single display
driver can control all of the amplitude, irrigation, TissueSelect, and aspiration
displays. A second display driver controls the number legends, the alerts, the
status indicators, and the button indicators.

Circuit Theory
Detailed Circuit Description
Each “circuit” works the same way. It simply repeats several times to allow
individual control over each light bar package. The following description details
the circuit for the aspiration column at a setting of 10%.
The 7218 display driver (U3) receives inputs from the machine control board via
the 50 pin ribbon cable connector, J1. The segment output of the display driver
connects to a 1k pull-up resistor (RA2) and the gate of an N-channel FET (U66).
The source of the FET ties to +5Vin and the drain connects to a resistor network
(RA32). Several of the resistors are tied together to achieve an average current of
12 mA through each LED of the light bar for a total of 96 mA per light bar. The
resistors, in parallel, connect in series with the light bar (U221). All diodes in the
light bar connect in parallel. The cathode of the diode connects to the drain of the
N-channel FET (U65). The source of U65 connects to ground. The gate connects
to a digit output of U3 and a pull-down resistor (RA6).
For any light bar to be illuminated, it must receive both the correct segment and
digit output from the display driver. Each LED light bar (except for the numeric
legends) has a unique map location; thus, each LED light bar is independently
controlled. The numeric legends are controlled together, not independently.

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-3

Machine Control Board

Machine Control Board

Introduction
The Machine Control board resides in the control panel assembly along with the
Display board. The Machine Control interfaces with the ultrasonic section of the
display and keypad. It also interfaces to the solenoid valves, pumps, and the
ultrasonic drive circuitry. This description presents the Machine Control
schematic. Refer to the Schematics Supplement.

Irrigation Pump
A resistor divider and operational amplifier network establishes control for the
irrigation pump. The programmable logic device (PLD) sets the levels. The
signals are optically isolated and sent as inputs to a quad analog switch. The
analog switch selects gain resistors for an op amp, which is amplifying a dc level.
The op amps output drives a pump speed controller (off board) which has a
greater than 10k ohm input resistance.
The 5-bit output signal range for the irrigation pump is approximately
0 to 5V DC. The following table shows the irrigation steps:
Table 7-1.
Irrigation pump voltage steps irrigation step 5v_x = 5.6v

display desired voltage setpoint theoret v

1 0.28 2 0.32

2 0.45 3 0.47

3 0.61 4 0.63

4 0.78 5 0.79

5 0.93 6 0.95

6 1.1 7 1.11

7 1.3 8 1.27

8 1.45 9 1.43

9 1.6 10 1.59

10 1.75 11 1.75

ff max 5 16 4.98

Suction Pump

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 Machine Control Board

Suction pump control results from the same kind of operation as irrigation pump
control. The 4 bit output signal range for the suction pump is approximately 0 to
6V DC. The following table shows the suction steps:
Table 7-2.
Suction pump voltage steps suction step +5v_sp = 6.15v

desired voltage setpoint theoret v

1 0.40

2 0.80

3 1.20

4 1.61

5 2.00

6 2.41

7 2.81

8 3.23

9 3.63

10 4.03

default 4.4 11 4.43

12 4.84

Circuit Theory
13 5.23

14 5.64

max 6 15 6.03

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-5

Machine Control Board

Cooling Pump
Cooling pump control results from the same kind of operation as irrigation and
suction pump control. The 3-bit D/A output signal range for the cooling pump is
approximately 0 to 5.1V DC. The following table shows the cooling steps:
Table 7-3.
Cooling pump voltage steps cool step +5v_x= 5.6v

desired voltage setpoint theoret v

1 0.73

2 1.46

default 2.208 3 2.19

4 2.94

5 3.67

6 4.40

max 5.152 7 5.13

Suction Valve
Optically isolated digital circuits control the suction valve. When current moves
through an internal LED, the output open collector transistor is saturated. The
pull-up resistors and the controlling hardware reside on the destination board.

Amplitude Control
The handpiece amplitude control circuit, a 4-bit D/A output signal range for the
handpiece control, operates from approximately 0 to 10V DC. The op amp
maximum supply voltage is 15V, so two diode drops prevent the op amp from
seeing the full 15V from the supply. The following table shows the handpiece
amplitude control steps:
Table 7-4.
Handpiece amplitude control amp step desired voltage D/A code theoret v
voltages
1 1.00

2 2.01

2.208 3 3.01

4 4.04

5 5.04

7-6 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 Machine Control Board

amp step desired voltage D/A code theoret v

6 6.05

7 7.05

8 8.11

9 9.11

max 10 10.13

11 11.13

12 12.15

13 13.15

14 14.16

15 15.16

Valve Controls
Optical isolators condition signals to and from the ultrasonics board. The signals
from the footswitch activate fast flush and the ultrasonics, and indicate whether
the footswitch is present. There are several isolated solenoid valve drivers for
controlling tissue release, suction, handpiece drain, and anti-siphon. The
handpiece feedback signals from the ultrasonics board go through opto-isolators
to the PLD. Alert signals such as cooling out of range, vibration, amplitude, and

Circuit Theory
handpiece not present also pass through opto-isolators before going into the PLD.

Power Control Input and Output Signals

When you turn the system power switch on, the softpower circuit, an input to the
PLD, activates all other systems. The shutdown handpiece bias signal, an output
from the PLD, activates the handpiece bias. The keypad signals (originating at the
display board) pass through filters, then go into the PLD. A power supervisor
resets the PLD when the supply voltage is below specification. The power
supervisor input is filtered with a time constant of 1mS to reduce the possibility of
false resets. The crystal and inverter generate the PLD master clock at 32.768
kHz. The right angled 10-pin connector allows in-circuit programming of the
PLD. An EE programmable read-only memory (prom) stores initial set points.

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-7

Ultrasonics Board–Ultrasonic Generator

Voltage Regulators
There are voltage regulators for the isolated supplies. LM317 adjustable
regulators provide op amps with supply voltages with enough overhead margin to
output voltages in the required range. A switching regulator boosts and regulates
the 5V supply for the machine control and display driver boards. This is necessary
because the 5Vin signal is expected to dip momentarily due to the voltage drop
when the displays are lit up. A diode placed around the regulator eliminates start
up delay in the 5V supply for the PLD. This sheet shows bypass capacitors as well
as the independent power shutdown driver circuits. The open collector output
signals drive an opto-isolator LED inside the power modules in order to shut off
the supplies.

Interface Connectors
J2 and J3 are the ultrasonics interface connectors. J1 is the 5V input power supply
connector. J5 is the power shutdown control connector. J4 is the display board
interface connector.

Ultrasonics Board–Ultrasonic Generator

Fundamentals of Operation
The CUSA EXcel ultrasonic generator is based on the principle of the Wien
Bridge Oscillator. The system has a non-inverting feedback loop to establish the
fundamental frequency of oscillation and an additional negative feedback loop,
which controls the amplitude of oscillation. The fundamental oscillation
component is a function of the resonant frequency of the magnetostrictive
handpiece.
Oscillation criteria for a Wien Bridge are that the gain around the loop must add
up to unity and the phase must add up to 360º or 0º. Only if the gain is initially
greater than unity and some perturbation (noise) in the initial conditions of the
system exists can startup occur.
The handpiece design uses the magnetostrictive and inverse magnetostrictive
effects. A magnetic field produces a small change in the physical dimensions of
ferromagnetic materials—on the order of several parts per million in steel—and,
conversely, a physical deformation or strain (or stress which causes strain)
produces a change of the magnetization in the material.
Much like a tuning fork excited by a “ping” or deformation, the handpiece
transducer—excited by these small deformations caused by the magnetostrictive
effect—resonates at an ultrasonic frequency. Linear operation within this
framework relies on biasing the magnetic field at a roughly linear point along the
main B-H curve. The feedback signal, sensing the change in the magnetic field
produced by the inverse magnetostrictive effect, is proportional to the
deformation.

7-8 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 Ultrasonics Board–Ultrasonic Generator

A tip, designed as an ultrasonic velocity transformer or horn connected to the

transducer or motor, makes use of the energy contained in the vibration of the
handpiece. The horn also increases the stroke and velocity with minimal losses.
The amount of transformation is referred to as “tip gain.”
Temperature and load affect the frequency of vibration. If the transducer heats, its
frequency decreases; if the transducer cools, its frequency increases. Transducer
inefficiencies can cause “self-heating.” Loading of the transducer can move the
frequency up or down depending on hardness, viscosity, and elasticity. Either case
requires a change in the amount of gain and phase from the generating circuit.
Additionally, this circuit must be able to react as quickly as possible to the load
changes; otherwise, the delivered power from the generator could exceed the
elastic limit of the tip material and cause fractures.

The Main Frequency Loop

The frequency loop consists of the following items:
• A CUSA EXcel handpiece
• A bandpass filter (BPF)
• An AGC/error amplifier circuit
• A phase compensator
• A driver stage
• Feedback signal
• Bias circuitry
• Frequency selection circuitry.
The handpiece has many potential operating points. The console must choose one
of these by way of some additional BPF function to select the phase and gain that
meet the oscillation criteria over the desired frequency range of operation. Flat

Circuit Theory
phase and gain over this region of interest is desirable; otherwise, poor power
factors and/or unstable operation could result. The AGC loop controls the
multiplier and, therefore, adjusts the frequency loop gain to control the amplitude
under varying load and handpiece operating conditions. Linear operation of these
two loops in conjunction is imperative to avoid handpiece operation at an
undesired point.
The output driver stage is a Class B push-pull current drive coupled to the
handpiece via a transformer and DC bias circuitry. Most magnetostrictive drives
use a current drive because the magnetic field intensity is linearly proportional to
the drive current—and, therefore, stroke—when the handpiece is properly biased.

Bandpass Filter (BPF)

The input bandpass filter consists of an instrumentation amplifier stage centered
around U7 and an active two-pole filter centered around U12. The
instrumentation amplifier has a common/differential mode loss pad and RF filter
consisting of R48, R49, R67, R68, C43, C46, and C53. The filter and pad pass the
differential mode ultrasonic frequencies at about 16 dB of midband loss due to the
large feedback voltage swings of up to 90 Vp-p of the 23 kHz handpiece/tip. The
gain set resistor R66, selected by the analog switch U10C when the 35.75 kHz

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-9

Ultrasonics Board–Ultrasonic Generator

handpiece is connected, compensates for some of this loss for the 35.75 kHz
circuit. The -3 dB point of the RF filter is at about 100 kHz to maximize RF losses
at 500 kHz and above, and to minimize passband phase.
The active filter is an analog state-variable structure “universal active filter” IC.
R95 and R96 determine the bandpass filter gain. R63, R75 and RV6 determine the
center frequency for the 23 kHz circuit (or R62, R65, and RV7 for the 35.75 kHz
circuit) as selected by the analog switches U10A, B, D, and U4C.
The BPF center frequency ensures that midband phase and gain are as flat as
possible, but losses at the undesired longitudinal modes are maximized. For the
23 kHz circuit, the first undesired mode occurs at about 26 kHz; for the 35.75 kHz
circuit, it occurs at approximately 43.8 kHz. Handpiece/tip length primarily
determines this mode, although handpiece/tip diameter also affects it. Loss at
these frequencies must come from two sources:
1. (Most obvious) BPF loss at these frequencies. However, the AGC loop gain
may, in most instances, be sufficient to negate this loss.
2. Phase. If the phase is sufficient that the only operating point possible at this
mode requires a very high gain, then this will not be a preferred mode.

AGC/Error Amplifier Circuit

The AGC function consists of the following components:
• A root mean square (RMS) to DC circuit centered around U23
• A handpiece (HP) amplitude input buffer centered around U22A
• An amplitude error amplifier centered around U22B
• A multiplier centered around U15.
C106 programs the RMS-to-DC conversion accuracy and low frequency pole.
R146, R147, C102, and C103, together with the internal buffer amplifier of the
IC, form a two-pole Sallen and Key low pass (LP) filter to remove high-frequency
noise. A time constant (the product of C106 times the internal resistor in the
RMS-to-DC converter) determines how fast the generator reacts and recovers
from load and operating point condition changes.
The amplitude input buffer, U22A, filters (R100 and C73) and inverts the
handpiece amplitude signal. The active rectifier circuit (CR16 and CR17)
prevents positive valued amplitudes that could cause loop instability at the error
amplifier.
The error amplifier, U22B, subtracts the RMS-to-DC signal from the handpiece
amplitude signal. The residual signal is the loop gain value sent to the multiplier,
U15. Two factors determine the steepness of the gain of this error amplifier:
• The input signal levels
• The minimum dynamic range required for the handpiece stroke levels under
load and start-up conditions.
RV8 sets the gain of the amplifier, while RV9 sets the gain for the feedback signal
levels.
The control function has an offset and a gain which limit the operating range
capabilities (start-up and load) of the handpiece. At minimum level settings the
control function must have a start-up gain of at least two times or greater the

7-10 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 Ultrasonics Board–Ultrasonic Generator

nominal error output. Under maximum load, the gain should be sufficiently large
to allow stroke, even if the stroke is at reduced levels. If the gain is too large,
however, a large enough feedback will force the error amplifier output to 0,
whereby control is lost.
RV11 is for calibration purposes only.

Phase Compensator
The two-pole, active filter, U9, provides loop phase compensation. This is a
Bessel filter characteristic implemented with a “low sensitivity” configuration. It
is “low sensitivity” in that it has low operational amplifier (op-amp) slew rate and
drive requirements, while component temperature and tolerance sensitivities also
remain low. The phase for the 23 kHz circuit depends on the RC value of RV5,
R52, and C41 selected by the analog switch U5A; the phase for the 35.75 kHz
circuit depends on RV4, R300, and C41 selected by U5D. The nominal -3 dB
point of the filter is 37.30 kHz.
The alignment of these filter poles with the BPF determines the amount of phase
at the undesired longitudinal modes. Too little phase from the BPF makes it
difficult to adjust these modes out; too much phase allows the center frequency to
remain mis-adjusted and, therefore, may sacrifice mid-band gain flatness.

Driver Stage
The driver stage consists of the following components:
• A pre-amp, U1B
• A push-pull rectifier or phase splitter, U1A
• A positive half-cycle driver, U2B
• A negative half cycle driver U2A.

Circuit Theory
For the 23 kHz circuit, output stage gain depends on the combination of two
gains:
• The pre-amp gain (R10 and R11)
• The phase-splitter gain (R19, R20, R24, and RV3).
For the 35.75 kHz circuit, output stage gain depends on RV2, selected by switches
U5C and U5B.
The RUN_HPO signal from the machine control board via switch U4D enables
the whole frequency loop.
U2A and U2B connect as non-inverting and inverting current sources via the
feedback of the 0.25 Ohm resistors. Maximum current in the output transistors (20
amps peak) depends on the gain set by R13 and R15 for the positive half-cycle,
and R41, R36, R18, and R17 for the negative half-cycle. Amplifier compensation
for the positive half-cycles depends on R14 and C21; for the negative half cycles,
R40, C35 and C15.
CR7 and CR2 protect output transistors Q15 and Q16 from the output transformer
flyback; R38 protects the output transistors from open-circuit loading (like a
short-circuit for voltage based designs). The output transformer is center tapped
with a ratio of 1:4.6 for each half coil.

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-11

Ultrasonics Board–Ultrasonic Generator

C10 provides AC coupling to the DC biased handpiece and its value is selected
low enough to avoid resonant circuit interactions with the handpieces.

Feedback Signal
U13B, U11, U14, and U18 filter and convert the feedback signal to digital. The
signal level depends on the gain of the amplifier U13B, R77, and R78.

Bias Circuitry
The bias circuit consists of the following items:
• A pass transistor switch, Q1
• Filter components L5 and C9
• CR1.
The filter prevents ultrasonic signal leakage from returning to the power supply,
while CR1 acts as a free wheeling diode when Q1 is turned off.

