Covaris M Series User manual

For research use only
M-Series
SERVICE MANUAL

M220 Service Manual Page 2 410085 Rev. B
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.
Information subject to change without notice
For Research Use Only
Not for use in diagnostic procedures
Publication P/N 410085
September 2013
Product covered by Patent No. US6, 719,449, US6, 948,843, and other pending applications
Copyright © 2013 Covaris, all rights reserved.
Covaris, Inc.
14 Gill St, Unit H
Woburn, Massachusetts
01801-1721 USA Printed in U.S.A.
UNIVERSAL PRECAUTIONS
Universal Precautions should be followed on all specimen samples, regardless of whether a sample is known to contain
an infectious agent. Laboratories handling specimen samples are advised to comply with applicable parts of the following
governmental and clinical standards, or their equivalent in the country of use:
•Centers for Disease Control (CDC), Universal Precautions for Prevention of Transmission of HIV and Other
Bloodborne Infections, published 1987, updated 1996
•Clinical and Laboratory Standards Institute (CLSI), GP17-A2 Clinical Laboratory Safety; Approved Guideline -
Second Edition, published 2004, ISBN 1-56238-530-5
•Clinical and Laboratory Standards Institute (CLSI), M29-A3 Protection of Laboratory Workers from
Occupationally Acquired Infections; Approved Guideline, Third Edition, published 2005, ISBN 1-56238-5674
•Occupational Safety and Health Administration (OSHA), 29 CFR 1910.1030 Bloodborne Pathogens
•International Standards Organization (ISO) 15190:2003, Medical Laboratories – Requirements for Safety

M220 Service Manual Page 3 410085 Rev. B
Warnings
For safety of operating personnel:
Make sure that the equipment is properly grounded. DO NOT operate if it is not properly grounded.
The unit is equipped with a power plug appropriate for the destination country. DO NOT, under any
circumstances, remove the grounding prong from the power cord.
DO NOT attempt to operate the equipment with the Acoustic Assembly and sample cover in the
open position the acoustic system will not work. If there is any indication that the Safety System is
not functioning properly, DO NOT operate the equipment and contact Covaris immediately.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by
the equipment may be impaired.
To prevent damage to the equipment:
The instruments are designed to operate in ambient laboratory conditions e.g., 15 to 32°C (60 to
90°F). DO NOT operate the instrument in a cold room environment; the system is designed to
operate with a water bath and heater/chiller apparatus to control sample temperature.
NEVER run a method without a water bath; this could damage the transducer. The instrument is
equipped with a water level sensor to protect the transducer. The system will not allow the acoustic
wave treatment to start unless an adequate volume of water is detected.
Covaris AFA water should be used to fill the water bath.
Empty the water bath and wipe it dry EVERY day with a lint-free cloth. DO NOT leave water in the
instrument for an extended time as there is no water filtration or water cleaning system with the
apparatus.
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 4 410085 Rev. B
1). Scope of This Manual................................................................................................... 6
2). Safety and EMC Compliance Information ................................................................... 6
2.1 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........................................................................................................ 7
Control Electronics System............................................................................................. 7
4). Maintenance and Repair ............................................................................................... 8
Recommended Daily Maintenance................................................................................. 8
Troubleshooting.............................................................................................................. 8
Diagnosis......................................................................................................................... 9
Contamination............................................................................................................. 9
Bath Temperature........................................................................................................ 9
Position of Treatment Vessel...................................................................................... 9
Water Level Errors...................................................................................................... 9
Acoustic Power Issues .............................................................................................. 10
Interlock Errors......................................................................................................... 10
Communication Errors.............................................................................................. 10
Other Indicators ........................................................................................................ 10
Repair Procedures......................................................................................................... 11
General Procedures................................................................................................... 11
Removing the outer Covers ...................................................................................... 11
Replacing the Water Level & Temperature Sensor Assembly................................. 16
Diagnosing and Replacing Printed Circuit Boards:...................................................... 25
RF Power Board........................................................................................................ 26
Controller Board:...................................................................................................... 29
Thermo-Electric (TE) Controller Board ................................................................... 33
Capacitor Reserve Board .......................................................................................... 35
Power Supplies.......................................................................................................... 38
24 Volt Supply.......................................................................................................... 38
48 Volt Supply.......................................................................................................... 38
Acoustic Power Testing Procedure................................................................................... 43

M220 Service Manual Page 5 410085 Rev. B
Measure Power.............................................................................................................. 43
5Tools and Fixtures......................................................................................................... 43
6). M220 Series: SonoLab 7............................................................................................. 43
7). Appendix A................................................................................................................. 45
8). System Wiring Diagram ............................................................................................. 46

M220 Service Manual Page 6 410085 Rev. B
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 SonoLabsoftware.
The following definitions apply in this manual:
NOTE: Inconvenience only if disregarded – no damage or personal injury
CAUTION: Equipment damage may occur, but not personal injury.
WARNING: Personal injury may occur – DO NOT DISREGARD.
2 Safety and EMC Compliance Information
2.1 General Instrument Safety
2.1.1 Acoustic Safety
The Covaris M-Series instruments generate a focused high-power acoustic field in the
water bath. Potentially hazardous acoustic energy exists in the water bath, the entire
sample vessel (above and below the water level) and in the sample vessel cap. Service
personnel who run the instrument with the safety system defeated must not touch the
water bath, the sample vessel or the sample vessel cap.
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.

