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Covaris E220 Service Manual

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Covaris E/LE220
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Summary of Contents for Covaris E220

  • Page 1 Covaris E/LE220 Service Manual...

  • Page 2: Table Of Contents

    Table of Contents 1. Scope of this Manual 2. Safety & Compliance 3. Introduction 4. Maintenance & Repair Daily Maintenance Periodic Maintenance Troubleshooting Ineffective Treatment Topics Repair Procedures Aligning Motion Stages Center Position LE Center Position Cabinet Disassembly Servicing the X, Y, Z, & Z-prime Stage Assemblies Stage Replacement Procedures Z Stage X/Y Stage...

  • Page 3: Scope Of This Manual

    1. Scope of this Manual This manual is intended provide Covaris service personnel the necessary information to perform effective fault finding and corrective actions for the Covaris E/LE220-series sample preparation instruments, running SonoLab version 6.2. The following definitions apply in this manual: Inconvenience only if disregarded –...

  • Page 4: Introduction

    3.4 Motion Control System The Covaris E-series is designed to treat multiple samples placed in a tray, without further operator intervention once the run is started. The system automatically positions each sample at the transducer’s focal point.
  • Page 5 The x and y stages consist of a single assembly, which, if necessary, must be replaced as a unit. The z axis is a separate stage, bolted to the x and y assembly. An additional stage, z` (z-prime), raises and lowers the transducer assembly into and out of the water bath.
  • Page 6 supply. A single 48volt DC power supply in conjunction with a capacitor storage assembly provide power to the transducer, via the RF Power board. See Figure below. The operation of the control electronics is detailed later in this manual. 48 Volt Power Supply Matching Network 24 Volt Power Supply Capacitor Board...

  • Page 7: Maintenance & Repair

    Covaris Water Conditioning System (WCS). 4.2 Periodic Maintenance Procedures Periodic maintenance (PM) service involves cleaning, inspection, and testing of the various instrument subsystems. Refer to Covaris document PN 440192 for the formal procedure. 410072 E/LE-series Service Manual Rev E Page 7 of 66...

  • Page 8: Troubleshooting

    TROUBLESHOOTING System Trouble Analysis Chart SYMPTOM PROBABLE CAUSE POSSIBLE SOLUTION Error message “Unknown Device Com ports were See Figure in Appendix B in Instrument Type” assigned incorrectly this manual for COM Port assignment verification. Degassing system not 1. Degassing dip tube may be 1.

  • Page 9: Ineffective Treatment Topics

    10 degrees C. While oxygen is not the only gas dissolved in the bath, it is not practical to measure them all. Covaris has determined that a dissolved oxygen reading of less than the described limits indicates that the total dissolved gas is sufficiently low to allow satisfactory operation of the acoustic process.
  • Page 10 Water Level Sensor Degas Outlet Tube Temperature Sensor Degas Inlet Tube Sensors and inlet tubes mounted on transducer bracket If the pump is running, but there are no bubbles coming from the outlet tube, the small holes in the inlet tube may be clogged.
  • Page 11 A chiller is required to remove heat from the acoustic treatment and the degassing system. For high-power operation, the bath temperature should be set according to the recommendations in Covaris Protocol section on the website. Covaris can supply or specify an appropriate chiller. Position of Treatment Vessel...
  • Page 12 Water level sensor assembly Testing Acoustic Power Follow the acoustic power test procedure described in Section Transducer If the software graphics indicate higher power than normal while the bath and sample vessel little activity, the transducer may be failing. Perform the acoustic power checks described in Section 6, and replace the transducer if necessary.