Frequency Selection Circuitry

Handpiece interlock jumpers in the handpiece connectors enable frequency
selection. A signal, filtered and “wired OR” for the HP_PRES signal, goes to the
Machine Control board when either handpiece is present. The 23_PRES and
23_PRES signals select analog switches. The default frequency selection is the
35.75 kHz circuit.

7-12 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 Ultrasonics Board–Other Circuits

Ultrasonics Board–Other Circuits

Audible Alert and Operation Indicator

A user adjustable tone indicates operation. U17A detects the presence of a signal
and asserts the signal SPKR1. SPKR1 signal enables a piezo buzzer driver circuit
that has a volume adjustment RV1. Alert tones override the operation indication in
volume via SPKR2 signal, driven by the Machine Control board.

Valve Drivers
Pulse and hold circuits driven by the Machine Control board control the suction,
syphon, and tissue release valves. U6, U3, and U19 provide drive current sinks.
Resistor combinations determine the pulse and hold currents.

Power and Other Signal Connections

The +24 VAMP power supply provides circuit power for the Ultrasonics board.
Sub-regulators U27 and U8 condition the power for the ±15 VUSB and +5 VUS.
The +24VX power supply also provides power to the valves, cooling fans, and
pumps.
Cooling sensor, footswitch, suction pump level, irrigation pump level, and cooling
pump level signals all pass from the Machine Control board to their respective
devices by way of connectors on this board.

System 24 V Power Supply Board

Circuit Theory
The CUSA EXcel uses an OEM medical grade 600 watt power supply with an
input voltage range of 88 to 264 VAC. The supply has two individually regulated
24 VDC outputs. This power supply is an enhanced leakage current version with
earth leakage of less than 150 A. This supply is a UL recognized component for
Canada and the U.S. and is CE labeled.

CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual 7-13

Notes

7-14 CUSA EXcel Ultrasonic Surgical Aspiration System Service Manual

 SECTION 8

Checkout Procedures
8

In this section:

• Inspections
Footswitch
Power cord
• Power on verification
• Handpiece test (optional).

Inspections
When you have unpacked the console, and at regular intervals afterward, inspect
the footswitch and the power cord.

Footswitch
1. Disconnect the footswitch from the console (rear panel).

2. Inspect the connector for damage or corrosion.

3. Inspect the footswitch for damage.

4. Inspect the cable for cuts, tears, or excessive compression.

5. Clean the footswitch and cable with a damp cloth and mild detergent.

6. Allow the footswitch to dry.

7. Connect the footswitch to the console (rear panel).

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 8-1

Power On Verification

Power Cord
1. Unplug the system power cord from the wall receptacle.

2. Inspect for damage or corrosion. Ensure that the connector screws are tight.

3. Inspect the cord for damage.

4. Clean the power cord with a damp cloth and mild detergent.

5. Allow the power cord to dry.

6. Plug the power cord into a wall receptacle.

Power On Verification
1. Connect the footswitch.

2. Plug the system power cord into a wall receptacle.

3. Turn on (|) the AC Main Switch, located on the rear panel. The front panel
indicators momentarily flash.
4. Turn on (|) the System Power Switch, located on the front panel.

5. The front panel indicators momentarily flash. The Handpiece and Alert
indicators (red, left side of control panel) illuminate.

Handpiece Test (Optional)

To perform this test, you need a handpiece. Further, you must assemble the
following components onto the handpiece:
• Tip
• O-rings
• Nosecone
• Flue.
For complete information on assembling the handpiece, refer to Section 9,
Assembling the Handpiece in a Nonsterile Area, in the CUSA EXcel Ultrasonic
Surgical Aspirator System User’s Guide.

Notice
To avoid product damage, NEVER hold the handpiece in your hand while using the
torque wrench to tighten or loosen the tip.

8-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Handpiece Test (Optional)

To test the handpiece, follow this procedure:

1. Plug the power cord into a wall receptacle.

2. Confirm that the AC main AC Main

switch located on the rear
panel is on (|).

Integra LifeSciences (Ireland) Limited

IDA Business and Technology Park
Stragh, Tullamore, County Offaly, Ireland

3. Fill the cooling water reservoir with 1000 cc distilled water.

4. Slide the cooling water

reservoir into the slot on the
console side panel until it
snaps into place.

Limited
(Ireland) Park
Ireland
Offaly,
Technology
LifeSciences
and
County
Integra
Business
IDA Tullamore,
Stragh,

Checkout Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 8-3

Handpiece Test (Optional)

5. Connect the handpiece to

the console.

a. Line up the notch on the

handpiece connector to
the key in the receptacle
(at the 12 o’clock
position).

b. Gently push the

handpiece connector onto the console connector.
c. Turn the connecting ring
in the clockwise
direction until the
yellow dot on the
handpiece aligns with
the yellow dot on the
console.

6. Turn on (|) the System

Power Switch located on
the front panel.

System Power
Switch

8-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Handpiece Test (Optional)

7. Wait for the Cooling Water and flashing Wait indicators (amber) to turn off
(this indicates that the handpiece cooling water circuit is working properly). It
usually takes about one minute.

Caution
Do not allow the handpiece tip to contact anyone or anything during tip activation.
Contact may result in patient injury, user injury, or handpiece tip damage.

8. Push the Test button (orange

box on a black button at the
top of the amplitude display
column) on the control
panel.

The system automatically

activates the handpiece at 100% vibration for 4 seconds. During the test, green
LEDs in the amplitude display light up to 100% to show that the handpiece is
working correctly.
9. Verify the following:
 The Vibration alert (red) is off.
 The LEDs light up to 100%.
If you see no Vibration alert, and if the LEDs light up to 100%, the handpiece
is working properly.
If the Vibration alert illuminates, or if the LEDs do not light up to 100%, the
handpiece is not working properly. This usually results from an improperly
attached tip. Troubleshoot by
 Removing and re-attaching the tip, then pushing the Test button again.
 If the problem persists, attach a different handpiece.
 If the problem still persists, contact the Integra Service Center nearest you.
10. If the test is successful, turn off the System Power Switch.

11. Wait for the handpiece cooling water to drain (the amber Wait and Cooling
Water indicators go off), then disconnect the handpiece. Checkout Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 8-5

Notes

8-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 9

Maintaining the CUSA EXcel System

9

In this section:

• Recommended maintenance schedule

• Clean the CUSA EXcel console
• Clean the sterilizer case
• Maintain the handpiece
• Maintain the tip torquing set
• Store the CUSA EXcel system and accessories.

For Your Information

Routinely performing a few simple maintenance tasks keeps your CUSA EXcel
system operating at maximum safety and performance levels. Biomedical
Engineering at your facility should perform these tasks.

CUSA EXcel Ultrasonic Surgical System Service Manual 9-1

Recommended Maintenance Schedule

Recommended Maintenance Schedule

The following chart shows routine maintenance tasks, the equipment on which
you perform them, and how often you perform each task. The term months refers
to calendar months.
Table 9-1.
Routine maintenance tasks Frequency Equipment Task

When used Handpiece Clean and wipe dry.

When used Tip torquing set Clean and wipe dry.

When used CUSA console Clean and wipe dry.

When used Cooling water Discard water from the reservoir.

reservoir

When used Footswitch 1. Discard the footswitch cover.

2. Clean the footswitch.

Every month or 20 CUSA handpiece Lubricate the handpiece connector

procedures, which- o-rings.
ever comes first

Every 3 months, or CUSA console 1. Fill the cooling water reservoir with
every 12 to 15 a solution consisting of 100 cc of
procedures, which- 70% alcohol and 900 cc of water.
ever comes first
2. Connect the handpiece, then turn on
the system.
3. Allow the system to run a few
cooling cycles to clean the interior
tubing.
4. Turn off the system.
5. Discard the alcohol solution, then
fill the reservoir with distilled
water.
6. Turn on the system, and allow it to
cycle the water to clean the alcohol
solution out of the tubing.
7. Turn off the system.
8. Discard water from the reservoir.

Every 6 months or CUSA console Replace the contamination guard. Write

when the surgeon either the installation date or the
notices a lack of expiration date on the new guard.
suction

Every 6 months or CUSA handpiece Replace the handpiece connector

100 procedures, o-rings.
whichever comes
first

9-2 CUSA EXcel Ultrasonic Surgical System Service Manual

 Clean the CUSA EXcel Console

Frequency Equipment Task

Once a year Tip torquing Check the torque.

CUSA EXcel System

wrench

Maintaining the
Once a year CUSA console Contact an Integra service
representative to replace the cooling
water pump tubing.

Clean the CUSA EXcel Console

You cannot sterilize the CUSA console, but you can clean it, disinfect it, or both.
Use a mild cleaning solution or disinfectant and a damp cloth.

Warning
Electric Shock Hazard Always unplug the CUSA system before cleaning.

Notice
Do not rub, press, or touch any panels with solvents; caustic, corrosive, or abrasive
cleaning or disinfectant compounds; or other materials that could scratch the panels. Do
not use a betadine-based solution; it will cause discoloration.

Do not allow fluids to enter the chassis.

1. Unplug the unit power cord from the wall receptacle.

2. Using standard procedures for your facility, thoroughly wipe all surfaces and
cords with a cleaning solution and disinfectant.
3. Make sure that the surface is completely dry before using the system again.

Clean the Sterilizer Case

Use a neutral detergent to clean the sterilizer case.

Notice
Do not clean the sterilizer case with abrasives. Product damage will result.

Maintain the Handpiece

Maintaining the handpiece involves cleaning the handpiece, lubricating the
handpiece connector o-rings with a high viscosity lubricant such as silicone
grease, or replacing the handpiece connector o-rings. If a problem develops, you
may also need to have the handpiece recalibrated.

CUSA EXcel Ultrasonic Surgical System Service Manual 9-3

Maintain the Handpiece

Clean the Handpiece

Items needed: Soft cloths (one moist, one dry), swab or pipe cleaner, mild
cleansing solution, and rinse water.

Notice
Product damage will result if you do not follow these notices when cleaning the
handpiece:
• Do not immerse the handpiece cable electrical connector in liquid.
• Do not use ultrasonic or automated cleaners.
• Do not use chlorinated substances such as bleach solution.
• Do not clean the handpiece with abrasives such as Ajax, Comet, or steel wool.

Procedure:
1. Using a soft cloth, manually clean the handpiece, handpiece cable, and
standard nosecone with a mild cleansing solution (neutral detergent) or blood
dissolving detergent according to hospital policy.
2. Using a swab or pipe cleaner, manually clean the internal threads and suction
port of the connecting body.
3. Using a soft cloth, manually clean the internal threads and face of the
connecting body. Refer to Figure 9-1.
Figure 9-1.
Cleaning the handpiece with a soft
cloth

4. Rinse the handpiece cable, handpiece housing, connecting body, and nosecone
thoroughly with water.
5. Using a soft cloth, dry the handpiece cable, handpiece housing, connecting
body, and standard nosecone.

9-4 CUSA EXcel Ultrasonic Surgical System Service Manual

 Maintain the Handpiece

Lubricate the Handpiece Connector O-Rings

Keeping the o-rings lubricated prevents them from drying out and cracking,
which may cause handpiece cooling problems.

CUSA EXcel System

Maintaining the
Items needed: A high viscosity lubricant such as silicone grease.
Items to be lubricated: The four o-rings on the handpiece connector water
prongs.

Replace the Handpiece Connector O-Rings

Regularly replacing the o-rings prevents excessive wear, which may result in
handpiece cooling problems.
Items needed: O-Ring maintenance kit (Part Number 260-650-000), which
includes o-rings, an insertion tool, and instructions.
Items to be replaced: The four o-rings on the handpiece connector water prongs.
Refer to Figure 9-2.
Figure 9-2.
Replacing the handpiece connector
o-rings

Handpiece connector Insertion tool

O-ring

Recalibrate the Handpiece

Handpieces for the CUSA EXcel system do not need recalibration unless a
problem develops. If this happens, contact Integra to arrange returning the
handpiece for service. (Refer to Return Equipment for Service in Section 13,
Repair Policy.)

CUSA EXcel Ultrasonic Surgical System Service Manual 9-5

Maintain the Tip Torquing Set

Maintain the Tip Torquing Set

Clean the Tip Torquing Set

Notice
Product damage will result if you do not follow these notices when cleaning the Tip
Torquing Set.
• Do not use ultrasonic or automatic washers.
• Do not autoclave.
• Do not use chlorinated substances such as bleach solution.
• Do not clean with abrasives such as Ajax, Comet, or steel wool.

Items Needed
Detergent, two soft cloths, and rinse water.
Procedure:
1. Using a soft cloth and a water and detergent combination, manually clean the
tip torquing base and the torque wrench.
2. Rinse the tip torquing set thoroughly with water.

3. Using a soft cloth, dry the tip torquing set.

Check the Torque on the Tip Torquing Wrench

A biomedical engineer or an Integra service representative should check the
torque on the tip torquing wrench.
Tools Needed
• Torque indicating wrench
• 7/32 in. hex socket
• 9/32 in. hex socket.
Procedure:
1. Attach the socket to the torque indicating wrench.

2. Clamp the torque indicating wrench handle in a vise.

3. On the torque indicating wrench, adjust the scale under the indicator needle to
zero.
4. Set the peak indicating needle on the torque indicating wrench to zero.

5. Place the green end of the torque wrench from the tip torquing set on the 9/32
in. hex socket.
6. Rotate the tip torquing wrench clockwise until you feel and hear a click.

7. Rotate the tip torquing wrench clockwise until you feel and hear a second
click.

9-6 CUSA EXcel Ultrasonic Surgical System Service Manual

 Store the CUSA EXcel System and Accessories

8. Read and record the peak torque.

9. Repeat steps three through eight for a total of three times.

CUSA EXcel System

10. Repeat the process on the blue end of the tip torquing wrench and the 7/32 in.
hex socket.

Maintaining the
11. All values must be in the following ranges:
Table 9-2.
Torque values for the torque wrench Handpiece frequency Range (inch-pounds)

23 kHz (green) 55 to 70

36 kHz (blue) 20 to 32

If the values are higher or lower, send the wrench to Integra for recalibration.

Store the CUSA EXcel System and Accessories

CUSA Console
Drain all liquids. Store the CUSA system in a low traffic area that is free of dirt,
blood, water, and other contaminants. Store the system at an ambient temperature
between -34° C (-29° F) and 65° C (149° F).

Handpiece
Drain all liquids. Store the handpiece in the sterilizer case according to your
facility’s policy.
Store the handpiece at an ambient temperature between -34° C (-29° F) and 65° C
(149° F).

Footswitch
If you have attached the footswitch to the console, you do not need to disconnect
it except for maintenance or service. When you are not using the CUSA system,
store the footswitch in the storage compartment in the rear of the console.

CEM Nosecone
The CEM nosecone is a sterile, single-use item. Store unopened packages; discard
used CEM nosecones.

CUSA EXcel Ultrasonic Surgical System Service Manual 9-7

Notes

9-8 CUSA EXcel Ultrasonic Surgical System Service Manual

 SECTION 10

10 Troubleshooting

In this section:

• Troubleshooting safety
• User troubleshooting
Responding to alerts
General troubleshooting
• Engineer troubleshooting
Guidelines
Flow Charts.

