Surge Canada provides repair services for phaco handpieces and harmonic scalpels. Phacoemulsification uses ultrasonic vibrations to break up cataracts during eye surgery. Harmonic scalpels also use ultrasonic technology to simultaneously cut and cauterize tissue. Both devices rely on piezoelectric crystals that convert electrical energy to mechanical vibrations. Surge Canada's repair process involves complete disassembly, replacement of worn parts, reassembly, and testing to restore functionality while maintaining quality standards.
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Phaco Harmonic Scalpel Repair
1. Surge Canada
Phaco Handpiece & Harmonic Scalpel
Design, Care and Repair
2. Phaco Emulsification
Surgical cataract removal procedure
Number 1 therapeutic surgery for
Canadians over 65 years of age.
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3. History of Phacoemulsification
Definition: Phaco lens shaped, relating to a lens. From
the Greek phakos, lentil (lens), anything shaped like a
lentil
Invented nearly 40 years ago by Dr. Charles Kelman,
M.D.
He received a $280,000 grant and 3 year time limit
Live cats were used as test animals. Early results were
poor and he had blind cats in his basement
The idea of using ultrasound came to him as he sat in
the dentists chair
4. How does Phaco work?
Operates on the principle of the
Piezoelectric Effect
PE discovered by Pierre & Jacques Curie
in the 1880’s
When crystals are subjected to an
electrical field, they expand and contract in
direct proportion to that electrical field
Converting electrical energy into
mechanical energy
5. Phaco Procedure
Handpiece primed and tuned
Small incision in the eye via diamond knife
Handpiece tip inserted under cornea
Phaco machine powers crystals in handpiece
Handpiece tip vibrates ultrasonically thousands
of times per second to break up (emulsify) the
cataract
Cataract aspirated and flushed with fluid
solution
Man-made Intra-Ocular lens inserted
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7. Phaco Machine
Microprocessor controlled
instrument
Has capability of irrigation,
aspiration, emulsification, cautery,
and cut modes of operation
Functions can be controlled by
footpedal, remote control, or on the
console
8. Phaco Handpiece
A slim, lightweight, piezo-electric,
air-cooled, autoclavable instrument
approximately the size of a magic
marker
9. Irrigation
port
Serial # etching Distal tip
Aspiration
port
Cord/strain Stainless steel or Titanium
relief casing/shell
Phaco Handpiece External
Components
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10. Main Internal Component
Piezoelectric crystal - each handpiece has a
pair or 2 pairs of ceramic crystals, which vary
in size. They resemble thick washers. When
electrified the tip vibrates longitudinally (like a
jackhammer) thousands of times per second.
Crystals are extremely sensitive to changes in
temperature.
There are no moving parts in the handpiece!
11. Examples of different
handpieces
Alcon 20,000 Legacy AMO Sovereign
Bausch & Lomb Millennium Bausch & Lomb Premiere
13. Alcon Legacy NeoSoniX
Alcon’s answer for “Cold Phaco”
Includes a motor that oscillates the tip as
well as performing the typical jackhammer
effect
Moisture intrusion again biggest source of
failure
15. ALCON INFINITI OZIL
Alcon’s newest phaco hand piece.
Has additional internal components.
Alcon’s most expensive exchange.
