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.

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.
7

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
8

6. Phaco Cataract Procedure
4

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
2

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

12. handpieces continued…
OMS Series 3 OMS Series 4
Chiron Catalyst Alcon 10,000

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

14. Alcon Infiniti NeoSoniX
Same handpiece that functions on the
Legacy system

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
14

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
19

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
22

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
26

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.

35. Phaco Handpiece
&
Harmonic Scalpel
surgecanada@msn.com