For Your Information

Two types of troubleshooting procedure are available for the CUSA EXcel
system:
• User troubleshooting—these procedures involve conditions that may occur
before or during the normal course of surgery. They are easy to diagnose and
to fix. Refer to the user oriented troubleshooting tables in this section or
Section 13, Troubleshooting the CUSA EXcel System, in the CUSA EXcel
Ultrasonic Surgical Aspirator System User’s Guide.
• Engineer troubleshooting—these procedures involve conditions that may
occur within subsystems. They require service from a biomedical engineer or
Integra service representative. Refer to the technical troubleshooting flow
charts in this section.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-1

Troubleshooting Safety

This section repeats the user troubleshooting tables presented in Section 13,
Troubleshooting the CUSA EXcel System, in the CUSA EXcel Ultrasonic
Surgical Aspirator System User’s Guide. It then presents engineer
troubleshooting, describing a visual inspection of the CUSA EXcel system (to
detect any obvious problems) and including flow charts for troubleshooting the
system as a whole and each of its subsystems.

Troubleshooting Safety
It is important that you read and understand the following warnings and notices:

Warning
Electric Shock Hazard Do not touch any exposed wiring or conductive surface while
the system is disassembled and energized. Never wear a grounding strap when working
on an energized system.

Electric Shock Hazard Take appropriate precautions (such as the use of isolated tools
and equipment; use of the “one hand rule,” etc.) when taking measurements or
troubleshooting the system.

Notice
Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.
When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

User Troubleshooting
The CUSA EXcel system runs nearly trouble free. However, on occasion, a
problem may arise. This section describes some conditions that may occur before
or during the normal course of surgery. They are easy to diagnose and to fix.

Warning
Do not activate vibration or the CEM handswitching nosecone while using the tip cleaner.
Tip damage, user injury, electrical shock, or any combination of these effects may occur.

10-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Responding to Alerts

Alert Causes Recommended Action

Footswitch Footswitch cable not properly connected Connect the footswitch to the console
to console (rear panel). Turn the connector until you
feel it lock into place.
If the alert persists after you connect the
footswitch to the console, call Integra for
assistance.

Handpiece Handpiece cable not properly connected Connect the handpiece to the console.
to console Twist the handpiece connector clockwise
until it locks into place, then verify that
the yellow dots align.
If the alert persists after you connect the
handpiece to the console, call Integra for
assistance.

Troubleshooting
Using a CUSA 200 system 23 kHz Connect a CUSA EXcel 23 kHz
handpiece (black connector) handpiece (green connector) or 36 kHz
handpiece (blue connector).

Cooling Water—continuously on Not enough distilled water in the cooling Add distilled water to the cooling water
water reservoir reservoir to the fill line.

Cooling water reservoir not properly Re-seat the cooling water reservoir in the
seated console.

A pinch or kink in the handpiece cable Remove the pinch or kink in the cable.

Handpiece cable not properly connected Connect the handpiece to the console.
to console Twist the handpiece connector clockwise
until it locks into place, then verify that
the yellow dots align.

Damaged, misaligned, or missing o-rings Connect a new handpiece to the

in the handpiece connector CUSA EXcel system, and test it for
proper function.
If the alert persists after you connect the
new handpiece to the console, call Integra
for assistance.

Cooling Water—flashing on and off Possible air bubble in the handpiece The CUSA EXcel system corrects this
cooling system condition. However, if the Cooling Water
alert remains lit, refer to the condition
immediately before this one: Cooling
Water—continuously on.

A pinch or kink in the handpiece cable Remove the pinch or kink in the cable.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-3

User Troubleshooting

Alert Causes Recommended Action

Vibration—In Test mode only Tip loose due to incorrect assembly Testing before sterilization:
1. Use the tip torquing base and wrench
to tighten the tip.
2. Test the tip.
3. Sterilize the handpiece.

Testing after sterilization when tip

assembled in a nonsterile area:
1. Remove the handpiece from the
sterile field.
2. Use the tip torquing base and wrench
to tighten the tip.
3. Test the tip.
4. Sterilize the handpiece.

Testing after sterile tip assembled to

handpiece on the sterile field:
1. Use the sterilizable torque base and a
disposable sterile wrench to tighten
the tip. (Refer to the Supplement,
Assembling or Changing Tips on the
Sterile Field, in the CUSA EXcel
Ultrasonic Surgical Aspirator
System User’s Guide.)
2. Test the tip.

Tip contacting another object Remove the contact with any other object.

10-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Alert Causes Recommended Action

Vibration—In Test mode only— Blocked tip 1. Verify that the manifold suction tube
continued connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.
2. Use the tip cleaner to dislodge the
blockage in the tip. Continue to push
the tip cleaner into the tip until the
cleaner becomes visible in the tubing.
3. When you have cleared the blockage,
verify again that the manifold suction
tube connects properly to the
nosecone.
4. If the tip remains blocked, disconnect
the manifold suction tube connector
from the nosecone. Use the tip cleaner
to dislodge blockage from the tubing,

Troubleshooting
then reconnect the tubing to the
nosecone.
5. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the suction tubing.

Damaged or cracked tip Testing before sterilization:

1. Use the tip torquing base and wrench
to replace the tip.
2. Test the tip.
3. Sterilize the handpiece.

Testing after sterilization when tip

assembled in a nonsterile area:
1. Remove the handpiece from the
sterile field.
2. Use the tip torquing base and wrench
to replace the tip.
3. Test the tip.
4. Sterilize the handpiece.

Testing after sterile tip assembled to

handpiece on the sterile field:
1. Use the sterilizable torque base and a
disposable sterile wrench to replace
the tip. (Refer to the Supplement,
Assembling or Changing Tips on the
Sterile Field, in the CUSA EXcel
Ultrasonic Surgical Aspirator
System User’s Guide.)
2. Test the tip.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-5

User Troubleshooting

Alert Causes Recommended Action

Vibration—In Test mode only— Damaged handpiece 1. Connect a new handpiece to the
continued CUSA EXcel console and test it.
2. If the new handpiece corrects the
problem,
• Verify that the previous handpiece is
correctly assembled, and
• If it was correctly assembled, send it
to Integra for repair.
If the problem persists after you replace
the handpiece, call Integra for assistance.

General Troubleshooting

Condition Causes Recommended Action

No power at the console AC Main Switch (on the rear panel) off Turn on the AC Main Switch (on the rear
panel).

System Power Switch (front of console) Turn on the System Power Switch (on the
off front of the console).

Power cord not plugged in Plug the power cord into the wall
receptacle.

Wall receptacle has no power available Try another wall receptacle, or check the
operating room circuit breakers.

Power interruption to the console Power cord becomes unplugged 1. Turn off the System Power Switch
(on the front of the console).
2. Plug the power cord into the wall
receptacle.
3. When power is restored, turn on the
System Power Switch.
4. When the Wait light (flashing) turns
off, press the Prime button to make
sure the irrigation system is ready to
use.
5. Adjust the Aspiration, Irrigation,
Amplitude, and TissueSelect settings.
6. Push the Status button to change to
Run mode.

10-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Condition Causes Recommended Action

Power interruption in the operating Facility power loss 1. Turn off the System Power Switch
room (on the front of the console).
2. When power is restored, turn on the
System Power Switch.
3. When the Wait light (flashing) turns
off, press the Prime button to make
sure the irrigation system is ready to
use.
4. Adjust the Aspiration, Irrigation,
Amplitude, and TissueSelect settings.
5. Push the Status button to change to
Run mode.

No irrigation flow from the handpiece I.V. administration set roller clamp closed Open the roller clamp.
flue; the handpiece tip gets hot

Troubleshooting
Irrigation tubing not routed properly Route the irrigation tubing properly
through irrigation pump through the irrigation pump.

Manifold irrigation tubing not connected Connect the Luer fitting.

to the handpiece flue tubing

Not enough time set at Prime to allow Press the Prime button, allowing time for
fluid to pass through the irrigation tubing irrigation fluid to drip from the tip.

Irrigation tubing pinched or kinked Remove the pinch or kink from the
tubing.

I.V. bag empty Replace the I.V. bag.

Note: For long periods of nonuse, switch

the CUSA EXcel console to Standby
mode to conserve irrigation solution.

Irrigation pump not turning Call Integra for assistance.

Excessive misting at the handpiece tip Flue not lined up with tip pre-aspiration Adjust the flue position to line up with the
holes pre-aspiration holes in the tip.

Too much irrigation Reduce the irrigation rate.

Low suction setting on the control panel Increase the setting.

Low or no suction due to suction tubing Verify that the manifold suction tube
improperly connected to handpiece connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-7

User Troubleshooting

Condition Causes Recommended Action

Excessive misting at the handpiece Blocked tip 1. Verify that the manifold suction tube
tip—continued connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.
2. Use the tip cleaner to dislodge the
blockage in the tip. Continue to push
the tip cleaner into the tip until the
cleaner becomes visible in the tubing.
3. When you have cleared the blockage,
verify again that the manifold suction
tube connects properly to the
nosecone.
4. If the suction remains low, disconnect
the manifold suction tube connector
from the nosecone. Use the tip cleaner
to dislodge blockage from the tubing,
then reconnect the tubing to the
nosecone.
5. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the blockage.

Blockage in the suction tubing at the 1. Immerse the handpiece tip in sterile
handpiece irrigation fluid briefly. This may clear
the suction tubing.
2. Press the Status button to change to
Standby mode. Use the sterile tip
cleaner to clean out the tip, then put
the tip in irrigating fluid to flush the
tubing.
3. As necessary, disconnect, clean, and
reconnect the suction tubing
connector at the handpiece.

A pinch or kink in the suction tubing Straighten the tubing to remove a kink, or
remove anything that might pinch the
tube.

A blockage in the suction tubing between 1. Examine the suction tubing along its
the handpiece and the suction canister entire length for a blockage.
2. Squeeze the blocked area to loosen it.
3. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the blockage.

Suction canister full Replace the suction canister.

10-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Condition Causes Recommended Action

Excessive misting at the handpiece Suction connections at the suction 1. Remove any unused suction canister
tip—continued canister not seated properly “elbow” connectors.
2. Reseat all connections.

Open port(s) on the suction canister Close any open ports on the suction
canister.

Suction canister improperly connected Refer to the canister manufacturer’s

instructions for connecting the canister.

Inside of the contamination guard wet and 1. Disconnect the contamination guard
blocked fitting from the suction canister
tubing. If you feel no suction at the
end of the contamination guard
fitting, the guard is blocked.
2. Replace the contamination guard.

Troubleshooting
Problem at the CUSA EXcel console Remove the contamination guard and put
suction port a finger in the suction system port. If you
feel no suction, call Integra for assistance.

Suction pinch valve working improperly Check the Lap mode indicator.
• If Lap mode is off, in Run mode the
pinch valve should be open.
• If Lap mode is on, in Run mode the
pinch valve should be open only when
you activate vibration.
If these conditions do not exist, call
Integra for assistance.

No green LEDs (other than setpoints) System in Standby mode Press the Status button to switch the
illuminate when you activate vibration system to Run mode.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-9

User Troubleshooting

Condition Causes Recommended Action

Little or no vibration or fragmentation Excessive tip/tissue pressure (stalling tip) 1. Verify that console settings are at
(Amplitude LEDs may illuminate well desired levels.
below setpoint)
2. Remove the tip from contact with
tissue, then reactivate vibration.
Note: When first activating vibration,
make sure that there is no tip/tissue
pressure.

Blocked tip 1. Verify that the manifold suction tube

connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.
2. Use the tip cleaner to dislodge the
blockage in the tip. Continue to push
the tip cleaner into the tip until the
cleaner becomes visible in the tubing.
3. When you have cleared the blockage,
verify again that the manifold suction
tube connects properly to the
nosecone.
4. If the tip remains blocked, disconnect
the manifold suction tube connector
from the nosecone. Use the tip cleaner
to dislodge blockage from the tubing,
then reconnect the tubing to the
nosecone.
5. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the suction tubing.

Incorrect flue installed Install the correct flue.

10-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Condition Causes Recommended Action

Little or no vibration or fragmentation Tip loose due to improper assembly 1. Press the Status button to place the
(Amplitude LEDs may illuminate well system in Standby mode.
below setpoint)—continued
2. Press the Test button to test the
handpiece and tip.
3. If the Vibration alert activates, do one
of the following:
If tip assembled in a nonsterile area:
a. Remove the handpiece from the
sterile field.
b. Use the tip torquing base and
wrench to tighten the tip.
c. Test the tip.
d. Sterilize the handpiece.

Troubleshooting
If sterile tip assembled to handpiece on
the sterile field:
a. Use the sterilizable torque base
and a disposable sterile wrench to
tighten the tip. (Refer to the
Supplement, Assembling or
Changing Tips on the Sterile
Field, in the CUSA EXcel
Ultrasonic Surgical Aspirator
System User’s Guide.)
b. Test the tip.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-11

User Troubleshooting

Condition Causes Recommended Action

Little or no vibration or fragmentation Damaged or cracked tip 1. Press the Status button to place the
(Amplitude LEDs may illuminate well system in Standby mode.
below setpoint)—continued
2. Press the Test button to test the
handpiece and tip.
3. If the Vibration alert activates, do one
of the following:
If tip assembled in a nonsterile area:
a. Remove the handpiece from the
sterile field.
b. Use the tip torquing base and
wrench to replace the tip.
c. Test the tip.
d. Sterilize the handpiece.
If sterile tip assembled to handpiece on
the sterile field:
a. Use the sterilizable torque base
and a disposable sterile wrench to
replace the tip. (Refer to the
Supplement, Assembling or
Changing Tips on the Sterile
Field, in the CUSA EXcel
Ultrasonic Surgical Aspirator
System User’s Guide.)
b. Test the tip.

Damaged handpiece 1. Connect a new handpiece to the

CUSA EXcel console and test it.
2. If the new handpiece corrects the
problem,
• Verify that the previous handpiece is
correctly assembled, and
• If it was correctly assembled, send it
to Integra for repair.
If the problem persists after you replace
the handpiece, call Integra for assistance.

Suction tube won’t assemble correctly Nosecone not assembled to handpiece Align the dot on the nosecone with the dot
to handpiece nosecone correctly on the handpiece.

Transducer is twisted inside handpiece Replace the handpiece.

housing

10-12 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 User Troubleshooting

Condition Causes Recommended Action

Low suction at the handpiece tip Low suction setting on the control panel Increase the setting.

System inadvertently in Lap mode Turn off the Lap mode by pressing the
Lap mode button.

Suction tubing improperly connected to Verify that the manifold suction tube
handpiece connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.

Blocked tip 1. Verify that the manifold suction tube

connects properly to the nosecone by
disconnecting, then reconnecting, the
tubing and its clip.
2. Use the tip cleaner to dislodge the
blockage in the tip. Continue to push

Troubleshooting
the tip cleaner into the tip until the
cleaner becomes visible in the tubing.
3. When you have cleared the blockage,
verify that the manifold suction tube
connects properly to the nosecone.
4. If the suction remains low, disconnect
the manifold suction tube connector
from the nosecone. Use the tip cleaner
to dislodge blockage from the tubing,
then reconnect the tubing to the
nosecone.
5. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the blockage.

Blockage in the suction tubing at the 1. Immerse the handpiece tip in sterile
handpiece irrigation fluid briefly. This may clear
the suction tubing.
2. Press the Status button to change to
Standby mode. Use the sterile tip
cleaner to clean out the tip, then put
the tip in irrigating fluid to flush the
tubing.
3. As necessary, disconnect, clean, and
reconnect the suction tubing
connector at the handpiece.

A pinch or kink in the suction tubing Straighten the tubing to remove a kink, or
remove anything that might pinch the
tube.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-13

User Troubleshooting

Condition Causes Recommended Action

Low suction at the handpiece A blockage in the suction tubing between 1. Examine the suction tubing along its
tip—continued the handpiece and the suction canister entire length for a blockage.
2. Squeeze the blocked area to loosen it.
3. Immerse the handpiece tip in sterile
irrigation fluid briefly. This may clear
the blockage.

Suction canister full Replace the suction canister.

Suction connections at the suction 1. Remove any unused suction canister

canister not seated properly “elbow” connectors.
2. Reseat all connections.

