Common Problems with Electrosurgical Instruments and How to Fix Them

As Intubation Healthcare realizes, it is crucial to have electrosurgical instruments for surgeries since they provide accurate results with minimal blood loss. But as is the case with any kind of technology, there are some potential malfunctions that can occur.

This is why we decided to compile a list of the common problems associated with electrosurgical instruments and ways to resolve them.

1. Loss of Power or Inconsistent Output

Problem:

One of the most common problems encountered with electrosurgical units is power loss or erratic power production. This can be highly problematic when carrying out operations that are very delicate.

Causes:

• Electrical connection problems with the power source
• Inappropriate generator settings
• Problems with the electrode/unit holder
• Deteriorated/worn-out power cords

Solving the Problem:

• Ensure that the generator is plugged in and switched on; when it works on batteries, replace them.
• Inspect the power cords for any damage; replace them, if necessary.
• Adjust the settings of the generator to match the particular process being performed.
• Inspection of the electrode to ensure that it is firmly connected to the handpiece.

2. Burning or Discoloration of Tissue

Issue:
Overburning or discolouration around the incision area might be due to improper settings or machine malfunctions.

Reasons:

• Improper settings, including setting too much power or using the wrong mode like cutting rather than coagulation
• Lack of proper contact between the electrode and tissue
• Inappropriate or defective electrodes

Remedies:

• Settings: Proper power setting should be made to ensure that the right mode and level of power are used. Cutting mode might need more power compared to coagulation mode.
• Contact between the electrode and tissue: Ensure there is proper contact between the electrode and tissue by adjusting its position if necessary.
• Electrodes: Different applications have varying needs regarding electrodes; always use the appropriate type.

3. Sparking or Arcing Between Electrodes

Problem:
A spark or arc might result if the instrument is faulty or used incorrectly. There might be dangers associated with this to the patient and the surgical staff as well.

Causes:

• Poor contact between the electrode and the tissue
• Faulty or deteriorated electrodes
• Improper power levels
• Generator problems

Solutions:

• Ensuring good contact between the electrode and the tissue: Sparking can occur due to poor contact between the two. Adjust the electrode accordingly.
• Replacements of the old electrodes: Inspect the electrode for wear or any faults. Replace the old electrodes in case of any problem.
• Setting the right power levels: Ensure that the correct power is selected. The wrong or too much power can lead to excessive sparking.
• Inspection of the handpiece: In case the problem persists, check the handpiece.

4. Unresponsive Footswitch

Problem:
The footswitch, which is employed to initiate the operation of the electrosurgical machine during the procedure, can fail or operate inconsistently.

Causes:

• Damaged footswitch cable
• Wiring problems with the footswitch
• Failure of the generator or footswitch circuit

Solution:

• Inspect the footswitch cable: Examine the cable for any signs of damage and loose connections. Replace the cable if it is found to be faulty.
• Inspect the footswitch: Ensure that the footswitch is appropriately wired to the generator. Press the footswitch to see whether it works as expected.
• Inspect the generator: If you notice that the footswitch is fine yet the machine fails to function, inspect the generator itself.

5. Inconsistent Electrode Functionality

Problem:
The electrodes might not function properly or even activate at all, which results in inefficient process.

Causes:

• Contaminated or dirty electrodes
• Wear or corrosion of electrode tips
• Faulty electrode cable connection
• Overuse of disposable electrodes

How to Fix It:

• Cleaning and sterilization of the electrodes: It must be ensured that all electrodes have been cleaned and sterilized as directed by the manufacturer.
• Checking for damage or wear: Look for any damage or wear in the electrodes’ tips, and replace them if necessary.
• Proper cable connection: Check the cable connection of the electrode.
• Proper utilization of electrodes: Dispose of electrodes after each procedure.

6. Generator Error Codes

Problem:
Many modern electrosurgical generators will give an error code whenever an issue exists. These codes can sometimes be challenging to decipher while operating.

Causes:

• Power surges or outages
• Failure of internal components
• Improper generator configuration

Solution:

• Look at the manual: Look at the manual for information regarding what that particular error code means.
• Reset the device: Switch off the machine, wait a bit, and then switch it back on to check whether the issue persists.
• Check the power supply: Check whether the power being used is adequate and working well.
• Seek assistance from technical support: Seek technical support help should you continue to receive the same error code.

7. Failure to Cut or Coagulate Effectively

Problem:
Occasionally, electrosurgery instruments do not cut or cauterize properly even if the settings seem to be right.

Reasons:

• Blunt or defective electrodes
• Insufficient contact between the electrode and tissue
• Generator defect or setting problem

Solution to Problem:

• Check electrodes: Make sure the electrodes are sharp and not worn out.
• Tune power settings: Make sure the generator settings are adjusted correctly for cutting or cauterizing.
• Make sure there is contact with the tissue: Adjust the electrode's position to get proper contact with the tissue.