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Patient 1
(B)(4). EVALUATION PROCESS: UNIT RECEIVED IN STANDARD SHIPPING BOX, IN GOOD CONDITION. NO POWER CORD, USER MANUAL, OR HANDPIECES WERE RECEIVED WITH THE UNIT. INTERNAL VISUAL INSPECTION FOUND NOTHING MISSING OR BROKEN IN UNIT. HANDPIECE FUNCTIONALITY WAS FAULTY; CUT BUTTON WOULD NOT OPERATE GENERATOR. COAG BUTTON WOULD ACTIVATE GENERATOR BUT ENERGY DELIVERY WOULD NOT SHUT OFF WHEN BUTTON RELEASED. WHEN USING THE FOOTSWITCH INSTEAD OF THE HANDPIECE FOR ACTIVATION THE UNIT DELIVERED RF ENERGY CORRECTLY INTO FIXED RESISTORS. TROUBLESHOOTING REVEALED THAT COMPONENT C154 ON THE RF AMP PCBA HAS A FAULTY SOLDER JOINT: THE COAG BUTTON SIGNAL VOLTAGE COULD BE FORCED TO SWITCH BETWEEN ITS EXPECTED (UNACTIVATED) VALUE TO ABOUT HALF OF ITS EXPECTED VALUE BY FLEXING THE RF AMP PCBA. WHEN THE SIGNAL WAS AT ITS HALF-VOLTAGE VALUE, CUT BUTTON CLOSURES WERE FOUND TO BE IGNORED. COAG BUTTON CLOSURES WERE FOUND TO CAUSE THE SIGNAL TO DROP TO ITS FULLY-CLOSED VALUE (THEREBY ACTIVATING COAG OUTPUT). RELEASING THE COAG BUTTON CAUSED THE SIGNAL TO RISE BACK TO THE HALF-VOLTAGE VALUE, WHICH WAS NOT RECOGNIZED AS A BUTTON RELEASE. REMOVING THE OLD SOLDER FROM C154, CLEANING THE PADS, AND THEN RESOLDERING THE PART RESOLVED THE ISSUE. ROOT CAUSE: FAULTY SOLDER CONNECTION OF CAPACITOR C154 ON THE RF AMP PCBA CAUSED THE DESCRIBED BEHAVIOR. THIS BEHAVIOR WAS SPURIOUS; THE PROBLEM COULD BE MADE TO APPEAR/DISAPPEAR BY FLEXING THE PCB. (B)(4).