THERMAL CYCLER
MODEL TC 6
Service Manual
Version 1.1
Kaltis International.
TC 6 Service Manual
CONTENTS
1.
2.
3.
4.
5.
Overview ........................................................................................ Error! Bookmark not defined.
1.1.
Layout .............................................................................. Error! Bookmark not defined.
1.2.
Specifications ....................................................................................................................1
1.3.
Operation ..........................................................................................................................2
1.4.
Installation .........................................................................................................................2
Structure .....................................................................................................................................2
2.1.
Upper case Assembly .......................................................................................................3
2.2.
Heated Lid Assembly ........................................................................................................4
2.3.
Sample Block Assembly ...................................................................................................4
2.4.
Chassis Assembly .............................................................................................................5
Theory of Operation...................................................................................................................5
3.1.
Theory of Peltier-based Thermo Pump ............................................................................6
3.2.
Drive Board .......................................................................................................................7
3.3.
Upper monitor board .........................................................................................................7
3.4.
Lower control board ......................................................... Error! Bookmark not defined.
3.5.
Software Version ...............................................................................................................7
3.6.
Electrical Wiring ................................................................................................................8
Diagnosing Problems ................................................................... Error! Bookmark not defined.
Disassembling and Reassembling the parts ........................................................................10
5.1.
Removing Heated Lid .....................................................................................................10
5.2.
Removing Sample Block .................................................................................................10
5.3.
Removing Lower control Board ......................................................................................10
5.4.
Removing 20V Switch Power .........................................................................................10
5.5.
Removing Driver Assembly .............................................................................................10
5.6.
Removing Upper monitor Board ..................................................................................... 11
5.7.
Removing LCD Display ................................................................................................... 11
5.8.
Software Update ............................................................................................................. 11
© Kaltis International Co., Ltd. reserves the copyright of the manual
Kaltis International Co., Ltd. reserves rights to implement changes to the product without prior
notice.
Kaltis International.
TC 6 Service Manual
For the latest service and support information, visit http：//www.kaltis.com
OR
For Service Contact: [email protected]
For technical Support: [email protected]
Kaltis International.
TC 6 Service Manual
1. Overview
1.1. Layout
Lid Handle
Sample Block Assembly
Heated Lid Assembly
Touchscreen
Air Vent
USB Port
Air Vent
Fig1 Front View
Lid knob
Air Vent
Air Vent
Feet
Fig2 Side View
Ethernet Port
Power Switch
RS232 Port
Power Inlet
Fig3 Rear View
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TC 6 Service Manual
1.2. Specifications
Input Power
600Watts, 85VAC~265VAC, 47 to 63Hz
Sample Block Capacity
0.2ml PCR tubes, 0.5ml PCR tubes, 8 or 12
strips, 96 well micro plate
LCD Display
7” Full Touch Screen
Language
Bilingual: English and Chinese
USB Interface Memory
Unlimited with U-disk expansion
Ports
Ethernet Port
RS232 Port
Heated Lid Features
Height of Heated Lid
Heated Lid Temperature
Auto Shut-off
Other Specifications
Dimension(L×W×H)
Net Weight
Connects up to 120 Thermal Cyclers to a
computer
Connects the instrument to a computer
Fully adjustable lid, accommodates a wide
range of PCR tubes and plates
Programmable: 30°C~112°C
Below 30°C of sample block temperature, or
after finishing running
36*25*25cm
7.3KG
-------------------------------------------------------------------------------------------------------------------------------
1.3. Operation
Refer to the User Manual for details.
1.4. Installation
Refer to User Manual for details.
2. Structure
The instrument consists of four sub-systems: Heated lid assembly, Sample block assembly, LCD
display and control assembly & Chassis assembly. These four systems function together to rapidly
and uniformly heat and cool the samples in the vials.
Kaltis International.
TC 6 Service Manual
Sample Block Assembly
LCD Display &
Control Assembly
Heated Lid
Assembly
Chassis assembly
Fig4 Assembly View
2.1. Heated Lid Assembly
Heated lid assembly consists of thumb wheel, upper cover, handle, fixed latch, lid bracket, link plate,
cover plate, lid cover and heated lid.
