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Covaris M Series Service Manual

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M-Series
SERVICE MANUAL

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  • Page 1 For research use only M-Series SERVICE MANUAL...
  • Page 2 International Standards Organization (ISO) 15190:2003, Medical Laboratories – Requirements for Safety Trademarks Patented or patent pending and registered or registration-pending are trademarks of Covaris. Registered names and trademarks used in this document, even when not specifically marked as such, are not to be considered unprotected by law.
  • Page 3 Do not employ isopropyl alcohol, ammonia-based or abrasive cleaners on the instrument, as these will damage the acrylic surfaces. DO NOT load third party software onto the system without consulting with Covaris. M220 Service Manual Page 3 410085 Rev. B...

  • Page 4: Table Of Contents

    1). Scope of This Manual ....................6 2). Safety and EMC Compliance Information ..............6 General Instrument Safety ..................6 2.1.1 Acoustic Safety ..................... 6 2.1.2 Safety and Electromagnetic Compatibility (EMC) Standards ...... 6 3). Introduction ........................7 Transducer ........................7 Interlock Subsystem ......................
  • Page 5 Measure Power......................43 5 Tools and Fixtures ......................43 6). M220 Series: SonoLab 7 ..................... 43 7). Appendix A ......................... 45 8). System Wiring Diagram ..................... 46 M220 Service Manual Page 5 410085 Rev. B...

  • Page 6: Scope Of This Manual

    1 Scope of This Manual This manual is intended to provide Covaris service personnel the necessary information to perform effective fault finding and corrective actions for the Covaris M220 Sample Preparation instruments. The M220 Series instrument is a third generation design that incorporates upgraded electronic circuit boards and more user-friendly SonoLab software.

  • Page 7: Introduction

    Mechanical energy is thus applied to the sample, without directly contacting the sample. At low energy intensities, gentle mixing is affected. At high energy intensities, intense shock waves result in DNA shearing. The M220 accomplishes this via the following subsystems, under the control of the Covaris SonoLab software. Transducer The transducer converts an electrical signal into an acoustic signal.

  • Page 8: Maintenance And Repair

    Recommended Daily Maintenance At the start of each day, fill the acoustic block as follows: • Fill the acoustic block with Covaris AFA grade water only. • At the end of the day, the bath should be emptied using the 500299 Fill and Drain Kit.

  • Page 9: Diagnosis

    Wipe down the inside of the bath and all submerged surfaces, including the transducer, with a soft, lint-free cloth before refilling with Covaris AFA-grade water. Bath Temperature Bath temperature is controlled by Thermo-Electric (TE) control board.

  • Page 10: Acoustic Power Issues

    Calibration values can be reviewed in SonoLab by accessing the Maintenance > RF Power Board menu location. Calibration data should be visible in a grid format. If calibration values are not visible within this menu, Covaris Technical Support should be contacted. Interlock Errors There is one interlock on the M220 associated with the sample door.

  • Page 11: Repair Procedures

    Repair Procedures General Procedures Removing the outer Covers • Open the front acrylic cover and lift it off the hinge pins on the left side. • Remove six 2mm button head screws around the base, and lift off the white, cosmetic cover. Removing the Electronics Drawer from Chassis •...
  • Page 12 SonoLab screen showing Setup tab, User Authentication tab & checkbox, and Login button • Click on the User Authentication checkbox. • Click on the Login button at the upper right. • Enter the login name service and password Fld1Svc. The login and password are case sensitive.
  • Page 13 Replacing the Transducer Assembly Replacing the transducer includes replacing the matching network and entering the new transducer data to instrument firmware. Note: the thermal block assembly should not be removed from the M220 when servicing the transducer. • Remove covers and invert instrument (alternatively, instrument may be placed at the edge of the bench, with the transducer assembly overhanging the edge, allowing access from below).
  • Page 14 Transducer viewed from bottom (with thermal block removed for demonstration purposes). Clamps • Verify that the replacement transducer includes a new orange O-ring. Do not reuse the O-ring from existing transducer. O-ring installed onto transducer • Reverse the above steps to install the replacement transducer, but do not connect the cable to the bulkhead BNC connector at this time.
  • Page 15 Matching network mounted to electronics tray. Cable to RF Power board • Disconnect the cable between the matching network to the RF Power board from the matching network. • Remove the two screws securing the matching network to the chassis, and the nut securing the BNC connector to the bulkhead. Remove the matching network.

