Power Drive
Contents
1. Insert a K wire into the quick coupling for K wires Completely open the adjusting sleeve at the end of the attachment Insert the K wire and close the adjusting sleeve until it clamps the wire Then open the adjusting sleeve three clicks The K wire is lightly held in the selected position Note Ensure K wire is centered in cannulation prior to tightening the adjusting sleeve Insert a K wire into bone Grasp the K wire by pulling the lever against the handpiece and press the lower forward trigger Remove a K wire from bone Open the adjusting sleeve of the attachment completely Slide the drive unit and coupling over the K wire Close the adjusting sleeve until it clamps the wire Then open the adjusting sleeve three clicks Grasp the wire by squeezing the lever toward the handpiece and press both triggers reverse simultaneously to remove the wire from the bone Synthes 11 Operating Instructions Attachments continued Quick Coupling for drill bits 511 75 Accepts quick coupling drill bits and screwdriver shafts Allows use of Oscillating Drill Attachment 511 20 and Radiolucent Drive 511 30 Large Quick Coupling 511 761 Accepts DHS and DCS triple reamers and large cannulated drill bits see page 10 for installation and removal of attachments Important To prevent injuries the safety lock should always be switched to the LOCK position when inserting or removing an Inst2. Charging time 80 minutes maximum Working temperature range 0 to 50 C 32 to 122 F Discharge protection Prevents total battery discharge eliminating memory effect maintaining battery capacity and increasing battery lite Important Do not sterilize batteries Batteries will no longer function Universal Battery Charger 530 601 Four charging bays accept Small Battery Drive Power Drive and Battery Power Line batteries One 1 battery can be placed in each charging bay allowing a maximum of four 4 batteries to be charged at the same time Status indicator panels Complies with standards UL 60950 IEC 60950 EN 55022 class B EN 61000 3 2 3 EN 61000 4 2 3 4 5 6 11 Synthes 3 Attachments for Power Drive 511 731 Jacobs Chuck Keyless Accepts K wires and Steinmann pins with round shafts trom 1 0 mm to 6 0 mm in diameter or triangular shafts up to 6 5 mm on heres Quick Coupling for drill bits Accepts quick coupling drill bits Allows use of Oscillating Drill Attachment 511 20 and Radiolucent Drive 511 30 511 761 Large Quick Coupling Accepts DHS and DCS triple reamers and large quick coupling cannulated drill bits 511 785 Reduction Drive Unit Allows direct medullary reaming with flexible shafts Reduces maximum speed to 270 rom Increases maximum output torque to 12 5 Nm A
3. drive unit Remove battery from casing Battery casing must be open for sterilization Note Do not sterilize batteries Batteries will no longer function The Synthes Power Drive Set should be steam sterilized in the graphic case in accordance with the following guidelines Minimum Wrapped Temperature Exposure Time Prevacuum 132 135 C 24 minutes 270 275 F Unwrapped Flash Prevacuum 132 135 C 24 minutes 270 275 F Times represent exposure times only and not total cycle times Important Do not accelerate the cooling process A thermal overload circuit prevents drive unit operation when the drive unit is overheated After cooling to room temperature the drive unit should function Hot air and ethylene oxide gas ETO sterilization are not recommended Synthes 21 Troubleshooting Drive Units and Attachments Problem Possible Causes Remedy Machine does not start Safety lock may be in the LOCK position Set LOCK to UNLOCK No electrical contact between drive unit and battery casing Reattach or change battery casing Battery is drained Charge or replace battery Drive unit has not cooled after sterilization Allow drive unit to cool to room temperature Machine lacks power Battery is drained Charge or replace battery Machine suddenly stops Battery is drained Charge or replace battery Dri
