Esco Aeris-BG4076 User manual

Service Manual

Aeris

Thermal Cycler

Thank you for purchasing the Esco Aeris Thermal Cycler.

Please read this manual thoroughly to familiarize yourself with

the many unique features and exciting innovations we have

built into cycler. You can view this manual online at

www.escoglobal.com, where you can find many other

resources to help you enjoy many years of productive and

safe use of your Esco equipment.

Chapter 1. Introduction

1.1 Products covered

This manual is applicable and specific to the following ESCO products:-

Aeris Thermal Cycler Aeris-MB with following blocks

Rated voltage (V) 96 wells

gradient

block

30 x 0.5ml +

48 x 0.2ml

mix block

384 wells

gradient

block

48 x 0.2ml x2

dual block

4 In Situ

Slides

100-240V, AC,

50/60Hz

AERIS-

BG096

AERIS-

B4830

AERIS-

BG384

AERIS-

BD048

AERIS-

B4076

1.2 Basic product information

1.2.1 QUICK VIEW

No. Name Description Note

1 Block With hot lid, heat sink and heating&

cooling system.

Five interchangeable blocks

are available for different

requirements.

2 LCD Screen

Display protocol, conditions and

other information during setting and

running.

6.5'' Color LCD Touch Screen

3 Keyboard For setting and controlling.

4 Ventilation vent Blow heat air out through

ventilation vent.

-Don’t block off ventilation

vent

5 USB interface Data transfer between USB and

equipment through USB interface -

6 Hot lid knob Adjust the height of the Knob

Turn the knob counter-

clockwise before closing the

lid. Note that the knob can be

tightened by turning it

clockwise, and can be

loosened by turning counter-

clockwise.

7 Unlocking Device Loose the hot lid knob

If hear click sound at the

beginning of turning the knob

clockwise and counter

clockwise, press the

unlocking device and turn the

knob counter-clockwise for

two rounds to loose the knob

8 RJ45 interface For PC control and software - Up to 30 Aeris thermal

upgrades cyclers can be connected and

controlled by normal

computer through RJ45

interface.

9 Power Switch Turn the equipment ON/OFF. -

10 Power Socket Connect power supply. -

11 Fuse Socket Install fuse in the socket to protect

equipment from over-current.

The fuse specifications are as

follows: 250V 8A, 5×20. Fuse

should be replaced by one

that complies with these

specifications.

1.2.2 Installing your instrument

Install and Remove the block as follows:

1.2.2.1 Installation:

• Place the block (1) into the housing well (2) and

push it slowly forwards until a connection between

the block socket and the main unit’s connection

plug (3) is achieved.

• Press the locking handle (4) downwards, the block

will move forward automatically until you hear the

click sound, which means the block is installed

successfully.

• Do not force!

1.2.2.2 Removing the Block

• Turn off the power supply.

• Uplift the locking handle (4), the block will move

backward a bit.

• Pull the locking handle to move block gently

towards the rear of the main body.

• Remove the block from the main body.

4

Note: • Turn off the power supply before installing block.

• When installing the block, pay close attention to pushing the block slowly and gently ; or the

main unit’s connecting plug may be damaged.

• When uninstalling the block, please pull the block from the block bath gently. Do not tilt the

block or the connection plug may break.

2

1

4

3

1.2.3 Technical specification summary table

General Specifications, Aeris Thermal Cycler

Block Code

AERIS

-

BG086

AERIS

-

B4830

AERIS

-

BG384

AERIS

-

BG384

AERIS

-

B4076

Sample Capacity

96 × 0.2ml 48 × 0.2ml + 30

× 0.5ml 384 wells 48 × 0.2ml + 48

× 0.2ml 4 slides

Applied

Consumables

0.2ml tubes

96 micro plate

12 x 8 strips

8 x 12 strips

0.2 ml tubes

0.5 ml tubes

4 x 12 strips

384 micro

plate

0.2ml tubes

6 x 8 strips

4 slides in situ

plate

Temperature

Range 4ºC ~ 105ºC

Max. Heating

Rate 4.0ºC / sec 2.8ºC / sec 2.8ºC / sec 4.0ºC / sec 1.8ºC / sec

Max. Cooling

Rate 4.0ºC / sec 2.8ºC / sec 2.8ºC / sec 4.0ºC / sec 1.8ºC / sec

Temperature

Uniformity ≤0.2ºC

Temperature

Accuracy ≤0.1ºC below 50 ºC

Max. Gradient

30ºC - 30ºC - -

Min. Gradient

1ºC - 1ºC - -

Hot Lid Temp.