Open port(s) on the suction canister Close any open ports on the suction
canister.

Suction canister improperly connected Refer to the canister manufacturer’s

instructions for connecting the canister.

Inside of the contamination guard wet, 1. Disconnect the contamination guard

blocked, or both fitting from the suction canister
tubing. If you feel no suction at the
end of the contamination guard
fitting, the guard is blocked.
2. Replace the contamination guard.

Problem at the CUSA EXcel console Remove the contamination guard and put
suction port a finger in the suction system port. If you
feel no suction, call Integra for assistance.

Suction pinch valve working improperly Check the Lap mode indicator.
• If Lap mode is off, in Run mode the
pinch valve should be open.
• If Lap mode is on, in Run mode the
pinch valve should be open only
when you activate vibration.
If these conditions do not exist, call
Integra for assistance.

The handpiece gets hot Surgeon holding handpiece at tip and flue Hold the handpiece at the nosecone.

Handpiece damage due to tip torquing Replace the handpiece.

without the torque base

The nosecone is loose Large o-ring not installed correctly, or Install the large o-ring in the proper
missing position on the handpiece.

Nosecone worn Replace the nosecone.

10-14 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Engineer Troubleshooting

Engineer Troubleshooting

Guidelines
1. Perform the user troubleshooting procedures.

2. Perform a visual inspection of the system.

3. Look for obvious causes of the malfunction first, such as loose connections,
broken wires, or discolored/burned components.
4. If a single function is not working, concentrate on that circuit or that part of
the system.
5. If several symptoms are present, locate a circuit that is common to all affected
functions. If the solution is not obvious, check the power supply circuits first.

Flowcharts

Troubleshooting
The following flowcharts present troubleshooting procedures:
• No power
• Handpiece alarm
• Footswitch alarm
• Cooling water alarm
• Low suction
• Low irrigation
• Vibration alarm.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-15

Engineer Troubleshooting

No Power

Integra

Call Integra Service for

Integra Service

10-16 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Engineer Troubleshooting

Handpiece Alarm

Troubleshooting
Call Integra for

Call Integra Service

Call Integra for

Call Integra Service Call Integra Service

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-17

Engineer Troubleshooting

Footswitch Alarm

Call Integra Service

Call Integra for

Call Integra Service

10-18 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Engineer Troubleshooting

Cooling Water Alarm

Troubleshooting
Call Integra Service for

Call Integra Service

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-19

Engineer Troubleshooting

Low Suction

10-20 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Engineer Troubleshooting

Call Integra Service

Troubleshooting
Call Integra Service

Call Integra Service

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-21

Engineer Troubleshooting

Low Irrigation

Call Integra Service

Call Integra Service

10-22 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Engineer Troubleshooting

Vibration Alarm

Troubleshooting
Call Integra for

Call Integra for

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 10-23

Notes

10-24 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 11

11 Replacement Procedures

In this section:

• Console covers
• System 24 volt power supply
• Ultrasonics and Machine Control printed circuit boards
• Control head components
• Suction control valve
• Suction pump and controller card
• Suction pinch valve
• Irrigation pump head and gear motor
• Handpiece flow sensor
• Cooling water pump tubing
• Cooling water reservoir o-rings
• Fuses.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-1

For Your Information

For Your Information

For each procedure, we list the tools you need, describe how to access the part to
be replaced, and describe how to install the part.
Most procedures include drawings. Where possible, the drawing appears on one
side of a two-page spread, and the instructions that apply to the drawing appear on
the other side of the two page spread.

Warning
Electric Shock Hazard Only trained biomedical engineers and technicians are
authorized to service the CUSA EXcel system.

Electric Shock Hazard Do not touch any exposed wiring or conductive surface while
the CUSA EXcel system is disassembled and energized. Never wear a grounding strap
when working on an energized CUSA system.

Electric Shock Hazard Take appropriate precautions (such as the use of isolated tools
and equipment; use of the “one hand rule,” etc.) when taking measurements or
troubleshooting the CUSA EXcel system.

High Current Hazard Do not touch the ultrasonics PCB heat sink while the
CUSA EXcel system is energized. The heat sink is isolated from ground and can deliver
very high current, resulting in injury.

Notice
If you plan to connect the handpiece for activation, ensure that an I.V. set is available to
supply cooling irrigation solution to the handpiece tip. Otherwise, damage to the tip and/
or handpiece may result.

Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.

When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

11-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Covers

Console Covers
You can open the left, right, or rear covers on the console to gain access to its
interior. The following procedures describe how to open and re-install each cover.
Figure 11-1.
Right and left sides of the console

Right Side
(includes the
cooling water
reservoir, arm,
Left Side (includes and I.V. Pole)
the system power
switch and the
handpiece
connector
receptacle)

Replacement Procedures
Tools Needed
Phillips head screwdriver

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-3

Console Covers

Open the Left Cover

1. Remove the left side lock screw (M5 Phillips) located under the console top
near the left rear corner.
2. Push the left side latch toward the front of the console. Tilt the cover outward,
then pull up to remove the cover.

Open the Right Cover

Important
The handpiece cooling water lines 1. Remove the right side lock screw (M5 Phillips) located under the console top
attach to the right cover. The near the right rear corner.
cooling water lines include a
service loop that allows you to 2. Remove the cooling water reservoir from its slot.
remove the cover for servicing the
3. Push the right side latch toward the front of the console. Tilt the cover
system. Be careful not to remove
outward, then pull up to remove the cover.
the cover far enough to damage
the lines. The cooling water lines include a service loop that allows you to remove the
cover for servicing the system. Be careful not to remove the cover far enough
to damage the lines.

Open the Rear Cover

1. Disconnect the footswitch connector from the receptacle on the rear panel.

2. Remove two screws (M5 Phillips) from the bottom of the rear cover.

3. Push the rear cover upwards to unhook it from the console, then remove the
cover.

11-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Console Covers

Re-install the Left Cover

1. Position the bottom of the cover on the left side of the console and tilted
slightly outward.
2. Push the top of the cover inward toward the console. When the cover is in
place, push the left side latch toward the rear of the console.
3. Replace the left side lock screw (M5 Phillips), located under the console top
near the left rear corner.

Re-install the Right Cover

1. Position the bottom of the cover on the right side of the console and tilted
slightly outward. Be sure that the cooling water line service loop fits into the
console side.
2. Push the top of the cover inward toward the console. When the cover is in
place, push the right side latch toward the rear of the console.
3. Replace the right side lock screw (M5 Phillips), located under the console top
near the right rear corner.
4. Replace the cooling water reservoir.

Re-install the Rear Cover

1. Position the bottom of the cover on the rear of the console and tilted slightly
outward. Allow it to slide downward and to hook into the console.
2. Hold the top of the cover against the console and replace the two screws (M5
Phillips).

Replacement Procedures
3. Reconnect the footswitch connector to the receptacle on the rear panel.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-5

System 24 Volt Power Supply

System 24 Volt Power Supply

Replacing the system 24 volt power supply involves removing the left side cover,
disconnecting wiring harnesses, and removing the power supply chassis.
Installing a new power supply reverses the process.
Tools Needed
• Phillips screwdriver
• 7 mm nut driver.

Remove the System 24 Volt Power Supply

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Remove the left side cover.

4. Disconnect the wiring harness (refer to Figure 11-2).

5. Remove two hex nuts (M4), two lock washers, and two flat washers to release
the power supply chassis from the console.
6. Slide the power supply and its chassis out the left side of the console.

7. Remove the power supply and its chassis from the console.

Install the System 24 Volt Power Supply

1. Replace the power supply in the console.

2. Slide the power supply and its chassis into the console.

3. Replace the two hex nuts (M4), two lock washers, and two flat washers to
fasten the power supply to the console.
4. Connect the wiring harness. Refer to Figure 11-2.

5. Replace the left side cover.

6. Plug the power cord connector into a wall receptacle.

7. Turn on the AC Main Switch, located on the rear panel.

11-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 System 24 Volt Power Supply

Figure 11-2.
The wiring harness on the system
24 volt power supply

Replacement Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-7

Ultrasonics and Machine Control Printed Circuit Boards

Ultrasonics and Machine Control Printed Circuit Boards

This procedure includes the steps for removing, then re-installing the ultrasonics
printed circuit board (PCB) and the Machine Control PCB. These two PCB
assemblies are supplied as a set; replacing one requires replacing the other.
Tools Needed
You will need the following tools:
• Phillips screwdriver
• 7 mm nut driver
• ESD wrist strap.

Remove the Ultrasonics PCB

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Remove the rear cover.

4. Disconnect the cable assemblies from the ultrasonics PCB. Refer to the
following table and Figure 11-3.

Notice
To avoid product damage, do not remove the jumper cable or the connector at J4.

Table 11-1.
Cable connections on the Loc. Connector Wire Color
ultrasonics PCB
J12 40-pin ribbon cable

J9 20-pin ribbon cable

J1 10-pin connector yellow, brown, violet, blue, orange, red,

black

J3 5-pin connector violet, yellow

J8 large 2-pin connector red, black

J11 small 2-pin connector red, black

J15 4-pin connector red, black, orange, brown

J16 4-pin connector red, black, yellow, gray

(marked COOL)

J17 4-pin connector red, black, orange, violet

(marked IRR)

J18 2-pin connector black, black (twisted)

11-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Ultrasonics and Machine Control Printed Circuit Boards

Loc. Connector Wire Color

J14 6-pin connector red, black, red, black, red, black

J13 large 2-pin connector orange, brown

J10 small 2-pin connector brown, orange

J7 12-pin connector black

J6 2-pin connector black, black

J5 2-pin connector green, white

5. Remove four screws (M5 Phillips) and four lock washers (M5) from the
ultrasonics PCB panel. Refer to Figure 11-3.
When you remove the ultrasonics PCB panel, you will find the heat sink and
cooling fan cables attached to it.
Figure 11-3.
Cables on the ultrasonics PCB
assembly M5 Phillips screw

M5 Phillips screw

Replacement Procedures
J1

J3
J5
J4

J8 J6

J7
J11
J10

J13
M5 Phillips screw
J9 J14
J12
J15
J16
J17
J18

M5 Phillips screw

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-9

Ultrasonics and Machine Control Printed Circuit Boards

6. Remove the ultrasonics PCB assembly from the console. Place the ultrasonics
PCB assembly on the floor next to the console.
7. Disconnect the ultrasonics PCB fan assembly by removing the following lead
wires from the 6-pin fan connector housing (removed from J14). Refer to
Figure 11-4.
Table 11-2.
Ultrasonics PCB fan assembly Color Pin
connectors
red 5

black 6

Figure 11-4.
The ultrasonics PCB fan assembly Red wires appear
connections gray in this graphic

Pin 5 (red wire)

Pin 6 (black wire)

11-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Ultrasonics and Machine Control Printed Circuit Boards

Install the Ultrasonics PCB

1. Place the new ultrasonics PCB assembly near the CUSA EXcel console. Insert
the following ultrasonic PCB fan assembly lead wires into the 6-pin fan
connector housing:
Refer to Table 11-2 and Figure 11-4.
2. Position the ultrasonics PCB assembly in the CUSA EXcel console.

3. Replace four screws (M5 Phillips) and four lock washers (M5) on the
ultrasonics PCB panel.
4. On the new ultrasonics PCB assembly, the header at J6 (syphon valve) has a
3.96 mm (0.156 in.) center. The CUSA EXcel console syphon valve lead
wires terminate in a 2-pin connector with either a 3.96 mm (0.156 in.) or a
2.54 mm (0.100 in.) center.
 If the connector for the console syphon valve has a 3.96 mm (0.156 in.)
center, connect it to the ultrasonics PCB assembly at J6.
OR
 ONLY IF the connector for the console syphon valve has a 2.54 mm
(0.100 in.) center, plug the syphon valve cable assembly adapter into the
connector, then connect the adapter/connector assembly to the ultrasonics
PCB assembly at J6. Refer to Figure 11-5.
Figure 11-5.
Plugging the adapter for the syphon
valve cable assembly into the
connector at J6 on the ultrasonics
PBC
J6

Replacement Procedures
Adapter for syphon
valve cable
assembly

J6 Detail

Syphon valve connector

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-11

Ultrasonics and Machine Control Printed Circuit Boards

5. Connect the cable assemblies to the ultrasonics PCB (Refer to the following
table and Figure 11-3).
Table 11-3.
Cable connections on the Loc. Connector Wire Color
ultrasonics PCB
J5 2-pin green, white

J7 12-pin black

J10 small 2-pin brown, orange

J13 large 2-pin orange, brown

J14 6-pin red, black, red, black, red, black

J18 2-pin black, black (twisted)

J17 4-pin (marked IRR) red, black, orange, violet

J16 4-pin (marked COOL) red, black, yellow, gray

J15 4-pin red, black, orange, brown

J11 small 2-pin red, black

J8 large 2-pin red, black

J3 5-pin violet, yellow

J1 10-pin yellow, brown, violet, blue, orange, red,

black

J9 20-pin ribbon cable

J12 40-pin ribbon cable

6. Replace the rear cover.

Now you must replace the Machine Control PCB, which resides in the control
panel assembly.

11-12 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Ultrasonics and Machine Control Printed Circuit Boards

Remove the Control Panel Assembly

1. Swivel the control head so that the front of the control panel is 90° from the
front of the console.
2. Remove four screws (M4 Phillips) and four lock washers (M4), located at the
rear of the control head, that fasten the control panel assembly to the control
head.

Important
When the screws are loose, take 3. Slide the control panel forward far enough to allow disconnecting the
care not to let the control panel following cables:
assembly fall out of the control
head.  40 pin ribbon cable (J3)
 20 pin ribbon cable (J5)
 10 pin cable (J4)
 6 pin cable (J2).
Refer to Figure 11-6.
Figure 11-6.
Disconnecting control panel assembly
cables

J3
J5

Replacement Procedures
J1
J4

J2

4. Remove the control panel assembly from the control head.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-13

Ultrasonics and Machine Control Printed Circuit Boards

Remove the Machine Control PCB

Notice
Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.
When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

1. Attach an ESD wrist strap, then disconnect the 50-pin ribbon cable from the
Machine Control PCB (J1).
Refer to Figure 11-7.
Figure 11-7.
Removing the Machine Control PCB Control panel
from the control panel assembly assembly

Machine
Control PCB

2. Remove five screws (M4 Phillips) from the Machine Control PCB.
3. Remove the Machine Control PCB from the control panel assembly.

Install the Machine Control PCB

1. Attach an ESD wrist strap, then remove the new Machine Control PCB from
its antistatic bag.
2. Position the new Machine Control PCB in the control panel assembly. Refer
to Figure 11-7.
3. Replace five screws (M4 Phillips) in the Machine Control PCB.

4. Connect the 50-pin ribbon cable to the Machine Control PCB (J1).

11-14 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Control Head Components

Install the Control Panel Assembly

1. Remove ESD strap.

Notice
To avoid product damage, remove the ESD wrist strap before connecting cables to the
Machine Control PCB.

2. Position the control panel assembly at the control head opening.

3. Before sliding the control panel assembly into the control head, connect the
following cables (Refer to Figure 11-6):
 40 pin ribbon cable (J3)
 20 pin ribbon cable (J5)
 10 pin cable (J4)
 6 pin cable (J2).
4. Slide the control panel assembly into the control head.

5. Replace four screws (M4 Phillips) and four lock washers (M4), located at the
rear of the control head, that fasten the control panel assembly to the control
head.

Important
While the screws are still loose, 6. Swivel the control head so that the front of the control panel aligns with the
take care not to let the control panel front of the console.
assembly fall out of the control
head. 7. Plug the power cord connector into the wall receptacle.