4. 0 0 6 5 519 1005 27 50 0 6 _ 519 1708 27 70 0 8 519 1705 OO 519 2008 27 70 1 0 519 2108 27 70 1 2 Se 519 1908 50 70 0 8 E E z i qi 319 2305 Please contact your Synthes Sales Consultant or Customer Service for additional information Illustrations not to scale Synthes 27 SYNTHES 2000 Synthes Inc or its affiliates All rights reserved Synthes USA Synthes Canada Ltd 1302 Wrights Lane East 2566 Meadowpine Boulevard West Chester PA 19380 Mississauga Ontario L5N 6P9 Telephone 610 719 5000 Telephone 905 567 0440 To order 800 523 0322 To order 800 668 1119 Fax 610 251 9056 Fax 905 567 3185 www synthes com DCS DHS and Synthes are trademarks of Synthes Inc or its affiliates Printed in U S A 8 08 J2971 F
5. 00 05 002 302S 19 12 5 90 1 19 05 002 303S 19 12 5 90 127 05 002 304S 19 12 5 90 137 05 002 305S 19 12 5 90 1 47 05 002 501S 25 60 0 89 519 1098 25 60 0 90 Please contact your Synthes Sales Consultant or Customer Service for additional information Illustrations not to scale Blade width Shaft width wl s s al l VEIAN ona L id Ke 919 1165 aa AE e o o 05 002 001S PITAA NAANA A A A A a 035 002 3025 VAAN p a a Ha E Pas 3 5 E 3 3 gt x 7 C C 3 319 1095 26 Synthes Power Drive Saw Blades for Oscillating Saw Attachment II 511 801 continued Saw blades with aggressive tooth calibrated sterile continued Blade Calibrated Cutting Width mm Length mm Thickness mm 05 002 101S 25 95 0 89 ea A AS AE 519 1085 25 95 0 90 N gt 05 002 1065_ 25 95 1 00 A S N 05 002 1075 25 95 1 07 SA 05 002 1025 25 95 1 19 05 002 1015 519 1158 25 95 1 25 05 002 1035 25 95 127 05 002 104S5 25 95 1 37 519 1175 25 95 1 40 05 002 1055 25 95 1 47 05 002 4015 25 85 1 47 Saw blades calibrated sterile 519 2308 6 25 0 6 ae t EF EF fk Foes 519 103S 10 25 0 6 o 519 1045 10 50 0 6 G0 SS 519 2505 14 25 0 6 st 519 1065 519 150S 14 50 0 6 519 1138 18 70 1 2 Pe ee ee ee ee ee ee 519 106S 19 70 1 0 Oe eee 5 519 105S 20 5
6. 957 Three Year Service and Extended Warranty tor Power Drive Set Saw Blades for Reciprocating Saw Attachment sterile 511 902 Cutting Cutting Length mm Thickness mm 511 905S 80 1 05 511 906S 70 1 27 511 9078 55 1 05 511 9098 55 0 85 SL L125 68 1 10 511 9135 68 1 00 511 914S 68 0 80 511 9155 40 1 10 t Use with Reciprocating Saw Blade 511 91559 Double sided Use with Sternum Top for Reciprocating Saw Attachment 511 904 4 o WARP R RRRA RRA RRA MANAN annnm ana 311 9035 511 907S aa PO IP IG IE IG ABIES IFIP IP II IP IF II IIAP IG APY 511 9098 Fes dk de A DAA AAAAALALALASAAA DADA Ad Adana 311 9125 Synthes 25 Also Available continued Saw Blades for Oscillating Saw Attachment II 511 801 Saw blades with aggressive tooth calibrated sterile Blade Calibrated Cutting Width mm Length mm Thickness mm 05 002 201S 12 5 90 0 89 519 1188 12 5 90 0 90 05 002 4055 12 5 90 1 00 05 002 202S 12 5 90 1 19 05 002 2035 125 90 1 27 05 002 2045 12 5 90 1 37 05 002 2058 T25 90 1 47 05 002 006S 19 80 0 89 05 002 001S 19 95 0 89 519 1075 19 95 0 90 05 002 007S 19 95 1 00 05 002 008S 19 95 107 05 002 002S 19 95 1 19 519 114S 19 95 125 05 002 003S 19 95 1 27 05 002 004S 19 95 137 519 116S 19 95 1 40 05 002 005S 19 95 1 47 05 002 301S 19 12 5 90 0 89 05 002 306S 19 12 5 90 1
7. automatically Synthes recommends an annual preventive maintenance service by gualified Synthes personnel Synthes 23 Power Drive Set 105 957 Graphic Case 60 550 020 Graphic Case Base Assembly 60 550 021 Lid 60 550 024 Insert tray for Battery Casings 60 550 032 Attachment Rack 60 550 033 Insert tray for Saw Attachments Note Graphic case components must be ordered individually for complete graphic case assembly Instruments AEI Jacobs Chuck keyless Dado Quick Coupling for drill bits 511 761 Large Quick Coupling 511 785 Reduction Drive Unit 511 791 Quick Coupling for K Wires 511 801 Oscillating Saw Attachment Il 530 100 Power Drive 530 200 Battery 2 ea 530 250 Battery Insertion Shield 2 ea 530 280 Battery Casing 2 ea 530 601 Universal Battery Charger 4 Bays 530 601 5 j e n 4 e e eeeeeoeoe es e e eeeee e Palle q a a 6 6 6 6 6 6 6 24 Synthes Power Drive Also Available 511 20 Oscillating Drill Attachment 511 30 Radiolucent Drive Mark Il S1173 Jacobs Chuck with key 511 782 Hudson Adaptor 511 783 Modified Trinkle Adaptor 511 784 Trinkle Adaptor 511 786 Reduction Drive Unit with Reverse 511 80 Oscillating Saw Attachment 311 902 Reciprocating Saw Attachment 511 904t Sternum Top for Reciprocating Saw Attachment Service and Extended Warranty Programs W1 105 957 Annual Service and Extended Warranty tor Power Drive Set W3 105