  • Page 16: Replacing The Water Level & Temperature Sensor Assembly

    Caution: prior to saving, review impedance and frequency values. Typical values for impedance are 35 to 45 ohms, for Center Frequency 490 to 510 KHz. Values substantially outside this range may damage the electronics and/or transducer. • Click the Save Configuration button at the bottom of the screen. •...
  • Page 17 • Remove the the (6) M3 x 6mm button head screws that secure the cosmetic cover. Remove the cover and set aside. • Remove the clear plastic safety door and set aside. • Disconnect the transducer cable from the BNC feed-through. See photo below.
  • Page 18 • Remove connectors P1, P2, P3, P8 and P11 from the TE Controller board shown below. • Remove the (4) M3 x 8 mm Pan hd screws securing the TE controller board. Remove the board and place it in an anti-static bag or on a static mat.
  • Page 19 • Install cable assembly 200425 included with the 500324 kit by inserting J5 and J6 into the feed through panel, attaching the ground terminal. Connect P4 and P6B to the RF Controller board. P6B connects to J6, at opposite end of board from J4. Cable Assembly 200425 Ground Ring •...
  • Page 20 Remove screws securing water level sensor Gen 2 cover. Two screws on top, one next to wire on • Remove the two Philips screws securing the capacitive unit to the water level sensor. This step is not necessary on old sensor assembly.
  • Page 21 • Lay the capacitive unit aside, taking care to not damage the wires securing the capacitive unit to the printed circuit board. Remove 3 Nylon Screws • Remove the three nylon screws and lift the sensor assembly off the transducer housing. These screws are stainless steel on the old sensor assembly.
  • Page 22 Inspect the thermistors which extend out the back of the water level sensor assembly. Only the tear-shaped ends should extend beyond the Teflon sleeving, and the ends must not be bent over. See pictures below of good and bad thermistors. Thermistors correctly seated in Teflon sleeving.
  • Page 23 Level/ Temperature Assembly with the mounting holes in the Transducer Housing Assembly. Gently work the Thermistors and the Teflon Sleeve into the Thermistor holes in the Transducer Housing while not disturbing the location of the Water Level Gasket. The Thermistors should slide in easily. Check to ensure that the Water Level Gasket has not moved and that the holes for the Nylon Screws line up.
  • Page 24 the orientation of the wires. Secure with (2) M2.5 x 8 Phil, Flat HD, SS screws. (PN310593) See the (2) photos below. Circle and Cross-hairs face down, against base plate. Capacitive sensor properly installed. Note routing of the wires. • Replace the Water Level Cover using (3) M3 x 6mm Button HD SS Screws.

  • Page 25: Diagnosing And Replacing Printed Circuit Boards

    Secure cable bundle to tie point Route Water Level/ Temperature Sensor cable through opening in bezel here. • Install cover onto base. Secure using 6 M3 x 6 screws. • Replace front plastic cover. • Power on the M220 and start SonoLab. Verify proper operation of the replacement water level sensor and temperature sensor.

  • Page 26: Rf Power Board

    RF Power Board The RF Power Board generates the controlled electrical signals that are converted into acoustic energy bursts by the M220 transducer. Each RF Power Board contains unique Calibration Data that is created prior to installation into an M220 unit. When installed in an M220 device, the transducer impedance and center frequency are programmed into the flash memory of the RF Power Board.
  • Page 27 Connections: J2, DC Fan: 3 Pin Header Connection between RF Power Board and +12V Fan used for cooling of the RF Drive Circuit (where Heat Sinks HS1 – HS4 are located) J3, Controller Interface: 26 Pin Ribbon Cable Connections between RF Controller and RF Power Boards: •...
  • Page 28 RF Power Board Replacement: WARNING: Ensure M 220 is turned off prior to attempting replacement • Remove covers from instrument and electronics drawer from chassis as described in the General Procedures section. • Remove fan box assembly from top of the RF Power Board by unscrewing 6 pan head screws at the rear of the device with a Philips-head Screwdriver.

  • Page 29: Controller Board

    Controller Board: The Controller Board serves as the interface between SonoLab Software (laptop) and the RF Power Board. Safety Interlock connections are controlled via the Controller Board. NOTE: Do not switch Controller Boards between instruments or install a new Controller Board in an instrument without programming the device Serial Number into the flash memory.
  • Page 30 power through communication between Main Microcontrollers (U2) on the RF Power Board on the RF power board and Controller Board. • CPU RX(+,-) and CPU TX(+,-) signal line connections are made for data transmission between the RF Power and RF Controller Board microcontrollers.
  • Page 31 Controller Board connector locations Controller board LED indications Controller Board Replacement: WARNING: Ensure M220 is turned off prior to attempting replacement • Note the Serial Number of the replacement Controller Board.. This will be located on the side of the voltage regulator case. See figure below.
  • Page 32 Serial Number, on tag on heatsink • Remove Electronics drawer from M220 main chassis using 10 screws at the rear, as described in General Procedures section. • Remove connectors from J2 (Rainbow Ribbon Connector), J4 (30- Pin Safety Interlock Cable), J5 (2-Pin +24V Connection), and J8 5 pin connection to TE PCB.