range 30ºC ~ 110ºC

Temp. Control

Mode Block mode or Tube mode

Display

6.5” Color LCD Touch Screen

Instrument

Memory Up to 250 programs, unlimited with USB flash drive

PC Interface

RJ45 & USB port

Dimensions

(W x D x H) 306mm x 386mm x 295mm (WxLxH)

Weight (kg)

10

Power Supply

100-240 V / 50-60 Hz 600W

Fuse

250V 8A ø5 × 20

Warranty

3 years on main body, 2 years on blocks

1.3 Security Notes

i. Turn the power OFF and unplug the power cord before performing any procedure.

ii. Please read all the instructions thoroughly before maintenance. Always follow this

service manual. Keep this service manual well for future reference and review it as

necessary.

iii. Engineers must inspect and ensure operation of the equipment is completely back to

normal after maintenance.

1.4 Guidance

Pay attention on the following before hand.

i. Investigate :-

 Situation of the equipment as operating

 Previous maintenance record

 Symptom of the failure

 Hardware environment

 Structure of the equipment

 Years of the equipment be used

ii. Check power supply.

iii. Check installation of the equipment.

iv. Clean internal of the equipment to eliminate failures caused by dust, dirt, redundant

solder, welding oil.

v. Read all the instructions thoroughly before maintenance to ensure full understanding.

1.5 Maintenance tools

• Wire-stripping pliers, wire stripper

• Torque screwdriver Φ3

• Word screwdriver Φ2

• Cross screwdriver Φ3

• Sharp nose pliers, diagonal cutting nippers

• Pen knife

• Tweezers

• Multimeter

Besides, a multi-channel temperature acquisition device is needed for temperature uniformity and

accuracy testing.

Chapter 2 Service Procedures

2.1 Assemble and disassemble the main body

2.1.1 Assemble procedure

• Assemble the PCB board, power supply and fan with the stainless steel stand.

Put the whole part in the bottom casing and make sure the part is fastened by the

buckle of the bottom casing. Refer to Fig. 1

Fig. 1

• Tighten the four screws to fix the rubber feet with bottom casing. Refer to Fig. 2

Fig 2

2.1.2 Disassemble procedure

• Remove the screws as showed in the red square. Take down the left and right

board. Refer to Fig 3, and then you can see the whole main body structure

without the cover(Fig 4)

Fig 3

Fig 4

• Unplug all the connectors. Remove the screws in the interface (connector) board.

As Fig.4 and 5

• Remove the screws as Fig 5, and take out the old fan and replace a new fan

Fig 5 Fig 6

Notes Please note the air flow direction of the fan and the polarity of the connection wire when

replacing the fans. Please mark them to avoid forgetting the correct sequence and make sure the

connection is secure.

2.2 LCD Replacement

 Remove the front cover and see the CPU control board as Fig.7

Fig.7

Note: A small brass screw on the resistor. Rotating the knob clockwise will brighten the display.

Rotating the knob anti-clockwise will darken the display.

 Remove the screws as Fig.8, and then remove the CPU control board.

Fig.8

 Remove the screws and get the LCD and LCD control board which are combined into

one part. As Fig.9 and Fig.10

Fig.9 Fig. 10

2.3 Key Pad replacement

 Remove the screws as Fig.8 above, and then remove all screws as Fig. 11.

LCD contrast

adjustable screw

Fig.11

 Replace the key pad and reconnect all wires back.

Fig.12

2.4 Hot Lid adjust knob repair and replacement

 Use a tweezers to remove the small hot lid lock device. As Fig.13

Fig.13

 The cover will be removed together with the lock device. As Fig.14

Lock device

Fig.14

 Remove the small rotate metal ring. As Fig. 15

Fig.15

 Remove the adjustable knob, and see the inner part .As Fig. 16

Fig.16

Note: Most of the time, the hot lid adjustable knob looses because the contact between the

four small gears and the big gear is broken. Please adjust and make sure the four gears are

in the same level, otherwise the hot lid can not be positioned even which will cause reagent

evaporation.