8. Turn on the AC Main Switch, located on the rear panel.

Replacement Procedures
Control Head Components
The control head contains three replaceable components:
• Machine control PCB
• Control panel overlay
• Display PCB.
The control panel overlay covers the front of the control panel (its fasteners are
accessible inside the control head). The Machine Control PCB and display PCB
(attached to a chassis) constitute two layers in a control panel assembly within the
control head (refer to Figure 11-8). Gaining access to any of these components
involves removing previous layer(s).

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-15

Control Head Components

Figure 11-8.
The layers of control head
components

Control panel
overlay

Control panel
bezel
Display PCB

Chassis

Table 11-4.
Procedures to access control panel To Access ... You must ...
components
Control panel assembly A: Remove it from the control head

Machine control PCB A+

B: Remove the Machine Control PCB from the
control panel assembly

Control panel overlay A+B+

C: Release the overlay fasteners from the
control panel assembly

Display PCB A+B+C+

D: Remove the display PCB and chassis, then
separate the display PCB from its chassis

The following procedures describe how to remove and install each individual
component.
Tools Needed
Phillips head screwdriver

11-16 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Control Head Components

Remove the Control Panel Assembly

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Swivel the control head so that the front of the control panel is 90° from the
front of the console.
4. Remove four screws and four lock washers (M4 Phillips), located at the rear
of the control head, that fasten the control panel assembly to the control head.

Important
When the screws are loose, take 5. Slide the control panel forward far enough to allow disconnecting the
care not to let the control panel following cables (refer to Figure 11-9):
assembly fall out of the control
head.  40 pin ribbon cable (J3)
 20 pin ribbon cable (J5)
 10 pin cable (J4)
 6 pin cable (J2).
6. Remove the control panel assembly from the control head.
Figure 11-9.
Disconnecting control panel cables

J3

J5

Replacement Procedures
J4
J1

J2

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-17

Control Head Components

Remove the Machine Control PCB

Notice
Electrostatic Sensitive Devices This unit contains electrostatic sensitive components.
When repairing the system, work at a static control workstation. Wear a grounding strap
when handling electrostatic sensitive components. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic sensitive
components and circuit boards.

1. Attach an ESD wrist strap, then disconnect the 50-pin ribbon cable from the
Machine Control PCB (J1). Refer to Figure 11-9.
2. Remove five screws (M4 Phillips) from the Machine Control PCB.

3. Remove the Machine Control PCB from the control panel assembly.

Remove the Control Panel Overlay

Four snap-in standoffs fasten the overlay to the control panel assembly.
1. To gain access to the standoffs within the control panel assembly, remove the
Machine Control PCB.
2. With your fingertips, squeeze the spring-loaded flanges on the standoffs to
retract them.
3. With the flanges retracted, push the standoffs out of the control panel
assembly to release the overlay.

Remove the Display PCB

1. Remove the control panel overlay.

2. Remove four screws and four lock washers (M4 Phillips) from the display
PCB chassis.
3. Tilt the display PCB and chassis backward at the top. Lift the display PCB and
chassis from the control panel bezel, being careful to make sure the silicon
buttons clear the bezel.
4. Remove the display PCB from the chassis (refer to Figure 11-11):

a. Remove eight screws (M4 Phillips) from the display PCB.

b. Lift the display PCB from the chassis.

11-18 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Control Head Components

Figure 11-10.
Machine
Disconnecting the 50-pin ribbon cable
Control PCB
and removing the Machine Control
PCB

Machine
Control PCB

Figure 11-11.
Removing the Display PCB from the
control head assembly

Replacement Procedures
Control panel
overlay

Control panel
bezel
Display PCB

Chassis

Install the Display PCB

1. Attach the display PCB to its chassis:

a. Position the display PCB onto the chassis.

b. Replace the eight screws (M4 Phillips) in the display PCB.

2. Being careful to make sure the silicon buttons clear the bezel, position the
display PCB and chassis in the control panel bezel.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-19

Control Head Components

3. Replace the four screws and four lock washers (M4 Phillips) on the display
PCB chassis.
4. Replace the control panel overlay.

Install the Control Panel Overlay

1. Identify the overlay to be used.

2. Position it correctly on the control panel assembly.

3. When the tips of the standoffs rest in the corresponding holes in the control
panel assembly, push on the standoffs with your thumbs until you feel and
hear them snap into place.
Note: Use an adhesive sealant at the top of the control panel overlay.

Install the Machine Control PCB

1. Position the Machine Control PCB in the control panel assembly.

2. Replace five screws (M4 Phillips) in the Machine Control PCB.

3. Connect the 50-pin ribbon cable to the Machine Control PCB (J1).

Install the Control Panel Assembly

1. Remove ESD strap.

Notice
To avoid product damage, remove the ESD wrist strap before connecting cables to the
Machine Control PCB.

2. Position the control panel assembly at the control head opening.

3. Before sliding the control panel assembly into the control head, connect the
following cables:
• 40 pin ribbon cable (J3)
• 20 pin ribbon cable (J5)
• 10 pin cable (J4)
• 6 pin cable (J2).
4. Slide the control panel assembly into the control head.

5. Replace four screws and four lock washers (M4 Phillips), located at the rear
of the control head, that fasten the control panel assembly to the control head.

Important
While the screws are still loose, 6. Swivel the control head so that the front of the control panel aligns with the
take care not to let the control front of the console.
panel assembly fall out of the
control head. 7. Plug the power cord connector into the wall receptacle.

8. Turn on the AC Main Switch, located on the rear panel.

11-20 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Control Valve

Suction Control Valve

The following procedure describes how to remove, then re-install, the suction
control valve.
Tools Needed
You will need the following tools:
• Phillips screwdriver
• Metric socket/driver set
• Metric Allen hex key wrench set
• Metric wrench set
• Pliers
• Razor blade knife
• Plastic wire ties.

Remove the Suction Control Valve

Access the Suction Control Valve

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Remove the left, right, and rear covers.

4. Disconnect the suction control valve from the ultrasonics PCB (J7).

5. Lift the arm and control head to the highest position.

Replacement Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-21

Suction Control Valve

6. Remove the left end of the suction pump chamber by removing four screws
(M4 Phillips) and four lock washers (M4). Refer to
Figure 11-12.
7. Remove the right end of the suction pump chamber by removing four screws
(M4 Phillips) and four lock washers (M4). Refer to
Figure 11-12.
8. Remove the suction pump enclosure. Refer to Figure 11-13.
Note: The suction pump enclosure, an L-shaped part, attaches to a baffle
suction pump enclosure. Do not disassemble the two parts.
a. Remove four screws (M4 Phillips) and four lock washers (M4)—two of
each on either end of the enclosure.
b. Slightly lean the enclosure toward the rear of the console so that, as you
remove it, the enclosure will clear other components in the console.
c. Carefully pull the suction pump enclosure out the left side of the console.

11-22 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Control Valve

Figure 11-12.
Removing the ends from the suction Left end of
pump chamber suction pump
chamber

Right end of
suction pump
chamber

Figure 11-13.
Removing the suction pump enclosure
from the console

Replacement Procedures

Suction pump enclosure

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-23

Suction Control Valve

Disconnect, Lift Out, and Disassemble the Control Valve Assembly

1. Disconnect the 3/8 in. inner diameter (ID) suction tube and clamp at the
contamination guard 90° elbow located above the right end of the suction
control valve.
Figure 11-14.
Disconnecting the suction tube at
the contamination guard 90° elbow

2. Remove the cable tie and disconnect the 1⁄8 in. ID tube that connects to the
left end of the control valve.
Figure 11-15.
Disconnecting the suction tube from
the left end of the suction control
valve

11-24 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Control Valve

3. Pull the strain relief bushing for suction pump motor wires away from the
manifold bracket (a mounting bracket for the suction control valve).
Figure 11-16.
Pulling the strain relief bushing away
from the manifold bracket

Bushing

Manifold bracket

4. Remove the manifold bracket from the console:

a. Remove two hex bolts (M5) and two lock washers that secure the
manifold bracket to the frame.
b. Carefully lift the manifold bracket (and suction control valve) out the left
side of the console.
Figure 11-17.

Replacement Procedures
Removing the manifold bracket from
the console

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-25

Suction Control Valve

5. Remove the suction control valve from the manifold bracket:

a. Remove three screws (M4 socket head cap screws) from the suction
control valve.
Note: A lock washer secures the screw on each end of the assembly, but
no lock washer secures the third screw.
b. Lift the suction control valve from the manifold bracket.
Note: The inlet screen for the suction control valve becomes unattached
when you lift the suction control valve off the manifold bracket.
Figure 11-18.
Removing the suction control valve
from the manifold bracket

Suction control
valve

Manifold bracket Inlet screen

11-26 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Control Valve

6. Remove 3/8 in. ID suction tube and clamp from the suction control valve: Set
them aside for re-use.
Note: The new suction control valve does not include this tube and clamp.
Figure 11-19.
Removing the suction hose and clamp
from the suction control valve

Install the Suction Control Valve

Assemble the Suction Control Valve to the Manifold Bracket

1. Attach the 3/8 in. ID suction tube and clamp to the suction control valve.

Replacement Procedures
2. Attach the suction control valve to the manifold bracket:

a. Position the suction control valve inlet screen on the manifold bracket so
that its three holes align with the three screw holes in the bracket.
b. Position the suction control valve on the manifold bracket so that its three
holes align with the three screw holes in the inlet screen and bracket.
c. Replace three screws (M4 socket head cap screws) in the suction control
valve.
Note: A lock washer secures the screw on each end of the assembly, but no
lock washer secures the third screw.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-27

Suction Control Valve

Install the Suction Control Valve in the Console

1. Install the manifold bracket in the console:

a. Position the manifold bracket in the console.

b. Replace two hex bolts (M5) and two lock washers, securing the manifold
bracket to the frame.
2. Secure the strain relief bushing for suction pump motor wires in the manifold
bracket.
3. Connect the 1⁄8-in. ID tube to the left end of the control valve and secure the
tube with one cable tie.
4. Connect the 3/8 in. suction tube and clamp to the contamination guard 90°
elbow located above the right end of the suction control valve.

Install the Suction Pump Enclosure and Close the Suction Chamber
1. Replace the suction pump enclosure:

a. Carefully insert the enclosure into the left side of the console.

b. Slightly lean the enclosure toward the back of the console so that, as you
slide the enclosure into the console, the enclosure will clear other
components.
c. Replace two screws (M4 Phillips) and two lock washers (M4) on each end
of the enclosure.
2. Replace the right end of the suction pump chamber by replacing four screws
(M4 Phillips) and four lock washers (M4).
3. Replace the left end of the suction pump chamber by replacing four screws
(M4 Phillips) and four lock washers (M4).
4. Return the arm and control head to normal position.

5. Connect the suction control valve to the ultrasonics PCB (J7).

6. Replace the left, right, and rear covers.

7. Plug the power cord connector into the wall receptacle.

8. Turn on the AC Main Switch, located on the rear panel.

11-28 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump and Controller Card

Suction Pump and Controller Card

The suction pump and the suction pump controller card are a set; replacing one
requires replacing the other. This procedure describes how to access and remove
the suction pump, install a new suction pump, remove the suction pump controller
card, and install a new suction pump controller card.

Remove the Suction Pump

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Remove the left, right, and rear covers.

4. Lift the arm and control head to the highest position.

5. Remove the left end of the suction pump chamber by removing four screws
(M4 Phillips) and four lock washers (M4).
6. Remove the right end of the suction pump chamber by removing four screws
(M4 Phillips) and four lock washers (M4).
7. Remove the suction pump enclosure:
Note: The suction pump enclosure, an L-shaped part, attaches to a baffle
suction pump enclosure. Do not disassemble the two parts.
a. Remove four screws (M4 Phillips) and four lock washers (M4)—two of
each on either end of the enclosure.
b. Slightly lean the enclosure toward the rear of the console so that, as you
remove it, the enclosure will clear other components in the console.
c. Carefully pull the suction pump enclosure out the left side of the console.

Replacement Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-29

Suction Pump and Controller Card

Disconnect and Remove the Suction Pump

1. Remove the 3/8 in. ID suction tube and clamp from the “T” fitting at the back
of the contamination guard.
Figure 11-20.
Removing the suction tube and
clamp from the “T” fitting

2. Pull the split bushing restraint on the suction tube away from the manifold
bracket (near the right end of the bracket).
Figure 11-21.
Pulling the split bushing away from
the manifold bracket

11-30 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump and Controller Card

3. Disconnect the cables from the suction pump to the suction pump controller
card:
Figure 11-22.
Disconnecting cables from the suction
pump to the suction pump controller
card

Table 11-5.
Suction pump cable connections to the Connector Wire Color
controller card
3-pin, white red, blue, yellow

7-pin, black yellow, brown, green, red, orange*

* The jumper wire occupies pins 6 and 7 on the connector.

Replacement Procedures
4. Pull the strain relief bushing for suction pump motor wires away from the
manifold bracket.

Notice
If you are installing the Noise Reduction Kit (NRK) to the system, refer to the
following addendum for instructions:
Addendum to CUSA EXcel® and CUSA EXcel®-8 Service Manuals:
Installing the Noise Reduction Kit (Document # 510I000IE)
Perform the procedures in this addendum in place of the instructions described
on pages 11-32 through 11-35 in this service manual.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-31

Suction Pump and Controller Card

5. Remove the suction pump and its bracket mount from the wire rope isolators:

a. Remove four screws (M5 Phillips) and four lock washers (M5).
You need a short Phillips screwdriver for this task.
b. Carefully lift the suction pump and its bracket mount from the wire rope
isolators.

11-32 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump and Controller Card

6. Remove the 3/8 in. ID suction tube and clamp from the 90° elbow on the
suction pump: Set them aside for re-use.
Note: Do not remove the split bushing restraint from the tube.
Note: The new suction pump does not include this tube, clamp, or bushing.
Figure 11-23.
Removing the suction tube and strain
relief bushing from the suction pump
and its wires

7. Remove the strain relief bushing from the suction pump wires: Set it aside for
re-use. Refer to Figure 11-23.
Figure 11-24. 8. Remove the suction pump

Replacement Procedures
Removing the suction pump from its from the suction pump
bracket mount bracket mount:
a. Remove four bolts
(M6), four lock washers
(M6), and four nuts
(M6).
b. Lift the pump off the
bracket mount.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-33

Suction Pump and Controller Card

Install the Suction Pump

Prepare the New Pump for Installation

1. Open the packaging for the new suction pump. You will find the pump pre-
connected to a pump controller card. A printed label covers the white 3-pin
connector.
a. Cut, but do not remove, the label on the white 3-pin connector.

b. Unplug the connectors.

c. Remove the new suction pump.

2. Attach the suction pump to the suction pump bracket mount:

a. Position the pump so that it centers on the bracket mount; no part of the
pump body should extend over any edge of the bracket.
b. Replace four bolts (M6), four lock washers (M6), and four nuts (M6).
Figure 11-25.
Attaching the suction pump motor to
its mounting bracket, making sure to
center the pump on the bracket

3. Install attachments:
a. Remove the red plastic cap from the 90° elbow at the pump inlet.

b. Connect the 3/8 in. ID suction tube and clamp to the 90° elbow on the
suction pump inlet.
Note: The split bushing restraint should still be on the tube.
4. Position the strain relief bushing on the suction pump wires 20 cm (8 in.) from
where the wires exit the pump. Crimp the strain relief bushing in place with
pliers.

