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Updated: b4, d9, g3, g6, h2, h3, h4, h6, h7, h8, h11.Distribution history: this complaint unit was manufactured at csi on 11/23/2023 and shipped on 12/13/2023.Manufacturing record review: dhrs were reviewed and no non-conformities, related to the complaint condition, were noted.Service history record: no additional service history records found for this unit.Historical complaint review: a review of the 2-year complaint history showed similar reported complaint conditions.Majority of complaints were not confirmed.The remaining complaints are similar to this one.Product receipt: the complaint unit was returned 4/14/2025.Visual evaluation: visual examination of the complaint unit revealed no physical damage.Functional evaluation: complaint unit was functionally evaluated and found not to function properly.Service & repair confirmed the unit rf leakage test for coag was not within the allowable watts range (5 - 14).Root cause: the potentiometer r77 in this unit was adjusted and assembled following standard procedures.The leakage threshold was originally set (in coag mode) to 11 watts in 2016, adjusted to 7w during rework in 2022, and later set to 8w during service in 2025.Coag mode involves higher voltage levels than the other modes and minimal isolation wear is expected over time.This may result in a slight increase in leakage current.This increase is very small and remains well within the safe limits - there is no indication the current leakage has come close to exceeding 120 ma.Regardless of a small increase of leakage due to wear, the device's electrical leakage monitoring system correctly responded by cutting power in response to detected excess amount of electrical current leaving the circuit.This occurrence is considered low in probability.The unit was adjusted, via r77, to the allowable watts for coag per procedure.It was tested to specifications free of defects and returned to the customer.The dfmea was reviewed confirming rf leakage was captured, appropriately rated and lists the monitoring circuit as a control for rf leakage.The pfmea was also confirmed to capture the controls in the assembly process.As the unit operated per its intended design, no additional actions are required.Coopersurgical will continue to monitor this complaint condition for trends.No further corrective action is necessary.
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