Fig. 5. Heated Lid Assembly
Thumb Wheel
Upper Cover
Link Plate
Handle
Lid Bracket
Fixed Latch
Cover Plate
Lid Cover
Heated Lid
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TC 6 Service Manual
Sample Block Assembly
Sample block Assembly consists of the block plate, sample block, thermistor, peltier thermal pump,
block PCB and heat sink.
Block plate
Sample Block
Thermistor
Peltier Thermal
Pump
Block PCB
Dual Socket
Outlet
Sink
Fig. 6. Sample Block Assembly
2.2. LCD Display And control Assembly
LCD display and control assembly consists of the screen case, vent case, touch screen, screen
plate and MCU control board.
Screen Case
Screen Plate
Touchscreen
MCU Control
Board
Vent Case
Fig. 7. LCD Display & Control Assembly
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TC 6 Service Manual
2.3. Chassis Assembly
Chassis assembly consists of the power switch, driver board, fan, chassis, air duct, air duct support,
left board, right board, table board, spring support, etc.
Table Board
Dual Socket
Outlet
Air Duct
Spring Support
Left Board
Fan
Air duct Support
Driver Board
Right Board
Power Switch
Fig.8. Chassis Assembly
Chassis
3. Theory of Operation
Thermal cycler functions as a user programmable, temperature controlled sample block. The user
interface of the electrical system allows the user to enter the thermal cycler run parameters,
including time and temperature parameters. The electrical system and temperature sensors located
in the sample block ensure that the temperature of the sample block corresponds to the
user-programmed information. The sample block assembly holds the tubes containing the PCR
sample.
The heated lid of the cycler is placed over the PCR vials during a reaction, preventing sample
evaporation, condensation buildup, and increasing heat transfer by pressing against the sample
tubes, thereby pushing these firmly into the wells of the sample block. Because the heated lid can
be moved upward and downward by rotating a thumb-wheel, the lid will adapt to most PCR tubes
and micro plates. The sample block is heated and cooled by a peltier type thermo pump.
The CPU module on the CPU main PCB collects the temperature from 8 thermistors, positioned in
sample block, and calculates the output to a PWM electronic driver. A controlled current then flows
into the peltier thermo pump to heat and cool the sample block.
Kaltis International.
TC 6 Service Manual
The peltier thermo pump helps to produce a thermal cycler that is small in size, low in weight,
reliable, safe for environment and with precise temperature control.
For the gradient thermal cycler, the thermo pump not only delivers sufficient power for heating and
cooling, but also produces one dimension of the temperature gradient on the sample block, as
needed. Three (3) thermo pumps under the sample block are used to achieve the gradient function.
These thermo pumps work independently and, when they hold at different temperatures, these
results in a temperature gradient on the block. The gradient function helps to determine the
optimum run conditions for the PCR.
Theory of Peltier-based Thermo Pump
The Peltier Effect was discovered in 1834 by French physicist named Peltier. Peltier type thermo
pumps have only recently become practical with the development of semiconductor thermocouple
materials. A peltier type thermo pump contains Bismuth Telluride semiconductor material, is heavily
creates either an electron excess (N-type), or electron deficiency (P-type). The material is attached
to electrical conductors and sandwiched between an insulating material, creating the thermal
coupler.
Electronic carriers moving
heat to the heat sink
HEAT SOURCE
Sample block
Electrical insulation
(Good Heat Conductor)
"N" Type semiconductor
excess of electrons
"P" Type semiconductor
deficiency of electrons
HEAT SINK
D.C.SOURCE
Fig 9
In the cooling mode, DC current passes from the N-type to the P-type semiconductor material. The
temperature of the interconnecting conductor decreases and heat is absorbed from the attached
sample block. This heat absorption occurs when electrons pass from a low energy level in the
P-type material through the inter-connecting conductor to a higher energy level in the N-type
material. This additional energy is absorbed by the electrons in the form of the thermal energy from
the sample block.
Kaltis International.
TC 6 Service Manual
The absorbed heat is transferred through the semiconductor by electron transport and is liberated
through the heat sink when the electrons return to a lower energy level in the P-type semiconductor.