11-34 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump and Controller Card

Install the Pump in the Console

1. Install the suction pump and its bracket mount onto the wire rope isolators:

a. Carefully position the suction pump and its bracket mount on the wire
rope isolators.
b. Replace four screws (M5 Phillips) and four lock washers (M5).
Tip: You need a short Phillips screwdriver for this task.
2. Connect the 3/8 in. suction tube and clamp from the pump to the “T” fitting at
the back of the contamination guard.
3. Push the split bushing restraint on the suction tube into the manifold bracket
(near the right end of the bracket).
4. Push the strain relief bushing for suction pump motor wires into the manifold
bracket.
5. Install the suction pump enclosure:
a. Carefully insert the suction pump enclosure into the left side of the
console.
Tip: When you replace the screws, replace the top screws
(enclosure-to-manifold bracket) first.
b. Replace four screws (M4 Phillips) and four lock washers (M4)—two on
each end of the enclosure.
6. Attach the right end of the suction pump chamber; use four screws
(M4 Phillips) and four lock washers (M4).
7. Attach the left end of the suction pump chamber; use four screws
(M4 Phillips) and four lock washers (M4).

Replacement Procedures
Ready for Suction Pump Controller Card Replacement
At this point, you have removed the suction pump, then re-installed several
components:
• New suction pump
• Suction pump enclosure
• Suction chamber end panels.
The new suction pump is not yet connected to the controller card. The reason is
simple: If you replace the suction pump, you must replace the controller card.
Likewise, if you replace a controller card, you must replace the suction pump.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-35

Suction Pump and Controller Card

Remove the Suction Pump Controller Card

1. Disconnect the controller card from the ultrasonics board at J15:
Table 11-6.
The suction pump controller card Connector Wire Color
cable to the ultrasonics PCB
4-pin red, black, orange, brown

Important
The cables in the cable clamps 2. Remove the two cable clamps on the bottom of the controller card bracket,
sometimes tangle. When you pull then separate the controller card cable from other cables in the clamps.
the controller card cable away
from the console, be careful to 3. Remove the suction pump controller card from the motor control bracket by
avoid pulling other cables with it. removing four screws (M4 Phillips), four lock washers (M4), and four flat
washers (M4).
Figure 11-26.
Removing the cable clamps and
screws from the suction pump
controller card

11-36 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump and Controller Card

Install the Suction Pump Controller Card

Notice
To avoid product damage, when handling the suction pump controller card, do not turn
the three white adjustment dials designated as current limit (R13), max speed (R12), and
min speed (R11).

1. Attach the new suction pump controller card to the motor control bracket
using four screws (M4 Phillips), four lock washers (M4), and four flat
washers (M4).
2. Replace the two cable clamps on the bottom of the controller card bracket.

3. Connect the controller card cables:

Table 11-7.
Suction pump cable connections Loc Connector Wire Color

J15 4-pin red, black, orange, brown

(ultrasonics
PCB)

Cable from 7-pin, black yellow, brown, green, red, orange*

suction
pump

Cable from 3-pin, white red, blue, yellow

suction
pump

* The jumper wire occupies pins 6 and 7 on the connector.

Replacement Procedures
Tip: To align the white, 3-pin cable connectors easily, line up the
corresponding segments on the white label that you cut when you removed the
new suction pump from its packaging.
4. Calibrate the suction pump and controller card. For instructions, refer to
Suction Pump in Section 12, Calibration, in this manual.
5. Return the arm and control head to normal position.

6. Replace the left, right, and rear covers.

7. Plug the power cord connector into the wall receptacle.

8. Turn on the AC Main Switch, located on the rear panel.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-37

Suction Pinch Valve

Suction Pinch Valve

Accessing the suction pinch valve requires removing the irrigation pump bezel.
The following procedures describe how to remove and re-install the irrigation
pump bezel and the suction pinch valve.
Tools Needed
You will need a Phillips head screwdriver.

Remove the Irrigation Pump Bezel

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Open the irrigation pump latch halfway so that the latch lever stands at the 12
o’clock position.
4. Four ball-end retainers hold the irrigation pump bezel in place. Remove the
pump bezel by pulling it straight forward. Refer to Figure 11-27.

Remove the Suction Pinch Valve

1. Remove the console rear and left covers.

2. Disconnect the suction pinch valve from the ultrasonics PCB (J18).

3. Remove the two screws (M4 Phillips) that hold the pinch valve onto the pinch
valve collar.
4. Remove the pinch valve electrical leads from the cable restraints.

5. Remove the pinch valve by pulling it forward. Refer to Figure 11-28.

Note: Ensure that the electrical leads are free to move.

11-38 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pinch Valve

Figure 11-27.
Removing the irrigation pump bezel

Irrigation pump bezel

Figure 11-28.
Removing the suction pinch valve

Replacement Procedures
Pinch valve
collar

Suction pinch valve

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-39

Suction Pinch Valve

Install the Suction Pinch Valve

1. Replace the pinch valve by pushing it into place.
Note: Ensure that the electrical leads are free to move.
2. Replace the pinch valve electrical leads on the cable restraints.

3. Replace the two screws (M4 Phillips) that hold the pinch valve onto the pinch
valve collar.
4. Connect the suction pinch valve to the ultrasonics PCB (J18).

5. Replace the console rear and left covers.

Install the Irrigation Pump Bezel

1. Align the 4 ball-end retainers that hold the irrigation pump bezel in place.
Attach the pump bezel by pushing it straight toward the console.
2. Close the irrigation pump latch by rotating the latch lever clockwise until it
reaches the 3 o’clock position.
3. Plug the power cord connector into the wall receptacle.

4. Turn on the AC Main Switch, located on the rear panel.

11-40 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Irrigation Pump Head and Gear Motor

Irrigation Pump Head and Gear Motor

Accessing the irrigation pump head requires removing the irrigation pump bezel;
accessing the irrigation pump gear motor requires removing the bezel and the
panel behind it. The following procedures describe how to remove and re-install
the irrigation pump bezel, head, and gear motor.
Tools Needed
You will need the following tools:
• Phillips head screwdriver.
• Slotted blade screwdriver
• 7 mm nut driver
• 3/32 in. Hex key or Allen wrench.

Remove the Irrigation Pump Bezel

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Open the irrigation pump latch half way so that the latch lever stands at the 12
o’clock position.
4. Four ball-end retainers hold the irrigation pump bezel in place. Remove the
pump bezel by pulling it straight forward. Refer to Figure 11-29.
Figure 11-29.
Removing the irrigation pump bezel

Replacement Procedures

Irrigation pump bezel

Remove the Irrigation Pump Head

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-41

Irrigation Pump Head and Gear Motor

1. Remove two screws (8 - 32 buttonhead) from the front of the irrigation pump.
These screws fasten the pump head to a flat panel.
2. Pull the pump forward to remove it from the panel.
Figure 11-30.
Removing the irrigation pump head

Irrigation pump head

Install the Irrigation Pump Head

Refer to Figure 11-30.
1. Open the irrigation pump latch completely.

2. View the end of the gear motor coupling, noticing the position of the slot in
the end of the coupling. Position the shaft tang in the pump head to match the
position of the slot in the gear motor coupling.
3. Insert the shaft tang into the slot on the gear motor coupling.
4. Position the pump head on the panel, making sure that the head is flat against
it.
5. Insert two screws (8 - 32 buttonhead), through the front of the pump head.

Important
Do not overtighten the screws. If 6. Set the screws with a 3/32 in. Hex key or Allen wrench.
the screws are too tight, they can
crack plastic parts in the pump 7. Rotate the pump shaft by hand to ensure that the shaft tang has seated properly
head. in the gear motor coupling.

11-42 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Irrigation Pump Head and Gear Motor

Remove the Irrigation Pump Gear Motor

Removing the gear motor requires removing the left side cover and the irrigation
pump bezel, but not the pump head.
1. Remove the four screws and four lock washers (M5 Phillips) that hold the
panel to the console.
2. Pull the panel forward and lay it on top of the console. It is not necessary to
remove the suction pinch valve or the irrigation pump head.
3. Remove the four hex nuts (M4), four washers (M4), and four lock washers
(M4) from the motor control card bracket.
4. Pull the control card bracket far enough from the frame to disconnect the
irrigation gear motor from the control card. Refer to Figure 11-31.
Figure 11-31.
IRRIGATION CONTROL CARD
Disconnecting the irrigation pump
gear motor from the control card 2 HP COOLING CONTROL CARD
PCOM
2 R21 J1
7 R4
R2
J2
J2
R4

IRRIGATION PUMP
A

B
+24V

C
PCOM +24V

Replacement Procedures
R21 J1
R2 COOLING PUMP

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-43

Irrigation Pump Head and Gear Motor

5. Disconnect the gear motor ground wire from the frame.

6. After disconnecting the gear motor from the control card, push the bracket
back in the frame and secure it with a minimum of one M4 hex nut.
7. Remove the four screws and four lock washers (M5 Phillips) that attach the
gear motor bracket to the console frame.
8. Pull the gear motor and its bracket forward and remove them from the frame.

9. Remove the four screws (10 - 32 Phillips) that attach the gear motor to the
bracket.
10. Remove the gear motor from the bracket. Refer to Figure 11-32.
Figure 11-32.
Replacing the gear motor/pump
head coupler on the motor drive
shaft

11. Measure the position of the gear motor pump coupler on the motor drive shaft.
Remove the coupling from the shaft by loosening the hex drive set screw.
12. Put the coupling on the new gear motor drive shaft, making sure that the
coupling is in the same position on the new drive shaft as it was on the old
drive shaft.

11-44 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Irrigation Pump Head and Gear Motor

Install the Irrigation Pump Gear Motor

1. When you have put the coupling on the new gear motor drive shaft, making
sure that the coupling is in the same position on the new drive shaft as it was
on the old drive shaft, tighten the drive set screw.
2. Position the gear motor on the bracket.

3. Replace the four screws and four lock washers (10 - 32 Phillips) that attach the
gear motor to the bracket.
4. Put the gear motor and its bracket into the frame, then push them into position.

5. Replace the four screws and four lock washers (M5 Phillips) that attach the
gear motor bracket to the console frame.
6. Remove the hex nut (M4) that secures the control card and bracket to the
frame.
7. Pull the control card bracket far enough from the frame to reconnect the
irrigation gear motor:
Table 11-8.
Irrigation pump control card Wire or connector Terminal
connections
6-pin J1

brown A

red B

orange C

8. Reconnect the gear motor ground wire to the frame.

Replacement Procedures
9. Push the control card bracket back in the frame and secure it with four hex
nuts, four washers, and four lock washers (M4).
10. Position the panel on the console frame. Ensure that the tang on the irrigation
pump shaft aligns with the motor shaft coupling.
11. Replace the four screws (M5 Phillips) and four lock washers (M5) that attach
the panel to the frame.

Replace the Irrigation Pump Bezel

1. Four ball-end retainers hold the irrigation pump bezel in place. Align the
retainers with their holes in the console, then push the bezel into place.
2. Close the irrigation pump latch by rotating the latch lever clockwise until it
reaches the 3 o’clock position.
3. Plug the power cord connector into the wall receptacle.

4. Turn on the AC Main Switch, located on the rear panel.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-45

Handpiece Flow Sensor

Handpiece Flow Sensor

Replacing the handpiece cooling water sensor involves removing the right and
rear covers, then accessing and disconnecting the sensor before removing it.
Installing the sensor involves reversing the access process.
Tools and Materials Needed
You will need the following tools:
• Phillips screwdriver
• Pliers
• Isopropyl alcohol
• Handpiece cooling water sensor spares kit:
 One handpiece cooling water sensor assembly
 Two plastic wire ties (one required)
 Instructions for use.

Remove the Handpiece Flow Sensor

1. Turn off the AC Main Switch, located on the rear panel.

2. Unplug the power cord connector from the wall receptacle.

3. Remove the right side cover and the rear cover.

4. Disconnect the flow sensor wiring harness from the ultrasonics board at J5.

5. Remove the handpiece cooling water sensor wiring harness from the cable
restraint located above the sensor.
6. Remove the 1.587 mm (1⁄16 in.) ID tube from the upper end of the flow
sensor.
7. Remove the two screws (M4 Phillips) that attach the flow sensor to the frame.
Lift the flow sensor upwards.
8. Remove the wire tie securing the 3.175 mm (1⁄8 in.) ID tube to the 90° elbow
fitting on the bottom end of the flow sensor.
9. Remove the 3.175 mm (1⁄8 in.) ID tube from the 90° elbow fitting on the
bottom end of the flow sensor.
10. Remove the flow sensor.

11-46 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Handpiece Flow Sensor

Figure 11-33. COM

Replacing the handpiece flow sensor

Plastic wire ties

NC

COM 1.587 mm
(1/16 in.)
ID Tubing

NO
Bottom end of sensor
Plastic wire tie

3.175 mm (1/8 in.)

ID Tubing

Replacement Procedures

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-47

Handpiece Flow Sensor

Install the Handpiece Flow Sensor

1. Apply isopropyl alcohol to the inside surface of the 3.175 mm (1⁄8 in.) tube
and the outside surface of the 3.175 mm (1⁄8 in.), 90° elbow tube fitting on the
bottom of the flow sensor.
2. Push the 3.175 mm (1⁄8 in.) ID tube onto the 90° elbow fitting on the bottom
of the flow sensor. Make sure to push the tube completely onto the fitting.
3. Secure the tubing with a plastic wire tie.

4. Lower the flow sensor into place and attach it to the frame using two screws
(M4 Phillips).
5. Apply isopropyl alcohol to the inside surface of the 1.587 mm (1⁄16 in.) tube
and the outside surface of the 1.587 mm (1⁄16 in.) tube fitting on the top end
of the flow sensor.
6. Push the 1.587 mm (1⁄16 in.) ID tube onto the tube fitting on the top end of
the flow sensor. Make sure to push the tube completely onto the fitting. Make
sure, also, that the tube is straight on the fitting.
7. Connect the handpiece cooling water sensor wiring harness to the ultrasonics
board at J5.
8. Secure the handpiece cooling water sensor wiring harness inside the cable
restraint located above the sensor. The cable restraint will contain two water
tubes and the wiring harness.
9. Replace the right side cover and the rear cover.

10. Plug the power cord connector into the wall receptacle.

11. Turn on the AC Main Switch, located on the rear panel.

11-48 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Cooling Water Pump Tubing

Cooling Water Pump Tubing

Integra offers a cooling water preventive maintenance kit. This kit allows you to
perform two tasks:
• Replace the cooling water pump tubing.
• Replace the o-rings on the cooling water reservoir connectors.
Perform each task every 12 months.
This section tells you how to replace the cooling water pump tubing; the
following section, Cooling Water Reservoir O-Rings, tells you how to replace the
o-rings on the cooling water reservoir connectors.
This replacement requires removing the left side cover of the console, then
removing the cooling water pump head. The following procedure describes how
to remove the cooling water pump head, replace the tubing, and re-install the
pump head.

Tools and Materials

You will need the following items:
• Phillips screwdriver
• Slotted blade screwdriver.
• Cooling water preventive maintenance kit:
 Pump tubing
 Two o-rings
 Four plastic wire ties

Replacement Procedures
 One packet of silicone lubrication
 Instructions for use.

Remove the Cooling Water Pump Head

1. Turn off the AC Main Switch, located on the rear panel.
2. Unplug the power cord connector from the wall receptacle.

3. Remove the left side cover.

4. Remove the wire ties. Disconnect the pump tubing from the cooling water
tubes at the fittings (2).
5. Remove two screws (8 - 32 Phillips) from the pump head. This releases one-
half of the pump head— an “end bell.” Pull the released end bell from the
console. Refer to Figure 11-34.
6. Remove the tubing from the inside of the released end bell.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-49

Cooling Water Reservoir O-Rings

Figure 11-34.
Removing the end bell and tubing
from the cooling water pump head

End bell

End bell

From handpiece
connector

Rotor

Install Tubing and Re-Assemble the Cooling Water Pump Head

1. Hold the released end bell with the tubing retainer grooves pointing down.

2. Center the tubing in the right groove and against the first two rollers. Hold the
tubing with your thumb.
3. With the other hand, working counterclockwise, wrap the tubing completely
around the rotor, pushing the tubing into the bell assembly. When the tubing
has wrapped completely around the rotor, hold the second end in place.
4. Position the end bell with the tubing on the end bell in the console. Ensure that
the flat end of the pump drive shaft fits into the slot on the end of the motor
coupler.
5. Replace the two screws (8 - 32 Phillips) that attach the end bells.
Note: If a gap remains between the two end bells after you position them
together, the pump head may pinch or cut the tubing. Rotate the pump shaft
until the gap disappears.
6. After determining that no gap exists between the end bells, tighten the two
screws.
7. Trim the length of the new tubing to reach the cooling water tube fittings.