16. Alcon Infiniti Ultrasonic
Functions on the Infiniti phaco system
Frequency is 40,000 Hz
An alternative to using the heavy
NeoSoniX or when the doctor does not
want to use the oscillating motion
17. Common Reasons Handpieces
Fail
In general, a handpiece will break
down
after approximately 500 procedures
Crystals cracked
Cord (wire) damage
Connector damage
Tip damage
Jammed needles
Clogged aspiration port
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18. Common Causes of Handpiece
Failure one cause of
Sterilization is the number
failure even when performed properly
−
Repeated exposure to heat and
pressure causes the crystals to
depolarize, or causes breaks in the
mold/seals which allows moisture
intrusion
−
Moisture intrusion will cause electrical
failure
−
FOLLOW MANUFACTURER’S
STERILIZATION AND COOLING
INSTRUCTIONS 16
19. Common Causes of Handpiece
Failure
Rapid Temperature Change
−
Not allowed to naturally cool for at least 15
min
−
Attempts to expedite cooling can damage
crystals
Mishandling
−
Dropping, pulling rubber boot loose,
misaligning pins, cutting cord, threading
improperly
Failure to clean
−
Failure to clear aspiration port
−
Build up of debris on connector 17
20. Repairs
Only damaged cords, connectors, and shells can
be identified by visual inspection
For all other problems, the handpiece must be
completely disassembled to evaluate the internal
components to determine cause of failure
In order to replace any component including the
connector and cord, the entire handpiece must
be taken apart and re-assembled
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21. Handpiece Repair
Complete disassembly including transducer
assembly from outer shell and transducer
Replaceable parts are discarded
Remaining parts ultrasonically
cleaned/inspected
Transducer reassembled using new parts and
tested
Transducer assembly mated to new tested
connector and cable assembly – tested again
then placed in shell housing
Autoclaved and re-tested. 20
22. Ethicon Harmonic Scalpel
repair
Surge Canada offers repair of all 3 early
generations of Ethicon harmonic scalpel,
plus the new Harmonic Blue.
23. What is a harmonic scalpel?
Ultrasonic instrument that cuts and
cauterizes at the same time- coagulates
blood proteins-55,000 Hz
Operates at a much lower temperature
than other instruments- electrical surgical
unit (ESU)
Produces very little if any smoke or
charring of tissue- clearer surgical field
Use improves recovery time of patient
24. Who uses the harmonic
scalpel?
Harmonic scalpel used in all types of open
and laparoscopic procedures
Very popular for tonsillectomy
Ob/Gyn
Can be used in most cases where ESU is
traditionally used
Becoming more popular for obvious
reasons
25. Scalpels vs. Phaco Handpiece
Scalpels are very similar to phaco
handpiece in technology
Also works on the piezoelectric effect
Plugs into the host system via a cable and
multi-pin connector
26. HARMONIC SCALPELS
Generation I, obsolete.
Generation II, diminishing.
Generation III, most popular.
Harmonic Blue, newest, growing in
popularity. ( 16 crystals)
27. What’s inside?
The scalpel has all of the same type
components as the Phaco handpiece
Piezoelectric crystals (4)
Connector
Cable
Electrodes
O-rings, seals
28. Repair Procedure
Repair procedure mimics that of the phacos
Complete disassembly of scalpel: discard cable,
connector, crystals, electrodes and o-rings
Inspect and clean salvaged components ultrasonically:
shell, header assembly, horn, etc.
Complete subassemblies and test each: cable assembly,
transducer stack assembly, cable stack assembly, final
assembly
Final test, autoclave and re-test
29. Service options
Manufacturer does not repair. Handpiece or
scalpel are replaced
Repair or exchange
−
Within two working days from approval of repair
Emergency exchange
−
Customer requires handpiece the next day. Send to
customer that night and customer’s broken handpiece
is sent in as an exchange
−
No loaners available
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30. Common Customer
Concerns
Currently using manufacturer
−
Possible reasons- quality, safety, ease,
bad experience with 3rd parties, does
not know alternative exists
−
Possible concerns- Price, poor service,
being controlled by manufacturer
We provide better service and price
without sacrificing quality.
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31. Common Customer
Concerns
Handpiece repair may void machine
warranty
−
Ask manufacturer rep to show language
in writing or put this statement in writing
−
If has statement in writing ask for a copy
−
Usually this cannot be provided
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32. Points to Remember
Most of the time a handpiece must be
disassembled to determine which components
have failed. The machine does not provide a
failure analysis on the handpiece. Only external
damage (cord or tip damage) and certain
connector problems can be detected prior to
disassembly.
Manufacturers do not trouble-shoot or do minor
repairs. They send out exchange handpieces
Standard warranty – 90 days failure of
component or due to workmanship
33. The Surge Canada Medical
Difference
All repairs utilize new components
Cable, crystals, electrodes, connector
assembly, o-rings and seals
Custom made cable w/ Aramid fiber
We use the same vendors for components
as the OEM’s whenever possible
Unmatched engineering support- lead
engineer for Alcon and AMO on staff
Annually audited Quality System
34. Quality Assurance is Key.
Our quality system is a living, breathing
thing. It does not sit on the shelf until
audit time. We use it every day.