The heat is dissipated by a fan mounted under the heat sink.
When heating is required, the D.C. current is reversed to the thermo pump. DC current will pass
from the P-type to the N-type semiconductor and electrons will transport heat from the heat sink
and transfer it to the sample block.
Driver Board
The Driver board has three-way outputs. These drivers receive D/A output voltage signal and
heat/cool enable digital signal from lower control board. Through IC 3842 current converter and LC
filter, they output controlled D.C. current to left, middle and right of three groups of thermo pump.
MCU Control Board
The MCU Control Board contains an LCD control (with MICR02440 for MCU) and operation control
component (with ATmega128 for MCU),
The LCD control component contains an LCD interface, Ethernet part, USB port, RS232 port, etc.
The operation control component contains an AD/DA convertor, sensor port, fan port, lid port,
RS232 port, etc.
LCD control component connect with the touch screen, by detecting input information from the
touch screen, and communicating with the operation control part in order to control thermal pumps,
heated lid and fan control, etc. At the same time it displays all running information from the terminal
on LCD screen.
Software Version
The different software versions for different model are shown in the table 1.
Model
A300
Software Version
VER3.3.1
Function
With Gradient
TC 6 Service Manual
Kaltis International.
Electrical Wiring
Electrical
Fig12
Diagram
YEL/BLU
FU1
115/250VAC
10A
N
L
FU2
WHT 1
Cx
RED
LCD-PCB
1a
2 2a
(A2001001)
1 N
1
40
+V 1
-V 2
1
+V 1
-V 2
24V
SWITCH POWER
2 L
(A2001002)
(A2001003)
(A2001013)
YEL/BLU
1
40
CON1
POWER
1 +
2 -
1 DCIN+
2 DCIN-
1
1
10
10
LID
1
2
3
4
J16X
+ 1
- 2
1
1
2
3
4
CON7
G 1
+ 2
- 3
v 4
RX
COM1X
G
+5
TX
CON9
J6X
1
2
3
4
5
RED
BLK
+
-
FAN
(A2001009)
(A2001012)
(A2001007)
USB-HOST-PCB
USBCON
1 G
2 +
3 4 v
1
2
3
4
(A2001010)
U1
U1
CONNECTOR
(A2001011)
1
2
3
4
5
1
2
1
2
3
4
CONNECTOR
OUTA-1 1
OUTB-1 2
3
4
5
6
(A2001004)
MCU CONTROL-PCB
J6X
J3
TEC DRIVER-PCB
OUTA-2 3
OUTB-2 4
5
6
(A2001006)
OUTA-3 5
OUTB-3 6
(A2001005)
1
2
3
4
1
RX
(A2001008)
PIN1
TX
G
+5
COMMUNICATIOG
PCB
NET2
THERMISTORS
1
2
3
4
LID-PCB
RESISTANCE HEATER
THERMISTOR
θ
ST
BLOCK-PCB
Kaltis International.
TC 6 Service Manual
4. TROUBLE SHOOTING
No.
Error or Message
1
No display and no fan sound
a. Power failure.
a. Check line voltage and adapter.
when power is on.
b. Power cord disconnected.
b. Connect power cord.
Switch power failure
C. Power off, ask for service.
Unstable bench
Change the bench
Uneven Bench
Level / Change the bench plane
Loose case screw
Fasten the screw
Thermal pump failure
Shut off the power and call service
LCD failure or fan motor failure
Shut off the power and call service
LCD displays:
Power off when protocol is
Cycler is OK, press any
History Power Lost!
running.
key to cancel this
Power cord unreliable.
message.
Poor quality of power outlet.
Use reliable power cord
2
3
Cause
Abnormal vibrating noise.
Normal display but heating &
Action
cooling terminated.
4
No display but fan is moving
when power on.
5
Use good quality power outlet
6
Instrument
heat
normal
but
could not reach to the target
Incubate at 4°C for longer / too
Open heated lid bonnet, let
much condensation.
the instrument incubate at
temperature.
93°C for
30 min..