  • Page 13: Repair Procedures

    Current motion parameters will be maintained in the 440144 document. The procedures are generally the same as described below, but include alignment of the E220 evolution. SonoLab 7 motion parameters are accessed through the SonoLab 7 ‘Motion’ tab, while SonoLab 6 motion is controlled from the ‘Control-Shift-F1’...
  • Page 14 Alignment Kit p/n 500313 Alignment Plate PN 900809 (E220 evolution only) Height Gauge Plate PN 900810 (E220 evolution only) Use the arrow controls on the motion screen to move the plate holder and transducer assembly as required. Step sizes can be edited by clicking in the middle box and selecting from the step increments listed.
  • Page 15 Using the Z arrow, move in steps of 10mm downward until there is clearance for the Alignment Bracket (PN 900067) and dial indicator (PN 900080). Attach the alignment bracket (PN 900067) to the transducer manifold using two pins to line up the fixture and tighten using the thumbscrews provided.
  • Page 16 Adjust step size to 0.1 or 0.2 and then raise the plate holder until the indicator’s contact point is centered in its travel. The extent of travel for the dial indicator can result in one full revolution on the gage. Ideally, the Z height should be adjusted such that the dial makes close to a half revolution (near the 15 tick mark if starting from 0).
  • Page 17 Dial Indicator in same position as above; but outer metallic ring has been rotated so dial hand is now at ‘0’ reference position. MEASUREMENT: Adjust X Axis step size to ‘10’ or ‘5’ and move plate holder away from you (X-UP Arrow) along the edge of the sample holder.
  • Page 18 X Axis Alignment Screws If adjustments are made, repeat the alignment measurement steps as needed to verify the plate holder now meets specification. Leveling the sample holder horizontally (Left-to-Right) Use the Z-Down arrow to slightly lower the plate holder enough to allow for adjustment of the dial indicator pin.
  • Page 19 Make necessary adjustments to center the dial indicator pin (as described in previous section) and set to ‘0’. Plate Holder Direction of Movement MEASUREMENT: Enter a step size of ‘10’ and click on the Y- LEFT arrow to move the plate holder to the left. Upon moving the plate holder 50-75% across the length of the holder, verify that the dial indicator deflection does not exceed +/- .003”.
  • Page 20 right level is secure, verify that both set screws contact surface of support block below. Sample Holder Parallelism (with respect to manifold block) Drop the well plate holder using SonoLab arrows (Z-DOWN) so the dial indicator can once again be rotated in the Alignment Bracket (900067).
  • Page 21 Make necessary adjustments to center the dial indicator pin (as described in previous section) and set to ‘0’. MEASUREMENT: Enter a step size of ‘10’ and click on the X-UP arrow to move the plate holder to the rear. Upon moving the plate holder 50-75% across the length of the holder, verify that the dial indicator deflection does not exceed +/- .003”.

  • Page 22: Center Position

    Remove all tools from system when finished. Center Position Note: E220 evolution center position is performed as below, but using the PN 900809 plate instead of the PN 900076 plate. Tools and Fixtures for Center Position Alignment •...
  • Page 23 • Install Pointer into Alignment Bracket so that is hovering above the PN 900076 Plate. Aligning Center Position • Gently push the pointer down so that it rests in the center hole. If ‘Center Position’ is correct, pointer will rotate freely with very little friction from the plate.
  • Page 24 Plate Holder Height Alignment Note: Plate holder height of the E220 evolution is set in the same manner as the standard E220, but using the PN 900810 holder to mount the drop gauge. Tools & Fixtures for Center Position Z Height •...

  • Page 25: Le Center Position

    • Enter the motion screen. • Click the “Go to Center” button. • Install the pointer fixture as shown for E220 system above. • Jog the well plate, if necessary, until the pointer is aligned to the center hole. Remove the pointer, its holder, and plate fixture.
  • Page 26 Drop Gauge Plunger Resting on Transducer Edge • Jog the Z axis up and down until the drop gauge reads 4.1mm, plus or minus .1mm. Note: if drop gauge plunger runs out of travel before reaching 4mm, the “+/-“ button of drop gauge should be pressed to reverse direction of “+”...
  • Page 27 Step Size Drop-down Lists The left-hand array of arrows controls motion in the x and y directions. The right-hand arrows are for the z and z` axes, or vertical motion. Each mouse click on an arrow results in a single movement of the displayed step size.

