Covaris E220 evolution Bedienungsanleitung

Covaris E/LE220

Service Manual

410072 E/LE-series Service Manual Rev E

CONFIDENTIAL FOR INTERNAL USE ONLY

Page 2 of 66

Table of Contents

1. Scope of this Manual 3

2. Safety & Compliance 3

3. Introduction 4

4. Maintenance & Repair 7

Daily Maintenance 7

Periodic Maintenance 7

Troubleshooting 8

Ineffective Treatment Topics 9

Repair Procedures 13

Aligning Motion Stages 13

Center Position 22

LE Center Position 25

Cabinet Disassembly 28

Servicing the X, Y, Z, & Z-prime Stage Assemblies 33

Stage Replacement Procedures 35

Z Stage 36

X/Y Stage 37

Z-prime Stage 39

Motion Controller Board 41

Degas Pump Replacement 42

5. Diagnosing & Replacing PCBs 45

Theory of Operation 45

RF Power Board 47

RF Controller Board 51

Capacitor Reserve Board 55

Transducer & Matching Network 57

Accessing Instrument Configuration Settings 60

6. Power Calibration Verification 62

7. Installing SonoLab Software 63

8. Tools and Fixtures 63

9. Appendix 64

Spare Parts 64

List of Service Notes 65

410072 E/LE-series Service Manual Rev E

CONFIDENTIAL FOR INTERNAL USE ONLY

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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:

NOTE: Inconvenience only if disregarded –no damage or personal injury will result

CAUTION: Equipment damage may occur, but not personal injury.

WARNING: Personal injury may occur –DO NOT DISREGARD.

2 Safety and EMC Compliance Information

2.1General Instrument Safety

2.1.1 Acoustic Safety

The Covaris E-Series instruments generate a focused high-power

acoustic field in the water bath. Potentially hazardous acoustic

energy exists in the water bath, including the entire sample vessel

(above and below the water level). Service personnel who run the

instrument with the safety system defeated must not touch the

water bath or the sample vessel.

WARNING: Service personnel who run the instrument with the safety system defeated

must not touch the water bath or the sample vessel.

2.1.2 Safety and Electromagnetic Compatibility (EMC)

Standards

Safety: Meets Low Voltage Directive 73/23/EEC with Amendment

93/68/EEC. Tested to EN/UL/CSA 61010-1:2004 Safety

Requirements for Electrical Equipment for Measurement, Control

and Laboratory Use, Part 1: General Requirements EMC: Meets

EMC Directive 2004/108/EC. Tested to EMI emissions

requirements for Industrial Scientific or Medical (ISM) equipment

EN55011:1998 + A2:2002 Class A Group1 and EMC requirements

- Electrical Equipment for Measurement, Control, and Laboratory

Use EN 61326-1:2005 Table 2,EN61000-3-2:2004 and EN61000-

3-3:1995 +A1:2001

410072 E/LE-series Service Manual Rev E

CONFIDENTIAL FOR INTERNAL USE ONLY

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3 Introduction

The Covaris Adaptive Focused Acoustics process works by sending

converging acoustic energy wave packets from a dish-shaped transducer to

a small, localized area. 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 cell lysing or tissue disruption. The E-series accomplishes this via the

following subsystems, under the control of the Covaris SonoLab software.

3.1 Transducer

The transducer converts an electrical signal into an acoustic signal.

Specifically, a burst of electrical sine-waves is converted into a series

of acoustic pressure waves. The transducer is focused such that the

pressure waves converge at a focal point inside the treatment vessel.

The primary mechanism to process a sample or compound is the

growth and collapse of cavitation bubbles within the acoustic focal

zone, inside the sample vessel. The collapse of the bubbles results in

an intense, localized jet of solute acting upon the sample.

3.2 Interlock Subsystem

Safety interlocks prevent motion and energizing of the transducer

when doing so might result in damage to the transducer or injury to

operators.

3.3 Degassing System

In order for the acoustic process to function properly, the level of

dissolved gas in the water bath must be reduced. A positive-

displacement degassing pump pulls vacuum on an inlet tube

submerged in the water bath. This inlet tube has 6 small holes through

which the bath water enters. The sudden pressure drop inside the tube

causes dissolved gasses to come out of solution and form bubbles. The

water and the bubbles flow through the pump to the outlet tube before

the gas can re-dissolve in the water. The bubbles float to the surface

and vent to the atmosphere.

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.

The motion of the tray is implemented by stepper motors driving three

mechanical stages, one for each axis: x, y, and z. The x-axis is front to

back motion, the y-axis is left to right, and the z-axis is up and down.

410072 E/LE-series Service Manual Rev E

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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.

The E-series robotic incorporates an additional shuttle stage and

modified enclosure, allowing the sample tray to interface with a

customer supplied sample handling robot.

A Galil brand motion controller interfaces between the SonoLab

software and the hardware stages.