8. chments with one to two drops of oil Operate the parts to distribute the oil and wipe off the excess oil Periodically apply one drop of Synthes autoclavable oil onto each trigger shaft and move it a few times Also lubricate the attachment release ring Cleaning battery and battery charger To clean battery wipe with a soft cloth Important Do not use solvents to disinfect the batteries Battery poles must not contact water or solvents Danger of short circuiting Synthes 19 Care and Maintenance continued Battery storage and charging After cleaning insert the batteries into the charger The charger continuously monitors the battery level and automati cally recharges as necessary This ensures that the batteries are fully charged and ready for use at any time When batteries occupy all charger bays extra batteries can be stored in a cool dry place Before the next use the batteries must be charged Important After prolonged storage of the batteries outside the charger two or three charging cycles may be necessary to achieve full battery capacity Always leave the charger switched on when a battery is inserted in a charging bay to ensure permanent availability and prevent discharge 20 Synthes Power Drive Sterilization To sterilize the Power Drive and attachments Disassemble all parts including attachments adaptors instruments and battery packs Remove battery pack from
9. e battery is fully charged and operational Figure 3 The battery should be left in the charging bay until needed ce i e The battery can be removed during the charging process however the battery may not be fully charged and opera tional duration may be shorter Important Q A Q Always leave the charger switched on when a battery is inserted in a charging bay Leaving a battery in the charger when it is switched off or unplugged may permanently discharge the battery a ae E Figure 2 Never attempt to insert more than one battery in the same charging bay Note If LEDs do not follow this sequence refer to the eg Cc troubleshooting section page 23 i Kh Figure 3 6 Synthes Power Drive Operating Instructions Battery Pack Assemble battery pack Instruments 530 250 Battery Insertion Shield 530 280 Battery Casing Inserting the battery into the casing and preserving the sterile field requires one scrubbed nurse operating room technician and one circulating nurse Scrubbed person 1 Hold the sterilized battery casing Open the lid by depressing the silver switch and rotating the latch counterclockwise 2 Place the sterilized battery insertion shield on the battery casing The insertion shield helps guide the battery into the case ensuring that the nonsterile battery does not contaminate the outside of the sterilized battery casing Circulating person 3 Ca
10. er running water to loosen and remove debris Open and close chucks and move quick couplings back and forth 1 Remove debris Manually remove blood and debris from the drive and attachments under running water Use a mild cleaning solution and a soft brush or cloth Do not allow water to enter the drive unit 2 Disinfect Wipe or spray the drive unit battery casing and attachments with disinfectant 3 Rinse Remove all residues trom the disinfected drive unit battery casing and attachments under running water using a soft brush or cloth Synthes I7 Care and Maintenance continued 4 Clean cannulations Instrument 519 40 Cleaning Brush Clean cannulations of the drive unit and attachments with the cleaning brush Note The quick coupling for K wires must be fully open to the largest diameter setting before inserting the brush 5 Dry all components Dry the drive unit and attachments with a soft cloth 18 Synthes Power Drive Lubricating Instrument 519 97 Synthes Autoclavable Oil Use only Synthes autoclavable oil to lubricate the power drive and attachments Lubricate the attachments after every cleaning and before sterilization The drive unit should only be oiled if resistance is noted in the triggers attachment coupling site or release ring Important NEVER lubricate the radiolucent drive Lubricate all moving parts of the atta