  • Page 28: Cabinet Disassembly

    Cabinet Disassembly Removing the upper housing • Disconnect the cables for the three motion stages from the bulkhead at the upper right rear of the enclosure. See figure below. Location of Connectors Described in Steps Above • Disconnect the three interlock cables from the bulkhead at the upper right front of the enclosure.
  • Page 29 • Disconnect the cable for the Z-prime stage from the bulkhead at the upper left rear of the enclosure. See figure below. Transducer, Thermistor, and Water Level Sensor cables Z-prime Axis Cables Transducer, Thermistor, Water Sensor & Z-prime Connectors • Remove the top of the upper enclosure by removing the 6 flathead screws on the top and the 2 philips head screws at the rear.
  • Page 30 • Remove the six screws securing the lower rear cover. Remove the panel sufficiently to disconnect the fan and pump power cables from their jacks. See figure below. Fan and Pump Jacks Lower Cover Removed Showing Fan & Pump Jacks •...
  • Page 31 • Locate the 6 screws that secure the upper cabinet to the lower. These are located on the flange between the two cabinets, 3 on each side. The two forward screws on each side are accessed through the front door of the enclosure. The rear screw on each side is accessed from the rear of the enclosure.
  • Page 32 • Open the front door and remove white nylon screws that secure the acrylic enclosure to the E sheet metal. There are five screws on the right and nine on the left. See figure. Some of the nylon screws. There are 9 on the left side and 5 on the right.

  • Page 33: Servicing The X-Y, Z, & Z-Prime Stage Assemblies

    After approximately three years of service (sooner if need is indicated by motion problems), the lead screws of all stages should be lubricated using Covaris part number 330047. Run each axis to one limit of its travel, using the knob on the axis motor.
  • Page 34 alignment parameters as described above. This procedure should minimize any necessary realignment. Limit Switch Service Limit switch failure manifests itself in different ways, depending on the axis that fails. Usually, the message “Last Method Not Found” following the homing process, followed by very erratic instrument operation, indicates a failure of the Z-prime axis.

  • Page 35: Stage Replacement Procedures

    Stage Replacement Procedures The sample plate holder must be removed before servicing the Z or X/Y stage assemblies. Right side bracket securing Z stage to X/Y stage assembly. Bolts securing Z bracket to X/Y stage Z Stage Mounted to X-Y Stage Remove Sample Plate Holder •...

  • Page 36: Z Stage

    When removing bolts from assembly, ensure 4 washers stay on the bolt shaft and remain in the same orientation (as shown). Detail of Sample Tray Shoulder Bolt • Carefully remove sample plate holder from assembly and set aside with bolts (and washers). Z Stage Replacement Replacing the stage is a two part process, replacing the physical stage and realigning the motion system.

  • Page 37: X/Y Stage

    • Manually adjust the Z-Axis Stage with rotary knob downward to the point where two upper screws are visible. Remove these screws with a 5/32 wrench while ensuring the loose Z Stage does not tip internally off of the XY Stage.
  • Page 38 Y Axis Motor X Axis Motor Shipping Brackets X and Y Axes Stage Assembly Replacing the X/Y stage: • Remove the upper housing (optional) or disconnect the X, Y, and Z axes interface cables from the bulkhead at the right rear. •...
  • Page 39 CAUTION: Make certain to remove the shipping brackets shown in Figure above. • Dress the cable harness using cable ties as shown below. • Reinstall the upper enclosure. • Align the motion stages using the procedure in described in the Aligning Motion Stages section of this manual.
  • Page 40 Z-Prime Stage Replacement Manifold / Transducer Assembly Z’ Stage Z-Prime Stage Assembled to Transducer and Manifold Assembly Replacing the stage: • Remove the four bolts securing the manifold/transducer assembly to the Z prime stage. The two upper bolts are shown in figure below. Lay the bracket down carefully to avoid damaging any components.

  • Page 41: Motion Controller Board

    Unused Upper Bolt Holes Upper Manifold Bolts Upper Mounting Bolts Exposed Z-Prime Stage Showing Upper Mounting Bolts Replacing the Transducer Assembly Refer to section Transducer & Match Network PCBA in Section 5 of this document, Diagnosing and Replacing Printed Circuit Boards. Motion Control board Replacing the Galil Motion Controller Motion Control Circuit Board...

