Technical note: Electrosurgery active lead failures

A cause of electro surgical burns in surgical procedures is faulty active leads. A survey of faults and modes of failures are reported. The design of a meter is given for use by a sterilizing department to enable leads to be checked. Using the criterion of two times the original resistance, 35 cables were found to be defective out of a population of about 200 cables. About half of these cables transmitted radio frequency (RF) power inefficiently: often power was intermittent and hot spots would develop. The commonest mode of failure was a break between the socket and the wire at the forceps end. Rejection criteria are reviewed and we suggest a resistance less than 0.3 Ω.