M220 Service Manual Page 7 410085 Rev. B
3 Introduction
The Covaris Adaptive Focused Acoustics process works by sending converging
acoustic energy wave packets from a flat 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 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.
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 micro streaming acting upon the
sample.
Interlock Subsystem
Safety interlocks prevent energizing of the transducer when doing so might
result in damage to the transducer or injury to operators.
Control Electronics System
The control electronics are mounted at the rear of the instrument enclosure,
and connect to components located in the treatment area via bulkhead
connectors. The M220 has a 24 volt DC power supply for low voltage and
digital components of the RF Controller, RF Power, and Thermo-Electric
(TE) circuit boards. A 48 volt DC supply powers the transducer via the RF
Power board.
The operation of the control electronics is detailed later in this manual.

M220 Service Manual Page 8 410085 Rev. B
4 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. Wipe down the bath and transducer with 500298
Swab Cleaning Kit or a soft cloth or sponge.
Troubleshooting
The following table summarizes problems and their solutions. Refer to the
text following the table for detailed discussion of the corrective actions.
Symptom Possible Cause Check / Corrective Action
No power to instrument
(indicator light fails to come
on)
Line cord missing or blown
Fuse in line entry module
24 volt power supply
Verify line cord is connected.
Replace fuse
Check 24v supply output
Check Green D2 on
Controller Board
Ineffective treatment,
possibly with loud buzzing
noise
Bath temperature too high
Contaminated bath
Insufficient acoustic power
Verify TE module operation.
Clean bath, change water,
Run acoustic power test (see
Section 5).
Temperature will not regulate
message,Temp too low,Temp
too high,Temp not at
setpoint, Temp not regulated
that do not correct within a
few minutes.
TE Fan not running
Peltier Board problem
Safety Fault 2nd thermistor
problems (you can check TE
module status by viewing
LED status lights on TE
board) see figure 10
Verify TE Fan running
TE board LED’s (command
side and delivery side) Blue
on both sides “on”- cooling
Amber on both sides ”on”-
heating
Red “on” on command side –
Safety fault(open/shorted
thermistor),or out of
temperature range(2°C -55°C)
Water level error Insufficient bath water
Contaminated level sensor
faulty sensor
Fill bath
Clean bath and level sensor.
Replace sensor.
Door Interlock Error Bath interlock problem Verify sample door closed
Communication Error Corrupted USB drivers
Defective USB cable
USB cable too long
Controller Board Failure
Verify connection status
under “Ports” in Device
Manager
Reload drivers
Replace USB cable.
Verify operation
Table 1, Troubleshooting

M220 Service Manual Page 9 410085 Rev. B
Diagnosis
Contamination
The water bath can become contaminated from the growth of bio-film in
the acoustic block or from debris on sample vessels. Contamination does
not have to be visible to affect processing. If there is any doubt about the
cleanliness of the water bath, it should be changed. 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.
The board is set to control temperature within +/- 2 °C. Temperature
values are set by user within the Method. The temperature is controlled
by a linear PID algorithm inside the controller. Default temperature will be
20 °C if not set by method. Heating and cooling is performed by a Peltier
thermo-electric device with a fan running continuously on the Peltier heat
sink to remove heat or cold as necessary. The operating temperature
range is 4-42°C (with 6-40°C set temperature). The bath temperature
can be adjusted by editing the method in SonoLab.
Bath Temperature Setpoint and Range in Method Editor
Position of Treatment Vessel
Check to ensure the proper waveguide fixture is being used with correct
tube. Insert waveguide fixture so notch is in bottom left corner when
inserting into treatment block.
Water Level Errors
If water level errors are not resolved by cleaning the sensor, the sensor
should be replaced. Follow the procedure provided in this manual.

M220 Service Manual Page 10 410085 Rev. B
Acoustic Power Issues
If acoustic activity is not observed in the sample vessel, follow the
acoustic power test procedure described at the end of Section 4 to verify
that acoustic components are operating properly and also check 48v
power supply output.
Transducer:A mechanical or electrical failure of the transducer
may cause weak acoustic output. If the on-screen power meter
deviates more than +/- 20% from the nominal specified power
(Peak Incident Power x Duty Factor), the transducer may be
damaged.
RF Power Board: As with the transducer, if the on-screen
power meter deviates more than +/- 20% from nominal, the RF
Power board may be damaged.
Calibration Data Missing or Incorrect: Calibration for the
M220 Series is performed on each RF Board prior to installation
in a device. 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. The
door must be closed and magnet/switch combination satisfied to allow
acoustic processing.
Communication Errors
In the event of communication errors, verify that the problem is not a
defective USB cable. Also use Windows Device Manager to verify that
Windows is recognizing the M220 and that the device drivers are
properly installed.
Other Indicators
Normal processor functioning is indicated by the blinking yellow
LED(approximately 1 blink per second) on the RF controller and by the
blinking green led(approximately 1 blink every ½ second) on the RF
power board (see Figures 14 and 15 later in this document).