  • Page 42: Z-Prime Stage

    • Remove the upper rear cover. • Disconnect the four D connectors, the ribbon cable, the four square molex connectors, and the 24 VDC supply cable. • Remove the four mounting screws and lift out the board assembly. • Install new board set in reverse order. Degas Pump Replacement The degas pump is mounted on the lower rear access panel, behind the Z- prime stage.
  • Page 43 Inlet hose Return hose • Remove the 4 Philips screws securing the pump bracket to the lower rear panel. Screws securing degas pump bracket • Remove the 6 Philips screws securing the lower rear cover. • Swing the left end of the cover to the right while keeping the right end in place.
  • Page 44 Fan and Pump Jacks at Lower Right of Enclosure • Disconnect the pump cable from its jack, and remove the pump, bracket, and hose assembly through the rear of the instrument. • Assemble the replacement pump to the rear panel. •...

  • Page 45: Diagnosing & Replacing Pcbs

    5. Diagnosing & Replacing Circuit Boards: E/LE220 Series 5.1 E/LE220 Circuit Board Theory of Operation and Service (Initial Cover Removal steps are common for all circuit boards) Ensure E/LE220 device is turned off. If possible, perform replacement in an ESD-Safe environment to avoid potential for static discharge damage on the PCBA.
  • Page 46 48 Volt Power Supply Matching Network 24 Volt Power Supply Capacitor Board RF Power Board RF Controller Board E220 Top Cover & RF Board Cooling Fan Removed 410072 E/LE-series Service Manual Rev E Page 46 of 66 CONFIDENTIAL FOR INTERNAL USE ONLY...

  • Page 47: Rf Power Board

    E220 transducer. Each RF Power Board contains unique Calibration Data that is created prior to installation into an E220 Unit. When installed in an instrument, the Transducer Impedance and Center Frequency are programmed into the flash memory of the RF Power Board at the factory.
  • Page 48 non-inverting input to a Slow Detect (U901B) and Fast Detect (U901A) comparator. The Slow Detect comparator will trip when repetitive pulses exceed the 1.1V reference voltage (corresponding to 14 Amps transducer current). The Fast Detect will trip when a single pulse exceeds the 1.24V reference voltage (corresponding to 23 Amps transducer current).
  • Page 49 used as the logic level switching device used to change the state of the feedback provided to the Main Microcontroller. 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 –...
  • Page 50 SonoLAB prior to resuming an acoustic treatment. RF Power Board Status Indicators RF Power Board Replacement: WARNING: Ensure E220 is turned off prior to attempting replacement • Remove connectors from J2 (3-Pin Fan Connection), J3 (Rainbow Ribbon Connector), J4 (3-Pin +48V Connection), and J5 (BNC) on the RF Power Board.

  • Page 51: Rf Controller Board

    • Remove 4 screws securing fan standoffs from bottom of RF Power Board. • Assemble fan and standoffs to new RF Power Board. • Secure new RF Power Board to chassis (6 screws) and reconnect J2 – J5. • Re-program transducer information in the SonoLAB > Maintenance >...
  • Page 52 Water Temperature: A thermistor is used to constantly monitor the water temperature within the tank. A temperature-dependant voltage is fed back to the main Microcontroller (U1). If the tank temperature falls outside the user-specified range for a Method, the acoustic treatment will be stopped in SonoLab.
  • Page 53 microcontrollers. Treatment parameters (Peak Incident Power, Duty Factor, etc.) are communicated to the RF Power via these connections, and diagnostic information (Power Level, Error Status, Temperature, etc.) is reported back to the Controller Board. J4, Safety Interlock Cable: 30 Pin Cable Connection to Device Sensors Connections are made to magnetic switch sensors for Water Tank, the access door control solenoid, and interior convenience light.
  • Page 54 Chips. Blinking LED’s indicate data transmission is occurring Controller Board LED Indicator locations Controller Board Replacement: WARNING: Ensure E220 is turned off prior to attempting replacement IMPORTANT: The Controller Board contains all information related to the Degas Pump, Device Serial Number, and Device Configuration. When a board is replaced, this information must be reprogrammed onto the board in SonoLab.