2.5 Hot lid repair and replacement.

 Remove screws as Fig.17

Fig.17

 Measure the resistance, as Fig.18. If the value is out of range, need to open the hot lid

cover and repair.

Fig.18

 Refer to Chapter 6.4, remove the hot lid knob. The hot lid as Fig. 19

Fig.19

 Remove the 6 screws in above picture, the heat film is as Fig. 20

Heating film, Resistance should

be <10Ω

Hot lid sensor, Resistance

should be around 10K Ω

Hot lid sensor Heat Film

Temperature fuse

Fig.20

 Remove the solder and replace heat film, fuse or sensor.

 Solder the new fuse or sensor, and make sure the fuse contact the hot lid surface well

after fixed.

2.6 Heating and Cooling parts Replacement

 Remove the screws as Fig.21 to remove the heat sink.

Fig.21

 The heating and cooling part is as Fig. 22

Fig. 22

 Use a tweezers to remove the heating film and you can see the peltier parts as Fig. 23

Fig. 23

 Fuse and Heat sink sensor can be replaced but the block sensor can be only replaced

by manufacturer.

 Replace the peltier (TE) and install back the heat sink by using Torque screwdriver Φ3

and the torque for four screws are 2.5KG.

Note: It is not recommend that distributor replace the heating and cooling parts, because it is

very difficult to control the temperature accuracy and uniformity. A temperature acquisition

device is necessary for replacing peltier. Is it recommend to send the whole block back to

manufacturer for repair .

2.7 Printed Circuit Board Recognitions and replacement

Fig.24

 Replace the Printed circuit boards above.

o Wrap the connector by using a damp cotton swab soaked with ethanol until can

unplug the plug.

o Note the connection sequence of the wires. Remove the wires.

o Unscrew the panel screws.

o Replace the panel.

o Reconnect all wire according to the recorded sequence.

Interface (connect) board

Power supply drive board

CPU control board

TE TE

Heat Sink sensor

Fuse

Block sensor

o Reconnect all plugs and sockets.

o Run the instrument. If no problem, add Thermosol to connector.

Chapter 3 Troubleshooting

PROBLEM Possible

Causes Corrective Action

No display when

power on

Power

Failure

• Check if there is power at the wall/building socket.

• You can use voltmeter or test pen to check power on the

wall/building socket.

• Ensure the socket switch is at ON position. As 1-1

Wall Socket

(Sample of Singapore Socket)

1-1

Power cord

is not

connected

properly or

faulty

• Check whether power cord has been connected properly

into wall/building socket and also into the unit.

• Check whether the power cord is giving power, measure the

AC voltage between the live and the neutral terminal of the

cord by using voltmeter (see drawing 1-2).

• If the voltage is NOT within +/-2% of the wall socket

voltage, replace the cord.

• If the voltage is within +/-2% of the wall socket voltage,

please proceed to next step.

LIVE NEUTRAL

1-2

Faulty fuse

• Use word screwdriver to take out the fuse holder, as 1-3

• Check whether the fuse is broken, as 1-4

• If yes, replace fuse. ((250V 5A Φ5×20)

1-3 1-4

Faulty Switch

• If the Switch is broken, unscrew the four screws of the

base cover, as 1-6

• Remove the side cover and top cover and take out the

Switch, as 1-7

•Replace Switch

1-5 1-6 1-7

Faulty LCD

• The beep sound is as normal and you can hear the noise

of the fan.

• Remove the top cover; remove all the wires, as 1-8.

• Connect a new LCD to the LCD port on main board.

• If the new LCD functions properly, means the old one is

defective. Replace it.

• Unscrew the screws, as 1-9

• Replace LCD

1-8 1-9

Defective

power supply

(SMPS)

•Check the SMPS (switching mode power supply)

•Input 230VAC or 115VAC +/- 10%.

•Output should be 9V-12V

If input is correct but output is not, then replace the SMPS.

Note: The power supply and power supply drive board are

combined into one part, need to replace the whole part.

1-10

Connection

problem or

Defective

power supply

Driver board

• Measure the incoming voltage on the power supply Driver

board at terminal J1, See drawing 1-11 below to locate

terminal J 1.

• Voltage should be 36VDC.

• If voltage is out of range, check connection between

SMPS and main board.

• If voltage is correct, the out put voltage is out of range,

refer to Appendix 1

• Replace the power supply driver board with.