11. increase the reliability and life span of the system Synthes recommends annual preventive services Yearly maintenance will ensure that the equipment maintains the highest standard of performance and will prolong the life of the system Important Disassemble battery pack and return batteries to charger immediately after each use Do not disinfect immerse or sterilize batteries Batteries may be wiped with a cloth Before cleaning and sterilization remove attachments instruments and cutting tools trom the drive units Cleaning and lubrication should be performed immediately after each use Clean the drive units attachments and battery casings by hand Never immerse or clean in an automatic washer or ultrasonic cleaner Use a mild neutral pH cleaning solution Caution Do not sterilize batteries Batteries will no longer function Cleaning batteries and universal battery charger To clean batteries and charger wipe with a soft cloth Important Do not use solvents to disinfect the batteries Battery poles must not contact water or solvents Danger of short circuiting 16 Synthes Power Drive Cleaning the power drive Important Disassemble battery pack and return batteries to battery charger immediately after each use Do not disinfect immerse or sterilize batteries Batteries may be wiped occasionally with a soft cloth Before cleaning manipulate all moving parts und
12. main body counter clockwise Remove an instrument Turn the main body clockwise to open the chuck jaws Remove the instrument Important To prevent injuries the safety lock should always be switched to the LOCK position when inserting or removing an Instrument Main body J 14 Synthes Power Drive Oscillating Saw Attachment II 511 801 Accepts standard and aggressive tooth saw blades Important To prevent injuries the safety lock should always be switched to the LOCK position when inserting or removing an instrument Insert a saw blade into the oscillating saw attachment II 1 Position the attachment The saw attachment can be locked in 8 different positions in 45 increments To reposition the saw attachment remove the attachment from the power drive and reattach at the desired position 2 Turn the locking knob counterclockwise to open blade mount 3 Insert saw blade into the blade coupling and adjust to the desired position The blade can be locked in different positions at 45 increments 4 Close the coupling by turning the locking knob clockwise Remove the saw blade Open the blade coupling and remove the saw blade See page 10 for installation and removal of attachments 3 Blade mount Ceanu SA Il I Locking knob G Synthes 15 Care and Maintenance Regular care and maintenance according to the following guidelines can significantly
13. owe Battery driven power we SEN for orthopaedics and traumatology User s Manual HOME RAD RE a Instruments and implants approved by the AO Foundation Table of Contents Introduction Power Drive 2 Battery and Charger 3 Attachments for Power Drive 4 Operating Instructions Universal Battery Charger 6 Battery Pack 7 Drive Unit 9 Attachments 10 Product Information Care and Maintenance 16 Sterilization 21 Troubleshooting 72 Set List 24 Synthes Power Drive 530 100 Variable speed 0 750 rom Weight including battery 1 750 g Torque 4 5 Nm Cannulation 3 2 mm diameter Attachment release ring Allows easy exchange of attachments Attachment coupling _ Accepts a wide variety of attachments Instant reverse trigger Reverses rotation to counterclockwise direction Variable speed trigger Controls rotational speed Safety lock Turns drive off for safe attachment exchange Battery casing Simple twist off design allows easy intraoperative battery exchange Holds battery in sterile environment This device complies with the following standards UL 2601 1 EN 60601 IEC 601 1 EN 60601 1 1 VDE 0750 part 1 and 2 EN 55011 VDE 0875 part 11 Limiting values of class B group 1 2 Synthes Power Drive Battery and Charger Battery 530 200 Voltage 12 VDC Capacity 1 0 Ah Type NiCd