  • Page 55: Capacitor Reserve Board

    Serial Number label location on Controller Board • Remove connectors from J2 (Rainbow Ribbon Connector), J4 (30- Pin Safety Interlock Cable), J5 (2-Pin +24V Connection), J7 (5-Pin Degas Pump Connection), and J9 (10-Pin connection to motion controller). • Remove +24 Light jumper from old Controller board and install on replacement Controller board (only if jumper not included with replacement board).
  • Page 56 Bleed Circuit described above. D1 is located near connector J2. Capacitor Reserve Board Replacement WARNING: Ensure E220 is turned off prior to attempting replacement The Capacitor Reserve Board is located near the middle of the chassis’...

  • Page 57: Transducer & Matching Network

    • Remove board and reverse steps to install NEW Capacitor Reserve Board. Transducer &Match Network PCBA The transducer converts electrical energy from the E220 RF Power Board into controlled acoustic energy to treat biological samples. The Transducer is paired with a dedicated Match Network PCBA. The Match Network PCBA contains components used to minimize reactive characteristics of the Transducer at the Center Frequency of ~ 500 kHz.
  • Page 58 After replacing the transducer and match network, instrument configuration settings must be updated with the new transducer data, which is included with the replacement transducer kit. The process is described at the end of this section. • Remove current board by unscrewing 2 bottom screws in standoffs to the left and right of J1.
  • Page 59 Remove 6 screws (3 on each side)allowing transducer to be removed. If replacement transducer is preassembled to brackets, remove transducer and brackets from the manifold as an assembly. LE 220 Transducer • Reverse previous steps and install NEW Match Network PCBA (and transducer).

  • Page 60: Accessing Instrument Configuration Settings

    • Start SonoLab version 7 by double-clicking the desktop icon (if there is no desktop icon, the SonoLab v7 application is located at C:\Program Files(x86)\Covaris\SonoLab) • Click on the Setup tab, then on the User Authentication tab. See figure below.
  • Page 61 • Click on the Maintenance tab. Instrument, power board, and transducer setup, and firmware updating are now accessible. • When finished, click on the Setup tab and uncheck the User Authentication box. 410072 E/LE-series Service Manual Rev E Page 61 of 66 CONFIDENTIAL FOR INTERNAL USE ONLY...

  • Page 62: Power Calibration Verification

    • Verify that the power readings are between 40 watts and 60 watts for each tube. There is no field calibration procedure for the E220 instrument. If the above measurement is out of range, it may indicate a problem with the system electronics.

  • Page 63: Installing Sonolab Software

    Drop Gauge clamp, p/n 900002 Calibrated Spacer, p/n 900004 Plate Fixture (E220 evolution) p/n 900809 Drop Gauge holding assembly for E220 evolution p/n 900810 Acoustic Test Load, 40 Ohm p/n 500399 410072 E/LE-series Service Manual Rev E Page 63 of 66...

  • Page 64: Appendix

    Thermistor Assembly 500075 Water Level Sensor Assembly 500076 24 volt DC power supply 500079 48 volt DC power supply, E220 500257 LE 220 Transducer Repair Kit 500322 Z Axis Limit Sensor Repair Kit 500360 Z-Prime Axis Limit Sensor Repair Kit...

  • Page 65: List Of Service Notes

    Service Notes The following is a comprehensive list of service notes related to the E and LE 220 Instruments. These notes are typically included with the replacement parts to which they refer. Much of the material in the notes is duplicated in this manual. Early E/LE220 24 VDC Power Distribution Cable 410052 LE220 Transducer &...
  • Page 66 AutoFill and RFID Retrofit 410107 Replacing Degas Pump Head 410108 410072 E/LE-series Service Manual Rev E Page 66 of 66 CONFIDENTIAL FOR INTERNAL USE ONLY...

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