8. Connect the tubing to the fittings, and replace the wire ties on the fittings. The
kit includes two extra wire ties in case you break or lose one.
9. Replace the left side cover.

10. Plug the power cord connector into the wall receptacle.

11. Turn on the AC Main Switch, located on the rear panel.

Cooling Water Reservoir O-Rings

11-50 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Cooling Water Reservoir O-Rings

Integra offers a cooling water preventive maintenance kit. This kit allows you to
perform two tasks:
• Replace the cooling water pump tubing.
• Replace the o-rings on the cooling water reservoir connectors.
Perform each task every 12 months.
This section tells you how to replace the o-rings on the cooling water reservoir
connectors; the previous section, Cooling Water Pump Tubing, tells you how to
replace the cooling water pump tubing.

O-Rings on the Cooling Water Reservoir Connectors

This replacement requires removing the cooling water reservoir from the console,
then removing the o-rings on the reservoir connectors. The following procedure
describes how to remove the reservoir, remove the used o-rings, install the new o-
rings, and re-install the reservoir.
1. Press the cooling water reservoir release button (just above the reservoir) on
the arm housing to release the fittings inside the housing.
2. Slide the reservoir toward the rear of the console.

3. Remove the o-ring on each male connector on the cooling water reservoir.
Refer to Figure 11-35.
Figure 11-35.
O-rings on cooling water reservoir
connectors

Replacement Procedures
4. Open (tear or cut the end) the packet of silicone lubricant.
5. Apply the silicone lubricant to the two o-rings in the cooling water preventive
maintenance kit.
6. Slide one o-ring over the end and into the groove at the distal end of each male
connector on the cooling water reservoir. Refer to
Figure 11-35.
7. Re-install the reservoir: Slide it into the slot on the console side panel until it
snaps into place.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 11-51

Fuses

Fuses
You must change the fuses (located on the rear panel) if a fuse burns out.
Tools needed
You will need a small slotted blade screwdriver.
Procedure
1. Using the screwdriver, turn the fuse cover counter clockwise (about 45°). The
fuse holder pops loose.
2. Remove the fuse holder from the rear panel.

3. Replace the fuse:

Table 11-9. Fuse values
Volts Amps Type

95–120 V T10A Time Delay (Default)

220–240 V T5A Time Delay

4. Insert the holder, and turn the cover clockwise.

11-52 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 12

12 Calibration

In this section:

• Tools/equipment needed for calibrations

• DC bias power supply
• Suction pump
• Motor for the cooling water pump.

For Your Information

In the CUSA EXcel system, several components may require calibration. This
section describes how to do the calibrations.
In most cases, you need to calibrate a component only when you replace it. These
procedures stand alone; that is, you can use one without reference to others.

Warning
High Current Hazard Do not touch the ultrasonics PCB heat sink while the
CUSA EXcel system is energized. The heat sink is isolated from ground, and can deliver
very high current, resulting in injury.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 12-1

Tools/Equipment Needed for Calibrations

Tools/Equipment Needed for Calibrations

The calibrations require one or more of the following tools:
• Tachometer
• Irrigation bottle with fluid and administration set
• Digital multimeter, Fluke 87 or equivalent
• Vacuum gauge with T fitting and hose, 0–30 in. Hg
• Ashcroft 5 in. Dial-Grade 3A 0.25% or equivalent
• Suction canister
• Contamination guard
• Slotted blade screwdriver
• Phillips screwdriver.

DC Bias Power Supply

1. Leave all power off.

2. Remove the rear panel.

3. Put DVM leads between pins 1 and 6 of the output jack on the DC bias power
supply. You will find it on the AC input assembly (facing the rear of the
console, you see it on the left side of the assembly).
4. Turn on the AC Main Switch (rear panel) and the System Power Switch (front
panel).
5. Adjust the potentiometer to 4.7 Vdc (-0 + 0.05).

6. Turn off the System Power Switch (front panel) and the AC Main Switch (rear
panel).
7. Apply a suitable potentiometer locking compound to the adjustment screw of
the potentiometer.

12-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Suction Pump

Suction Pump
1. Remove the left cover.

2. Remove the left end panel from the suction pump enclosure.

3. On the control panel, set the unit to Run mode.

4. Apply the digital tachometer to the suction pump motor shaft.

5. Adjust the Max. speed pot on the suction pump controller card so that the
motor operates at 3200 ± 20 rpm.
6. On the control panel, set the unit in Standby mode.

7. With the digital tachometer, verify that motor speed is greater than 1200 rpm.

8. Apply Torque Seal compound (Integra part number xxxx232 301 176xxxx) to
the Max. speed pot.
9. On the suction pump enclosure, replace the left end panel.
10. On the console, replace the left cover.

Motor for the Cooling Water Pump

Set Up
Before calibrating the motor for the cooling water pump, prepare the cooling
water system:
1. Fill and attach the cooling water reservoir.

2. Attach a handpiece to the console.

3. Turn on the AC Main Switch (rear panel) and the System Power Switch (front
panel).
When you turn on the System Power Switch, the CUSA EXcel system begins
to circulate cooling water through the handpiece. This takes about one minute
to complete. While the system is performing this task, the amber Wait
indicator flashes and the Cooling Water indicator (upper right on the control
panel) illuminates.
When the system turns the Wait and Cooling Water indicators Off, it turns On
the suction pump, the Test button LED, and the Prime button LED. The
cooling water system is ready for calibration.
4. Prime the system: Press the Prime button (blue box on a black button at the
top of the Irrigation display).
Watch for irrigation fluid to drip from the handpiece tip. Priming takes about
Calibration

one minute.
After priming, the system automatically turns the Prime button LED Off, then
goes to the Standby status.

Procedure

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 12-3

Motor for the Cooling Water Pump

1. Remove the left cover from the CUSA EXcel console.

2. On the control panel, set the unit to Run mode.

3. While the unit is in Run mode, apply the digital tachometer to the cooling
water pump shaft.
4. Adjust the Max. Speed trim pot “R2,” located between J1 and J2 on the
control card for the cooling water motor, to operate the motor speed at the
maximum speed attainable within the range of 61 to 68 rpm.
5. On the CUSA EXcel console, replace the left cover.

12-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 13

13 Repair Policy

In this section:

• Return equipment for service:

Obtaining a return authorization number
Returning the console
Returning the handpiece
Returning circuit boards
Ordering replacement parts
• Integra service centers.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 13-1

Return Equipment for Service

Return Equipment for Service

Before you return CUSA equipment, call your Integra representative for help. If
the representative tells you to send the equipment to Integra, first obtain a Return
Authorization Number. Then clean the equipment and ship it to Integra for
service.

Obtaining a Return Authorization Number

Call Integra Customer Service for your area (refer to “Integra Service Centers” in
this section) to obtain a Return Authorization Number. Have the following
information ready when you call:
• Hospital/clinic name/customer number
• Technician’s name
• Telephone number
• Department/address, city, state, and zip code
• Model number
• Serial number
• Description of the problem
• Type of repair to be done.
Clearly mark the Return Authorization Number on the device and package before
shipping to the service center. Attach a tag with this same information to the
equipment when you ship it for service.

Returning the Console

It is very important that you use the proper materials—original packaging
materials, if possible—and the proper packing procedures to ship the console. If,
in Integra’s judgement, you fail to use the proper packing procedures or if you use
improper packaging materials to return the console, you may void the warranty on
this system.

13-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Return Equipment for Service

Tools and Materials Needed:

• Shipping materials:
 Pallet

Repair Policy
 Corrugated shipping crate, cover, tray, and ancillary container
 Right foam cushion
 Left foam cushion
 Top lock cushions (2)
 Bottom lock cushions (2)
 Foam head cushion
• Poly bag 30 in. x 60 in. x 26 in.
• Poly bag 10 in. x 14 in. (1)
• Poly banding, approximately 65 ft
• Banding seals or banding buckles (5)
• Box edge protectors (12)
• Staple gun with 1/2 in. staples
• Pliers (optional).
Procedure
1. Position the pallet with the ramp down and all other materials removed.

2. Roll the console up the

ramp. If the rear casters are
unlocked, be sure that you
do not allow the console to
roll off the side of the ramp.

3. Put the power cord inside a

polyethylene bag, then secure the cord and bag with a wire tie. Put the bagged
power cord on the footswitch storage shelf in the console rear.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 13-3

Return Equipment for Service

4. Raise the arm and control

panel, then place the
U-shaped foam cushion
under the control panel.
Lower the arm, locking the
control panel into the foam
cushion.

5. Lock the front (brake) casters and the rear (directional) casters by pushing
each lock lever downward.

6. Place the clear plastic bag

over the console.

13-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Return Equipment for Service

7. Route a vertical band over the clear plastic bag:

a. Over the top of the arm

b. Around the left side of the console

Repair Policy
c. Through the footswitch bracket on the bottom of the console

d. Around the right side of the console.

Be sure the clear plastic bag does not bend the reference cards in the control
panel.
Secure the band with one banding seal.

8. Attach the right (5) and left (6) foam cushions to the console.
Attach the four interlocking foam pieces (1–4) from the foam cushion around
the console (refer to the following figure).

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 13-5

Return Equipment for Service

9. Position the corrugated

crate walls on the pallet so
that the front of the crate is
on the same side of the
pallet as the ramp.
Close the right front panel
of the corrugated crate
around the console.

10. Raise the ramp.

Caution
To prevent the ramp from falling and causing injury, be sure to hold the ramp in the up
position while stapling the corrugated tab that secures it to the crate.

11. Secure the ramp to the

corrugated tab on the right
front panel with two 1/2 in.
staples.

13-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Return Equipment for Service

12. Close the left front panel

around the front of the
console and the right front
panel.

Repair Policy
13. Secure the crate closed by locking the three plastic clips into the slots on the
side of the corrugated crate. Refer to the next figure.
a. With the clip oriented so that the tab is on its bottom edge, insert the clip
into the slot. Push hard enough that the flange on the clip rests firmly on
the outside of the left front panel and the leading edge of the clip is inside
the corrugated crate.
b. Push the horizontal bars inside the clip toward the crate until the bars lock
into place.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 13-7

Return Equipment for Service

14. Pack the CUSA EXcel footswitch into its original packaging, and seal the
packaging with tape.
15. Place the sealed footswitch
packaging into the
corrugated tray.
Note: If returning a
handpiece, secure it into its
original packaging, then
place the handpiece
packaging into the
corrugated tray.
Install the tray in the top of
the corrugated crate.
16. Install the cover on the
corrugated crate.

17. Secure the shipping crate

closed with two horizontal
bands, two band seals, and
eight box edge protectors.

18. Secure the shipping crate to

the pallet with two vertical
bands, two band seals, and
four box edge protectors.

13-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Integra Service Center

Returning the Handpiece

Clean, disinfect, and sterilize the handpiece before you package it for shipping.
Package the handpiece and handpiece cable in a way that will protect the
handpiece and handpiece cable connector from damage.

Repair Policy
Package each handpiece in a separate packaging container.

Returning Circuit Boards

When packaging circuit boards use the following guidelines:
• Whenever possible, use the same packing materials in which you received the
circuit board.
• Place each circuit board or subassembly in an electrostatic discharge (ESD)
bag or container.
• Provide a separate packing container for each circuit board.
• When returning a subassembly with electrical components, use at least four
inches of tightly packed, industry approved, shock absorbing, ESD packing
material on all sides, including the bottom.

Ordering Replacement Parts

When ordering replacement parts for the console, include this information:
• Model number (located on the label on the CUSA system rear panel)
• Serial number (located on the label on the CUSA system rear panel)
• Part number (Refer to the Replacement Parts section in this manual).
When ordering replacement parts for the handpiece, include the serial number
(located on the handpiece connector).

Integra Service Center

Integra NeuroSciences
5965 Pacific Center Blvd.
Suite 714
San Diego, CA 92121
Ph: 858-455-1115
Fax: 858-455-8298
E-mail: camts@integra-ls.com

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 13-9

Notes

13-10 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 SECTION 14

14 Service Parts Lists

In this section:

• Ordering replacement parts

• Replacement parts
• Electronics parts.
• Miscellaneous spare parts

Ordering Replacement Parts

When ordering replacement parts for the console, include this information:
• Model number (located on the label on the CUSA system rear panel)
• Serial number (located on the label on the CUSA system rear panel)
• Part number.
When ordering replacement parts for the handpiece, include the serial number
(located on the handpiece connector).
Replace all components with parts of identical construction and value.
Replacement part ratings and tolerances must be equal to, or better than, original.
Substituting lower grade parts can adversely affect system performance.
If you have any questions about ordering parts, please call the Integra Service
Center nearest you.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 14-1

Replacement Parts

Replacement Parts

Handpiece Cooling
Table 14-1.
Handpiece cooling replacement Reference Integra
parts Designator Description Part Number

Isolation Diaphragm Valve 221004474

Handpiece Cooling Sensor Assembly S202750084

Cooling Water Reservoir Assembly 202750115

Cooling Water Coupling, Console, In 243500009

Cooling Water Coupling, Console, Out 243500259

Cooling Water Tubing, 3.175 mm (1/8 in.) ID 625028007

Cooling Water Pump Gear motor, 18:1 Ratio 1004269

Cooling Water Pump 577014003

Coupling, Pump/Motor 223400735

Cooling Water Preventive Maintenance Kit S911000014

Irrigation
Table 14-2.
Irrigation replacement parts Reference Integra
Designator Description Part Number

Irrigation Pump Gear motor, 25:1 Ratio 1004270

Irrigation or Cooling Motor Control Card 1004268

Irrigation Pump Head 243500267

Coupling, Pump / Motor 223400735

IV Pole 223400733

14-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Replacement Parts

Miscellaneous
Table 14-3.
Miscellaneous replacement parts Reference Integra
Designator Description Part Number

CUSA EXcel Footswitch 150000090

O-rings Maintenance Kit 260650000

Torque Seal 232301176

23 kHz Handpiece/Tip Maintenance Kit C0023

CUSA EXcel Reference Card Set 225550157ILS

Cooling Water Maintenance Kit S91100014

Service Parts Lists

Power
Table 14-4.
Power replacement parts Reference Integra
Designator Description Part Number

Power Switch, Mains 243080001

Power Supply, 40W, 5 VDC 207000223

Fuse, 5X20mm, 5 AMP, 250 V, Time Delay 215100084

Fuse, 5X20mm, 10 AMP, 250 V, Time Delay 215100082

Standby Switch, VAC 243080005

Power Supply, 800W x 2 x 24V 207000277

Solid State Relays (International) 230007008

Power Cable 10ft/3m (Europe/Continental) 207002061

Power Cable 15ft/4.57m Domestic 207002065

Power Cable 16.5ft/5m (Europe/Continental) 207002066

Power Cable 15ft/4.57m (UK) 207002073

Power Cable 15ft/4.57m (Swiss) 207002074

CUSA EXcel+: Power Supply, 800W x 2 x 24 V 207000278

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 14-3

Electronic Parts

Suction
Table 14-5.
Suction replacement parts Reference Integra
Designator Description Part Number