14. refully insert the nonsterile battery into the battery casing and oress firmly until it engages The battery design guarantees correct positioning of the charging poles on insertion Note Do not sterilize batteries Batteries will no longer function Synthes 7 Operating Instructions Battery Pack continued Assemble battery pack continued Circulating person 4 Remove the battery insertion shield Scrubbed person 5 Close and lock the battery casing lid without touching the battery or the inside of the battery casing Rotate the latch clockwise to a vertical position until you hear the safety lock engage Note Although one battery is usually sufficient for one operation two battery packs battery casing with inserted battery should always be prepared to ensure a quick intra operative battery pack exchange under sterile conditions Install battery pack 6 Turn the battery pack battery casing with inserted battery clockwise to couple it to the lower part of the power drive via the locating posts at the base of the handle The geometry prevents incorrect coupling Remove battery pack Turn the battery pack counterclockwise to uncouple it Note Installing the battery pack just before use extends the life of the battery and minimizes intraoperative battery exchange 8 Synthes Power Drive Operating Instructions Drive Unit Speed control For forward clockwise rotation pre
15. rument Insert an instrument Push the collar of the quick coupling forward and insert the instrument shaft completely with a slight rotation to align the keyway When the shaft is fully inserted release the collar Pull slightly on the instrument to ensure that it is held securely Remove an instrument Push the collar of the quick coupling forward to release the instrument 12 Synthes Power Drive Reduction Drive Unit 511 785 Allows intramedullary reaming with flexible shafts and reaming rods Automatic locking of reverse trigger prevents damage to wound shafts Reduction Drive Unit with Reverse 511 786 Allows intramedullary reaming with flexible shafts and reaming rods See page 10 for installation and removal of attachments Insert an instrument Insert the instrument shaft into the opening until it engages Remove an instrument Retract the collar of the quick coupling to release the instrument el ee Oe Eini aa H Synthes 13 Operating Instructions Attachments continued Jacobs Chuck keyless 511 731 Accommodates instruments K wires and Steinmann pins with round shafts from 1 0 mm to 6 0 mm or triangular shafts up to 6 5 mm See page 10 for installation and removal of attachments Insert an instrument Open the chuck jaws by grasping the collar and turning the main body clockwise Insert the instrument into the opened chuck Close the chuck by turning the
16. ss the variable speed bottom trigger of the power drive For reverse counterclockwise rotation press both triggers Speed correlates directly to the amount of pressure on the variable speed trigger and can be varied continuously from O to 750 rom Safety lock The power drive has a satety lock which prevents the drive trom being accidentally started Important The safety lock must be in the UNLOCK position to operate the drive Attachment release ring Variable speed trigger Synthes 9 Operating Instructions Attachments Important To prevent injuries the safety lock should always be switched to the LOCK position when inserting or removing an Instrument Insert an attachment Insert the attachment into the power drive attachment coupling until the parts engage It is not necessary to operate the attachment release ring for insertion Ensure that the attachment is correctly held in the coupling by pulling on it slightly Remove an attachment Turn the release ring and remove the attachment Do not pull on the attachment while turning the ring 10 Synthes Power Drive Quick Coupling for K Wires 511 791 For insertion of K wires from 0 6 mm to 3 2 mm in diameter see page 10 for installation and removal of attachments Important To prevent injuries the safety lock should always be switched to the LOCK position when inserting or removing an instrument