  • Page 33: Thermo-Electric (Te) Controller Board

    Thermo-Electric (TE) Controller Board The Thermo-Electric (TE) board is the electronic drive unit for the Peltier device which heats and cools the water bath. The RF Controller board monitors the bath temperature and operates as the temperature controller. It provides a reference voltage to the TE board via the unused fountain pump output.
  • Page 34 Indicators: D2: Amber LED indicates Peltier device is in heating mode. D3: Blue LED indicates Peltier device is in cooling mode. D16: Red LED indicates hardware safety fault, thermal block temperature below minimum or above maximum. Voltage Indicators: green LEDs, one each, indicating +5 volts, +12 volts, -12 volts, +24 volts, and +48 volts.

  • Page 35: Capacitor Reserve Board

    Capacitor Reserve Board The Capacitor Reserve Board employs large value capacitors for charge storage. This is distributed to the RF Power Board when large current is demanded during a High Power treatment. M220 units manufactured prior to February 2013 employ this board, but those built after February 2013 do not, as it is unnecessary at M220 power levels.
  • Page 36 Capacitor Reserve Board Replacement (NOTE: Removed from design Feb 2013) The Capacitor Reserve Board is located on the bottom forward section of the electronics drawer. WARNING: Ensure M220 is turned off and RED led not illuminated prior to attempting replacement •...
  • Page 37 Capacitor Reserve Board in lower electronics drawer • Reverse steps to install new Capacitor Reserve Board. M220 Service Manual Page 37 410085 Rev. B...

  • Page 38: Power Supplies

    Power Supplies 24 Volt Supply A 24 Volt DC power supply provides power for the low voltage and digital components on the following assemblies: the RF Controller Board, RF Power Board, and power supply cooling fan. Additional 12 Volt, 5 Volt and 3.3 Volt DC supplies are derived from the main 24 Volt supply.
  • Page 39 Measure 48 volt supply here. 48V Supply Measurement Location Power Supply Replacement: 24 Volt Supply: • Remove instrument covers and remove electronics drawer from chassis as described in the General Procedures section. • Disconnect J2 and J4 from the RF Power Board. Remove J5 from the RF Controller Board, and remove J2 from the TE Board.
  • Page 40 Electronics drawer showing removal of top shelf Remove 2 screws here and at opposite end of shelf. • Remove wire connections to 24V Supply terminal blocks. The 24 V supply is mounted above the 48V supply. See image below. • Remove 2 screws securing supply to sheet metal (see below) and remove power supply.
  • Page 41 Cable # 200343 Cable# 200406 Cable # 200412 Cable # 200402 Cable # 200331 Cable #200405 Cable # 200406 Cable # 200404 Cable # 200402 24V and 48V Power Supply Wiring Connections. All cables have part number tags. M220 Service Manual Page 41 410085 Rev.
  • Page 42 48 Volt Power Supply: • Remove instrument covers and remove electronics drawer from chassis as described in the General Procedures section. • Disconnect J2 and J4 from the RF Power Board. Remove J5 from the RF Controller Board, and remove J2 from the TE Board. •...

  • Page 43: Acoustic Power Testing Procedure

    • Multi meter 6 M220 Series: SonoLab 7 PROCEDURE FOR A NEW INSTALL OF USB DRIVERS AND COVARIS SONOLAB 7SOFTWARE ON A WINDOWS XP or 7 COMPUTER Begin with the USB cable disconnected and the instrument powered off. Load the INSTALL CD onto the Laptop’s CD-Drive.
  • Page 44 “Run As Administrator”. NOTE: As soon as SonoLab is launched from the first run, quit SonoLab and then restart normally from the desktop icon. If the instrument does not perform as expected, please contact Covaris Technical Support: Technical Support – On-going assistance with the operation or application of the equipment and/or troubleshooting is provided via: •...
  • Page 45 7 Appendix A Spare Parts All Series: Fan 60mm Repair Kit 500357 Water Level /Temperature Assembly 500324 48v 7A power supply 500257 24v 3.2a power supply 500256 RF Power assembly 500254 RF Control Assembly 500342 Capacitor Reserve Board 500258 M-Series Safety Cover repair Kit 500366 Transducer Kit, M220 500355...
  • Page 46 8 System Wiring Diagram...
  • Page 47 M220 Service Manual Page 47 410085 Rev. B...

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