Modify 4°C
infinite to 10°C
infinite.
7
LCD display:
Instrument failure:
Instrument failure!
Sensor error
Power off, ask for service.
Error code：01
8
LCD display:
Instrument failure:
Ambient temperature is too high,
Instrument failure!
Ambient temperature is too high
Instrument is protected. When the
Ambient temperature drops to
Error code：02
30Deg.
9
LCD display:
Instrument failure:
Instrument failure!
Sink temperature is too high
Power off, ask for service.
Error code：03
10
LCD display:
The sample block type does not
Instrument failure!
match the instrument.
Power off, ask for service.
Error code：04
11
LCD display:
Instrument failure!
Error code：05
Can't locate the SD card.
Power off, ask for service.
Kaltis International.
TC 6 Service Manual
5. Disassembling and Reassembling the parts
5.1. Removing Heated Lid
Unscrew the four M4 Hex screw connecting upper case and chassis assembly, two in front of
instrument, two on rear. Disconnect the wires between upper monitor board and lower control board.
Lift the upper case and carefully lay it on the chassis side. Disconnect the four wires connecting
heated lid assembly and sample block aided with flat screwdriver. Rotate the thumb-wheel to move
heated lid downward, until it detaches from the plastic cover, take the four wires connecting heated
lid off the shaft support, and free the heated lid. Replace a new heated lid and reverse previous
steps to reinstall it. Pay attention to the correct connection of the four wires connecting the heated
lid and sample block.
5.2. Removing Sample Block
The same procedure as above: Disassemble the upper case and chassis, disconnect the four wires
between heated lid and sample block, move away the upper case. Unscrew another two M4 screws
connecting the support bracket and sample block. Note: Never let the washers on the support
bracket drop into chassis assembly. Disconnect several sets of wires connecting sample block and
chassis assembly aided with a flat screwdriver. Replace a new sample block and reverse previous
steps to reinstall it.
5.3. Removing Lower control Board
The same as above mentioned, disassemble the upper case and chassis, disconnect the wires
between heated lid and sample block, use a straight edge screwdrivers to disconnect the power
wires, wires between lower control board and heated lid, wires between lower control board and
driver board, wires of RS232 port from chassis back, unscrew six pieces of M3 cross screws, move
away lower control board. Replace a new lower control board and reverse previous steps to
reinstall it. Note: usually it need to be re-calibrated the temperature if you had replaced the lower
control board.
5.4. Removing 20V Switch Power
The same as above mentioned, demount upper case and sample block. Lift the upper case and
carefully lay it on the chassis side, unscrew four pieces of M4 Hex screw, take out the 20V switch
power, disconnect the wires. Replace a new switch power and reverse previous steps to reinstall it.
5.5. Removing Driver Assembly
The same as above mentioned, demount upper case, sample block, lower control board and switch
power, unscrew six pieces of M3 cross screws which fixed the drive board on chassis back,
demount the drive board, disconnect related wires, replace a new drive board and reverse previous
steps to reinstall it.
Kaltis International.
TC 6 Service Manual
5.6. Removing Upper monitor Board
Demount upper case assembly, make the LCD screen face to the surface of the table (underlay a
soft mat to avoid scratch). Unscrew four pieces of M3 cross screw which fixed the upper monitor
board and LCD screen. Demount the upper monitor board and disconnect related wires, replace a
new drive board and reverse previous steps to reinstall it.
5.7. Removing LCD Display
The same as above mentioned, demount upper monitor board assembly, unscrew four pieces of
M3 cross screw, demount LCD support bracket, unscrew four pieces of M3 cross screw, take down
the LCD screen and disconnect related wires, replace a new one and reverse previous steps to
reinstall it.
5.8. Software Update
Disassemble the upper case and chassis assembly, lift the upper case and carefully lay it on the
chassis side. You will see a MCU module on it. Take off the MCU module and replace a new module
with updated software. Reverse previous steps to reinstall the instrument. Note the pin number on
MCU module must have same number on the socket of MCU Main PCB.
Note: Before disassembling and reassembling the parts, disconnect the power and pull out
the power cord from the electrical outlet.