17. utomatically locks reverse trigger to prevent damage to wound reaming shafts Accepts reaming rods up to 3 2 mm in diameter 511 786 Reduction Drive Unit with Reverse Allows direct medullary reaming with flexible shafts Reduces maximum speed to 270 rom Increases maximum output torque to 12 5 Nm Accepts reaming rods up to 3 2 mm in diameter 4 Synthes Power Drive 511 791 Quick Coupling for K Wires For insertion of K wires from 0 6 mm to 3 2 mm in diameter Allows use of any length K wire 511 801 Oscillating Saw Attachment Il Keyless quick coupling for saw blades allows quick intraoperative blade exchange Saw blade oscillates 4 5 for optimal cutting performance Accepts standard or aggressive tooth saw blades ra FEFA tarre EaI a Eq L 1 Dan i E G mi TEN u Synthes 5 Operating Instructions Universal Battery Charger 530 601 Connect the charger to the electrical cord and plug the cord into a 110 120 VAC outlet Q Q Turn on the charger by pressing the power switch to ON All LEDs on the status indicator panels will illuminate red yellow and green when the charger is empty and Oo Ae O ready to charge Figure 1 Insert the battery into one of the appropriate charging bays Only the yellow LED should remain illuminated indicating Q ee oO that the battery is charging Figure 2 Figure 1 When the green LED illuminates th
18. ve unit has overheated Allow drive unit to cool to room temperature Machine continues to run after trigger Is released Trigger is jammed by residue Immediately turn the safety lock to LOCK Operate trigger several times clean and oil according to instructions Use only Synthes autoclavable oil Attachments cannot couple to drive unit Coupling is blocked by residue Engage safety lock Do not use sharp tools Remove solid particles with pickups Difficulty removing attachments from drive unit Release inhibited by pulling on attachment while turning attachment release ring Turn attachment release ring before attempting to remove attachments Cannot attach instrument or difficulty attaching instruments Attachment or instrument excessively worn Replace attachment or instrument K wire completely inserted into coupling cannot be advanced K wire inserted incorrectly into rear of machine Disconnect quick coupling hold drive unit with opening down and shake out K wire Set safety lock to LOCK 22 Synthes Power Drive Troubleshooting Batteries and Universal Battery Charger Problem Possible Causes Remedy Drive unit lacks power Battery is drained Charge or replace battery Battery is not fully charged Charge or replace with a fully charged battery Battery cannot be fully charged Replace battery Battery is physicall
19. y damaged Battery has been dropped from height Replace battery Battery was autoclaved Replace battery Before inserting battery into charger LEDs do not illuminate Battery charger is switched OFF Switch battery charger to ON Electrical cord is not plugged in Plug in cord Fuse is blown Call Synthes Service Department Battery charger requires service Return charger to Synthes Service Department When battery is inserted into charger red LED illuminates Battery is not correctly inserted Remove battery and insert again Battery cannot be fully charged Replace battery After battery is inserted into charger red LED flashes Battery type could not be identified Remove battery and insert again Battery is warm Leave battery in charger When the battery begins cooling the yellow LED will illuminate and the red LED will flash After the battery has cooled down the red LED will stop flashing and the charging process will start automatically During the charging cycle the red LED flashes and yellow LED illuminates See page 6 for universal battery charger operating instructions Battery is warm If the suggested solutions are unsuccessful please contact the Synthes Service Department at 1 800 288 6698 Leave battery in charger After the battery has cooled down the red LED will stop flashing and the charging process will start
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