Vacuum Pump 220250010

Suction Control Valve 243500261

Suction Pinch Valve 243500006

Contamination Guard C0005

Tubing Suction 3/8 X 1/8 inch 625028007

Tubing Silistic Neoprene 624405000

Tubing Contamination Guard 249101651

Electronic Parts
Table 14-6.
Printed circuit board spares Reference Integra
Designator Description Part Number

PCBA Display 207700237

Ultrasonics and Machine Control Printed S202750281

Circuit Boards

Interconnection Cables
Table 14-7.
Interconnection Cables Reference Integra
Designator Description Part Number

Assembly Cable GND Lug Chassis 207500659

Assembly Cable Power Supply - GND 207500678

Assembly Cable AC/SW - Fuse 207500635

Assembly Cable Fuse - Line Filter 207500636

Assembly Cable Line Filter - MC Power 207500753

Assembly Cable Filters - Power Supply 207500684

14-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Electronic Parts

Reference Integra
Designator Description Part Number

Assembly Cable MC - Solid State Relay 207500641

Mechanics
Table 14-8.
Mechanics Reference Integra
Designator Description Part Number

Control Panel Overlay 223301187

Control Panel Bezel 223150231

Cover Top CUSA 223150225

Service Parts Lists

Cover Front CUSA 223150226

Cover Leg Left CUSA 223150227

Cover Leg Right CUSA 223150228

Cover, Lift 223150230

Bezel, IRR Pump 223150289

Cover, Left Side 223200687

Cover, Right Side 223200641

Cover, Rear 223200679

Panel, Pump Bezel 223301180

Bracket Resevoir 223301205

Bottom Left Channel 223301254

Bottom Right Channel 223301255

CUSA EXcel+: Bezel, IRR Pump 1103001 IE

CUSA EXcel+: Cover Top CUSA EXcel+ 1103000 IE

CUSA EXcel+: Cover, Left, EXcel+ 1102000 IE

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 14-5

Electronic Parts

FETs
Table 14-9.
Ultrasonics board parts—FETs Reference Integra
Designator Description Part Number

Q4, 7, 8, 9, 12, FET, BSS110 239200069

13

Q2, 3, 5, 6, 11, 2N7000 N Channel MOS 239200071

14

Q1 FET, P Channel RFP10P03L 239200072

Integrated Circuits
Table 14-10.
Ultrasonics board parts—integrated Reference Integra
circuits Designator Description Part Number

U18 IC, Timer LM555CN 210006001

U19, 3, 6 UDN2596A 210100053

U14 IC, 74HC00 210230007

U21 DG201A 210250102

U28 IC, Flip-Flop MC1417B 210250103

U8 LM78L05 210300109

U13 LF353 210400037

U17 IC, LM 393 AN 210410004

U11 AD570JD 210740014

14-6 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 Electronic Parts

Connectors
Table 14-11.
Ultrasonics board parts—connectors Reference Integra
Designator Description Part Number

J6 Connector PCB, 2 CKT, 0.256 in. centers 208160052

J4 Connector PCB, 3 CKT, 0.256 in. centers 208160053

J15 Connector PCB, 4 CKT, 0.256 in. centers 208160054

J3 Connector PCB, 5 CKT, 0.256 in. centers 208160055

J1 Connector PCB, 10 CKT, 0.256 in. centers 208160060

J14 Connector PCB, 6 CKT, 0.100 in. centers 208200321

Service Parts Lists

J12 Connector PCB, 40 CKT Dual Row, Ribbon 208200323

J7 Connector PCB, 12 PIN, Dual Row, 0.100 in. 208200382

centers

J9 Connector PCB, 20 PIN, Dual Row, Ribbon 208200383

J5, 10, 11, 18 Header, 2 PIN, 0.100 in. centers, Lock 208200389

J16, 17, 19 Header, 4 PIN, 0.100 in. centers, Lock 208200390

J8, 13 Header, 2 PIN, 0.295 in. centers, Lock 208200391

J2 Connector CIR Receptacle, 7 CKT 208300818

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual 14-7

Miscellaneous Spare Parts

Miscellaneous
Table 14-12.
Ultrasonics board parts— Reference Integra
miscellaneous Designator Description Part Number

All TPs Test Point 208200284

6 Contact Socket CPC PC MO 208200378

All JMPs Jumper, 0.100 in. center, Wire 208400117

5 Socket FET Single Pin 208500106

7 Nut Plate, Footswitch Connector 223301195

2 Heatsink, T0-220 Pkg. 223400757

4 Nut Hex 4-40 STL NKL PLD 224011023

K1 Relay Reed, Ultramini, SPST 230017010

3 Screw, Pan Hd, Phil 4-40 X 1/2 237100680

SW1, 2, 3, 4 Dip Switch 243080015

U27 TRANSF, 24 V dc to 15 V dc Converter 251200086

All DFs Filter, EMI, 1MHz FC, 3 Pins 251400011

Miscellaneous Spare Parts

Reference Integra
Designator Description Part Number

CUSA EXcel Service Transportation Case 4103002IE

14-8 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 APPENDIX A

Warranty
A

Integra Warranty for CUSA EXcel® Ultrasonic Surgical Aspiration System

1. Warranty.
INTEGRA LIFESCIENCES CORPORATION and its wholly owned subsidiaries
("Integra") warrant to Integra authorized distributors and the original purchaser only that
each new Integra Cusa Excel Ultrasonic Surgical Aspirator (hereinafter the Equipment or
the product) is free from manufacturing defects in material and workmanship under normal
use and service for a period of one (1) year (except as otherwise expressly provided as to
accessory items) from the date of invoice by Integra (or its authorized distributor) to the
original purchaser, but in no event beyond the expiration date stated on any product
labeling (hereinafter the Warranty Period). For purposes of products sold by Integra
through an authorized distributor of Integra, "original purchaser" shall include the
purchaser of Integra products to whom the distributor first sells the product. The original
purchaser is hereinafter referred to as Customer.
1.1. Coverage. During the Warranty Period, Integra shall provide free-of-charge
service and maintenance consistent with the provisions of Section 3 of this Warranty,
so that the Equipment conforms to the specifications defined in the Cusa Excel
Ultrasonic Surgical Aspirator Operator’s Manual, as such Operator’s Manual may be
modified by Integra from time to time (the “Specifications”).
1.2. Exclusions. The Warranty shall not apply in any manner to service or maintenance
of the Equipment, or to replacement of its parts, with respect to:
(i) use of Equipment with any tips, flues, and manifold tubing sets and
accessories other than those manufactured by Integra LifeSciences;
(ii) defects arising out of materials or parts provided, modified or designed by
anyone other than an authorized Integra service agent (the Integra “Service
Agent”);
(iii) defects emanating from improper or negligent installation, storage or use of
the Equipment or any component thereof, including but not limited to operating
the Equipment not in accordance with instructions provided in the Operator’s
Manual;
(iv) defects arising from improper or negligent cleaning or sterilization methods or
improper maintenance of the Equipment;
(v) defects resulting from repairs or service of the Equipment provided other than
by Integra or its authorized representatives;

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual A-1

 (vi) defects arising from accidental damage to the Equipment, acts of God, electrical
power damage, equipment malfunction, unusual stress, unreasonable operating
procedures or abnormal or extreme operating conditions; and
(vii) normal wear and tear.

2. Service, Repairs and Replacement.

2.1. Service and Repairs. All service and repairs covered by this Warranty may be
referred to hereinafter as "in-warranty repairs," and all service and repairs not covered
by this Warranty may be referred to as "out-of-warranty repairs." Integra's sole
obligation for in-warranty repairs shall be to make all necessary adjustments and
repairs in accordance with this Warranty. Integra shall charge Customer at Integra
standard rates for any out-of-warranty repair performed by Integra.
2.2. Equipment Replacement. The defective Equipment or part thereof that is replaced
in accordance with the Warranty shall be the property of Integra. Integra reserves the
right to fill spare parts requests using refurbished sub-assemblies provided that such
sub-assemblies are functionally equivalent to new sub-assemblies and carry the same
warranty as the replaced sub-assemblies.
2.3. Notification. In order to avail itself of its rights under the Warranty, Customer or
Integra authorized distributors, must immediately notify Integra of any defects and
provide Integra every opportunity to inspect and remedy defects.

3. Repair Parts and Services.

3.1. Included under the Warranty are the following services:
3.1.1. Consoles. Integra or its distributor, when authorized for this purpose, shall,
if possible, perform on-site repair of consoles and where not possible or otherwise
decided at the sole discretion of Integra, Integra or its distributor shall arrange and
pay to ship the affected Equipment to the designated repair facility. Integra or its
distributor authorized for this purpose shall repair the affected Equipment or
replace a console by a new or refurbished console (all of which at the discretion of
Integra), that shall carry the same remaining warranty as the original equipment.
3.1.2. Handpieces. Integra shall repair or replace any defective handpieces covered
by the Warranty by a new or refurbished handpiece (all of which at the discretion
of Integra) that shall carry the same remaining warranty as the original equipment
(an "Exchange Handpiece").
3.2. Modifications to Covered Equipment. From time to time, at its sole discretion,
Integra may propose modifications to the covered Equipment and to the Specifications
for the Equipment. Subject to Customer's approval and at its sole expense, the
Customer may request Integra to make such modifications to the covered Equipment
and to the Specifications. Integra shall make such modifications for the Customer,
which modifications may include the installation of new parts in the Equipment, at a
price equal to the then-current list price for such modifications, as such list price is
established by Integra in its sole discretion.

4. Quality Control.
4.1. Customer shall maintain reasonable standards of quality control, operations,
procedures, safety testing and inspection of Equipment to ensure that unnecessary
service or maintenance is not required hereunder.
4.2. Customer shall provide a technical counterpart to Integra's Service Agent for
assistance in Integra's telephonic diagnosis of the malfunction with the Equipment.
Customer shall reasonably accept Integra's determination whether a repair or service is
an in-warranty repair or an out-of-warranty repair.

A-2 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual

 5. Limitation of Liability.
5.1. INTEGRA's sole responsibility under the warranties described in Section 1 shall
be repair or replacement, at INTEGRA's sole discretion at INTEGRA's expense,
subject to the terms of this warranty and applicable agreements. THE WARRANTIES
DESCRIBED IN SECTION 1 HEREOF ARE EXCLUSIVE AND ARE GIVEN AND
ACCEPTED IN LIEU OF ALL OTHER WARRANTIES OF INTEGRA OR ITS

Warranty
SERVICE AGENTS WITH RESPECT TO THE QUALITY, PERFORMANCE AND
OPERATION OF THE EQUIPMENT, WRITTEN OR ORAL, EXPRESS OR
IMPLIED, AND WHETHER OR NOT ATTRIBUTABLE TO SERVICE
PERFORMED PURSUANT TO THE WARRANTY. ALL OTHER
REPRESENTATIONS OR WARRANTIES OF INTEGRA OR ITS
REPRESENTATIVES, EXPRESS OR IMPLIED, WITH RESPECT TO THE
EQUIPMENT OR THE SERVICES, DIAGNOSIS, ADVICE, ASSISTANCE OR
PARTS TO BE TENDERED PURSUANT TO THE WARRANTY, INCLUDING,
WITHOUT LIMITATION, THOSE OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY DISCLAIMED. IN NO
EVENT SHALL INTEGRA, ITS ASSIGNEES OR SERVICE AGENTS BE LIABLE
FOR LOSS OF USE, REVENUE OR PROFIT OR ANY OTHER INDIRECT,
INCIDENTAL, EXEMPLARY, CONSEQUENTIAL, SPECIAL OR OTHER
DAMAGES, WHETHER ARISING IN CONTRACT OR IN TORT, BY VIRTUE OF
THE WARRANTY OR ANY PERFORMANCE OR BREACH BY INTEGRA, ITS
ASSIGNEES OR SERVICE AGENTS HEREUNDER OR PURSUANT HERETO.
5.2. Customer agrees that, notwithstanding the technical assistance provided pursuant
to the Warranty by Integra or its representatives, Customer shall be fully and solely
responsible for all treatments performed or attempted with the Equipment. INTEGRA
MAKES NO REPRESENTATION OR WARRANTY AS TO THE EFFICACY OF
THE EQUIPMENT OR OF THE TECHNICAL ASSISTANCE TO BE RENDERED
BY INTEGRA, ITS ASSIGNEES OR SERVICE AGENTS, FOR PURPOSES OF
THE PARTICULAR TREATMENT THAT CUSTOMER INTENDS TO PERFORM
FOR THIRD PARTIES. Moreover, Integra disclaims any liability with respect to the
efficacy of the Equipment or of said technical assistance or with respect to any claims
by third parties related to any treatment performed by Customer.
5.3. THIS INTEGRA LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND OF ALL OTHER
OBLIGATIONS OR LIABILITIES ON INTEGRA'S PART OR THE PART OF ITS
DISTRIBUTORS, AND INTEGRA NEITHER ASSUMES NOR AUTHORIZES
ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR IT ANY
OTHER LIABILITY IN CONNECTION WITH INTEGRA'S PRODUCTS.
INTEGRA DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR A PARTICULAR PURPOSE OR APPLICATION OR WARRANTY
OF QUALITY AS WELL AS ANY EXPRESS OR IMPLIED WARRANTY TO
PATIENTS. No warranty or guarantee may be created by any act or statement nor may
this Standard Warranty be modified in any way, except as a result of a writing signed
by an officer of INTEGRA. These limitations on the creation or modification of this
warranty may not be waived or modified orally or by any conduct.
5.4 IN NO EVENT SHALL INTEGRA AUTHORIZED DISTRIBUTORS BE
LIABLE TOWARDS CUSTOMER FOR ANY INCIDENTAL, INDIRECT,
CONSEQUENTIAL OR PUNITIVE DAMAGES IN CONNECTION WITH THE
ACQUISITION OR USE OF ANY INTEGRA PRODUCT. Further, this warranty
shall not apply to, and INTEGRA authorized distributors shall not be responsible
towards Customer for, any loss, arising in connection with the purchase or use of any
INTEGRA product that has been repaired by anyone other than an authorized
INTEGRA service representative or altered in any way so as to affect its stability or
reliability, or which has been subject to misuse, negligence or accident, or which has
been used otherwise than in accordance with the instructions furnished by INTEGRA.

CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual A-3

 THIS INTEGRA DISTRIBUTOR LIMITED WARRANTY IS EXCLUSIVE AND IN
LIEU OF ALL OTHER WARRANTIES TOWARDS CUSTOMER, EXPRESS OR
IMPLIED, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES TOWARDS
CUSTOMER ON INTEGRA AUTHORIZED DISTRIBUTOR'S PART.
INTEGRA AUTHORISED DISTRIBUTORS DISCLAIM ALL OTHER
WARRANTIES TOWARDS CUSTOMER, EXPRESS OR IMPLIED INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE OR APPLICATION OR WARRANTY OF QUALITY AS
WELL AS ANY EXPRESS OR IMPLIED WARRANTY TO PATIENTS OR OTHER
THIRD PARTIES.
5.5 Force Majeure. Notwithstanding anything to the contrary herein contained, if the
performance of the Warranty by Integra, Integra authorized distributors, or Customer
or any obligation of Integra, Integra authorized distributors, or Customer hereunder is
prevented, restricted or interfered with by reason of fire, explosion, act of God, labor
disputes or accidents affecting performance under the Warranty, or war, mobilization,
civil commotions, blockade or embargo, or any future law, regulation, ordinance or
requirement of any government or regulatory agency or any other act, whatsoever
similar to those above enumerated, or any other circumstance being beyond the
reasonable control of Integra, Integra authorized distributors, or Customer, then and in
that event Integra, Integra authorized distributors, or Customer, as the case may be,
shall promptly notify the other party hereto of the difficulties resulting therefrom, and
any of the foregoing events shall excuse any performance required under the
Warranty.

A-4 CUSA EXcel Ultrasonic Surgical Aspirator System Service Manual