The E-series robotic option adds a Trinamic single axis stepper card,

controlled via a digital I/O port on the Galil controller. This Trinamic

board drives a stepper motor which positions the shuttle stage

described above.

Motion Control Electronics at Rear of Enclosure.

3.5 Control Electronics System

The control electronics are mounted at the top, rear of the instrument

enclosure and connect to components located in the treatment area via

bulkhead connectors. A 24 volt DC power supply provides power for

the low voltage and digital components on the following assemblies:

the RF Power Board, the RF Controller Board, the degassing pump,

the cooling fan, the interior cabinet lamp, and the Galil motion

controller. Additional voltages are derived from the main 24 volt

410072 E/LE-series Service Manual Rev E

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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.

Boards and Power Supplies in Upper Rear Enclosure

RF Power Board

RF Controller Board

Capacitor Board

24 Volt Power Supply

48 Volt Power Supply

Matching Network

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4. Maintenance and Repair

4.1 Recommended Daily Maintenance

WARNING: The water bath is heavy when filled. Use caution when moving it.

At the start of each day, fill the water bath as follows:

•Click the “Service Bath” button on the main screen. This will

move the mechanics to the service position.

•Fill the water bath tank with AFA grade distilled or deionized

water only.

•Slide the bath into position in the instrument.

At the end of the day, the bath should be emptied as follows:

•Click the “Change Bath” button on the main screen. This will

move the mechanics to the service position.

•Slide the water bath out of the instrument and empty it.

•Replace the empty water bath, and run the degas pump a few

seconds to empty the pump lines.

•Empty the bath, and wipe it down with a soft cloth.

•Sponge off the transducer with a soft cloth or sponge, and

allow it to dry.

The above steps can be changed from daily to monthly if customer

uses a 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

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4.3 TROUBLESHOOTING

System Trouble Analysis Chart

SYMPTOM

PROBABLE CAUSE

POSSIBLE SOLUTION

Error message “Unknown

Instrument Type”

Device Com ports were

assigned incorrectly

See Figure in Appendix B in

this manual for COM Port

assignment verification.

Degassing system not

generating bubbles.

1. Degassing dip tube may be

clogged

2. Pump not working

1. Remove and backflush

under running water. Use

fine wire to unclog holes.

2. Replace pump.

Incorrect positioning,

inconsistent treatments

1. Home position lost, system

misalignment

2. Wrong Well Plate Definition

used

1. Reinitialize system by

clicking ‘Home’ on the Ctrl-

shift-F1 screen (SonoLab 6)

or clicking ‘Home’ on the

‘Run’ screen (SonoLab 7).

2. Verify correct Well plate

definition selected

Safety interrupt

1. Water tank is misaligned

2. Door is open.

3. STOP button is depressed

4. Door interlock is bypassed

1. Check tank alignment

2. Check door

3. Check safety interlock

4. Correct Door Interlock

Homing/Initializing not

completed successfully

1. Stage limit switch failure

2. Stage motor stalling

1. See section on stage and

limit switch service in this

manual.

2. Ensure nothing obstructs

stage movement

Values for Dithering and

Vertical Sweep are different

from the values that were

entered

Values entered are larger than

the limits for a particular Well

Plate

Use lower values

410072 E/LE-series Service Manual Rev E

CONFIDENTIAL FOR INTERNAL USE ONLY

Page 9 of 66

4.4 Ineffective Treatment Topics

Water Bath, Degassing, and Transducer Issues

•Buzzing Noise

A loud buzzing noise indicates that cavitation is occurring

on the outside of the treatment vessel rather than on the

inside. Cavitation on the outside of the vessel prevents the

acoustic energy from getting through the vessel to the

sample. In order for the water bath to effectively conduct

the energy to the sample it must be degassed and clean.

•Degassing

Degassing takes a minimum of 60 minutes in room

temperature water; do not attempt to degas chilled water.

The dissolved oxygen level should be 3.5 parts per million

or less in room temperature water; it will be somewhat

higher at temperatures below 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.

Test the dissolved oxygen level with either a dissolved

oxygen meter (see list of tools and equipment) or with

Covaris’ Degas System Verification Kit, part number

520143.

Service Note 410076, included with the kit and available

separately, describes the testing procedure.

410072 E/LE-series Service Manual Rev E

CONFIDENTIAL FOR INTERNAL USE ONLY

Page 10 of 66

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. Raise the transducer arm in the service position and

slide out the inlet tube. Unblock the holes by rinsing, or, if

necessary, by using a fine wire.

End of inlet tube

showing small openings.

Once the tube is cleaned, slide it into the bracket, working it

past the o-ring seal until it bottoms. A tube that is not seated

properly will result in excessive bubbling.

Water Level Sensor

Degas Inlet Tube

Degas Outlet Tube

Temperature Sensor

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