Covaris S220 Quick start guide

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Important: if servicing an S220 produced prior to December 15, 2011, (serial
number less than 1760) it will be necessary to obtain the current SonoLab CD
image from the Covaris website. Instructions are included in the ‘New
Controller Laptop Support’ section below. Obtaining the software requires a
user account which may take a day or more to become active. Make certain
that your user account is active prior to beginning work.
PROCEDURE:
GAINING CIRCUIT BOARD ACCESS
1. Ensure S220 device is turned off and power cord is unplugged. If possible, perform
replacement in an ESD-Safe environment to avoid potential for static discharge damage
on the PCBA.
2. Remove pump cover by unscrewing 4 button-head cap screws with 2mm hex wrench (2
screws on each side of device).
Figure: Pump Cover Location
Covaris, Inc.
14 Gill Street, Unit H
Woburn, Massachusetts
01801-1721 USA
[phone]
Service Note
TITLE: Replacing Pre-Programmed Controller or RF Power Boards in a Covaris
S220 Instrument
PURPOSE: Instructions for replacing 220 series
Controller or RF Power Boards which have been
pre-programmed for use in an
existing instrument.
NOTE: if installing an UNPROGRAMMED board,
follow instructions in appropriate Covaris Service
Manual.
MATERIALS:
•#1 and #2 Phillips Screwdriver
•2mm Hex Driver / Allen Wrench
•
Appropriate 220 Series Controller
Board or Power Board Repair Kit

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3. Remove chassis cover by unscrewing 11 small pan head screws with Philips-head
Screwdriver (5 in front, 6 in back).
Figure: Electronics Chassis Cover
RF Power Board Replacement
1. Remove fan box assembly in front of the RF Power Board by unscrewing 6 pan head
screws at the rear of the device with a Philips-head Screwdriver.
Figure: Fan Box Assembly location
2. Remove connectors from J2 (3-Pin Fan Connection), J3 (Rainbow Ribbon Connector),
J4 (3-Pin +48V Connection), and J5 (Match Network BNC) on the RF Power Board.
WARNING: Ensure S220 is turned off prior to attempting replacement
Fan Box Assembly

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Figure: Interface Connectors on RF Power Board
3. Remove 6 screws securing RF Power Board to the device chassis.
4. Reverse procedure and secure NEW RF Power Board to chassis (6 screws), reconnect
J2 – J5, and install Fan Box Assembly.
Controller Board Replacement
1. Remove connectors from J2 (Rainbow Ribbon Connector), J4 (30-Pin Safety
Interlock Cable), J5 (2-Pin +24V Connection), and J7 (5-Pin Degas Pump
Connection).
2. Remove 4 screws securing the Controller board to the device chassis and replace
with NEW Controller PCBA. Reconnect cable connections to the Controller Board.
3. Re-install 4 screws using a Phillips-head Screwdriver to secure the NEW Controller
Board back onto the chassis.
Figure: Controller Board Connections and Screw Locations (Yellow)
WARNING: Ensure S220 is turned off prior to attempting replacement
J4
J3
J5
J2

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New Controller Board Laptop Support
Depending on your S220 date of manufacture, you may have to install new FTDI Drivers on your
laptop to support current Controller Boards.
If your instrument was built AFTER Dec 15, 2011 (SN greater than 1760) – Your laptop
should already have current FTDI drivers to support your replacement Controller Board.
No further action required.
If your instrument was built BEFORE Dec 15, 2011 (SN less than 1760) and drivers have
not been updated since this time– New FTDI Drivers will need to be installed to
support your replacement Controller Board. To perform manual update of drivers:
- Delete contents of C:\ProgramFiles\Covaris\Driver directory on your laptop.
(For 64-bit Windows laptop, this will be ...\ProgramFiles(x86)\..)
- Obtain the CD image for the current version of SonoLab software from the Covaris
website:
oGo to www.covarisinc.com
oRoll over the ‘Resources’ menu item. Click on ‘Registered Users Login’.
oLog in to your account (or create an account if necessary).
oClick on ‘E-Series Resources Page’
oClick on the ‘SonoLab 7 (zipped) link to download the CD image.
- Extract contents of “210015 Covaris Controller Board FTDI Driver…” zip file from the
SonoLab CD image onto your instrument laptop.
- Copy contents of extracted zip folder to C:\ProgramFiles\Covaris\Driver directory.
- Follow further instructions in Covaris Service Note 410061 to update drivers.

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Install Verification
1. Re-install S220 device power cord and USB cable connection between laptop and
the instrument.
2. Turn on power to the S220 and then start SonoLab 7 on device laptop.
3. Verify the unit properly connects to SonoLab 7.
4. Navigate to the ‘About SonoLab’ tab. Verify the following are accurate:
Unit Type
Unit Serial Number
Controller Board Serial Number
Power Board Serial Number
Transducer Serial Number, Center Frequency, Impedance (if known)
5. Attempt to run a saved Acoustic Method and verify power levels are as expected (or
refer to User Manual for Acoustic Power Test procedure).
6. Re-install Pump Cover and Electronics Chassis Cover if all steps are successfully
completed.
♦Refer to Service Manual #010142, check cable connections, or contact
Covaris Technical Support if steps are not successfully completed.