Note:

The power supply and power supply drive board are

combined into one part, need to replace the whole

part.When replacing power supply driver board board,

please re-connect all the wires back correctly. Any wrong

wiring may result in damage.

1-11

Connection

problem/

Defective CPU

control board

• Measure the incoming voltage on the CPU control Board

at terminal J 22, See drawing 1-12 above to locate

terminal J 22.

• Voltage should be 12VDC.

• If voltage is out of range, check connection between

SMPS and CPU control board.

• If voltage is correct, replace the CPU control Board.

Note: When replacing CPU control Board, please re-

connect all the wires back correctly. Any wrong wiring may

result in damage.

Terminal J22 = DC12V

1-12

Two beeps after

power on. The

screen displays

“Please insert block”

with audible beep.

Loose

connection

between the

block and main

unit.

• Turn off the power.

• Remove the block from the main unit.

• Reinstall the block.

• Turn on the power.

1-13

Defective

connector

• Exchange with a new block, if the problem is solved,

the original block is damaged.

• Send back the block to Esco for repair.

1-14

Defective

interface board/

CPU control

• If the problem still exists after exchange the block,

check the

connector of the main body.

• If all the pins are leading through, then the connector

has no prolem.

• Replace the CPU control board.

1-15 1-16

During the run, the

screen shows:

Please check error,

or one of the

following options:

Temperature sensor

disconnect

Temperature

sensor1 disconnect

Temperature

sensor2 disconnect

Temperature

sensor3 disconnect

Bad

connection

between the

block and

main unit.

•Turn off the power.

•Remove the block from the main unit.

•Reinstall the block.

•Turn on the power.

1-17

Damaged

block

temperature

sensor

• Block sensor is not allowed to be changed by customer/

distributor. Please contact manufacturer and send the block

back for repair. As 1-18

Connector

1-18

During the run, the

screen shows:

"Please check error"

and shows "Heat

sink sensor

disconnect"

Bad

connection

• Turn off the power.

• Remove the block from the main unit.

• Reinstall the block.

• Turn the power on.

Damaged

sensor

• Refer to Chapter 2.9, measure the resistance of the heat

sink sensor.

• If the sensor resistance is not around 10 K Ω, Replace the

heat sink sensor and solder it, as 1-19.

• Then you need to use torque screw drive to install the

heat sink back to the block.

• It is not recommended doing it locally and better sending

back to Esco for repair if the heat sink sensor is damaged.

1-19 Heat sink sensor

Control board

problem

• If the block has no problem, replace the CPU control

board.

Note: When replacing CPU control Board, please re-

connect all the wires back correctly. Any wrong wiring may

result in damage.

1-20

During the run, the

screen shows:

Please check error

and indicates Hot lid

Sensor disconnect

Bad

connection

• Turn off the power.

• Remove the block from the main unit.

• Reinstall the block.

• Turn the power on.

Disconnected

hot lid sensor

• measure the resistance. The resistance should be around

10kΩ. As 1-21. If not,

• Change hot lid sensor, refer to Chapter 2.6

Block sensor

resistance should be around 10KΩ

1-21 1-22

Abrupt change in

heating rate or poor

temperature control

accuracy / The

temperature of the

block can not reach

the setting

temperature

Ventilation

Blocked Clear the blockage

Bad

connection

Open the instrument; Check all the connectors are

connected properly.

Peltier failure

• Measure the resistance of the peltier, refer to Chapter

2.9.If resistance is beyond the range,

• Replace Peltier, as Chapter 2.7

Note: It is not recommended that distributor replace the

peltier, because it is very difficult to control the temperature

accuracy and uniformity. A temperature acquisition device

is necessary for replacing peltier.

Resistance should be around 0

1-23

Significant change in

cooling.

Temperature will not

cool to below

ambient.

Fan failed or

stopped

• Reconnect the connection wire of the fan,

• If still not good, remove screws, as 1-24

• Replace the fan. As Chapter 2.2

Notes Please note the air flow direction of the fan and the

polarity of the connection wire when replacing the fans.

1-24 1-25

The screws of

the heat sink

is loose

Use Torque screwdriver to tighten the screw. Torque is

equal to 2.5kg.

Resistance should be <10Ω

Peltier module

Hot lid sensor

Screws

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