Service Manual Light Cycler
Contents
1. Chapter 5 Page 7 Light Cycler 5 3 3 Printed C Page 1 of 4 400250 800250 ano Woo 548 19077 ino 14 1309 E ane ana one T 200259 800280 Woo 100 N 20 280 20001 2100 32001 180 771 800281 32 2 35 QN9 Woo N 209 286 99A 148 1504 eld 150 60020 NS 800280 ans 00280 ino Moo GND ino NI hed 250 218 ino N 234184 286149 7 200250 214650 41841 QNO qu Sd 250 Woo Wega 81100 MP o od 281 Via 180 002 Ley 200280 ane Woo 4018 NOLON 0 ino 2 lt 7 gt susa 2 oF 5 em 1 ride 150 130 eee 150 8 5 148 150 25020880 2198 180 3080550 Noo 2 L V L 25047 zr 229A nA Vast VASt 92 HLA N38d 280 lt 1 35 V de 939 VM 1393 tsa 180 132 a1 sag UAI 280 VINE 180 aW 180 isu 07 159 114864 250 LUS td 150 188 042 t OL Y amp d 280 o1 r e 150 2804 37 6d 1 280 1181 64 190 VE Ed 2804 57 ised QINIZ d 184 FANIE Ed 280 ELIT Ed 202 orta 1127 28042 1 112. Fig 221298 4 Final 1 0 January 1999 24 Chapter 5 Light Cycler Service Manual 5 8 Heating Element 5 8 4 Location Heating element Fig 240998k2 Final 1 0 January 1999 Page 25 Chapter 5 Light Cycler Service Manual 59 Fluorimeter 5 9 1 Location Functional Description of the Fluorimeter The fluorimeter is located on a linear bearing below the measuring chamber It can be moved radially with the help of a linear stepper motor It has an excitation channel and 3 measuring channels with different wavelengths The essential features of the fluorimeter are its metallic body with a system of optical lenses and filters and 4 printed circuit boards with the following functions a LED PCB with a blue light emitting diode for illuminating the capillaries three identical printed circuit boards with optohybrids photodiode with integrated amplifier and program mable amplifiers A 12 bit analog to digital converter is used for programming the amplifiers as well as for the offset adjustment with which a negative output value of the optohybrids can be corrected Both 12 bit analog to digital converters are accommodated a housing and are serially activated via a 24 bit string For activating and transferring the measuring values the fluorimeter PCBs are connected to the PCB controller with a cable plug JP1 on PCB controller Fluorimeter Fig 221298k2 Final 1 0
3. Heating coil Carousel with capacity for 32 samples Stepper motor to position fluorimeter Stepper motor Fan to position samples over optics Filters Photohybrids Maintenance free LED light source Microvolume fluorimeter with Rodenstock quality optics Fig scheme1 Page 8 Chapter 1 Final 1 0 January 1999 Light Cycler Description of the Instrument The sample capillaries are thermostatted with hot air in the thermal chamber a ventilator ensures efficient aspiration distribution and temperature homogeneity of the air during the heating process During the cooling process the ventilator operates at a higher speed in order to ensure adequate cooling A heating coil controls the temperature For measurement the sample rotor is propelled by a stepper motor this brings the capillary tip precisely to the focal point of the photometer optics The photometer itself is placed in a radial position in relation to the signal maximum in order to compensate for any radial deviation of the capillary tip 3 microprocessors incorporated in the instrument control the process Processor 1 is forcommunication processor 2 regulates the temperature and processor 3 controls the measurement procedure as well as the rotor and photometer movements For online display data are transmitted to the PC Here sample data are entered the PCR reaction temperature is monitored measurement modes and initial evaluation
4. to PCB controller JP8 to PCB controller S1 to PCB controller S2 Fig 140798k8 Final 1 0 January 1999 Page 20 Chapter 4 Light Cycler Service Manual 4 6 3 2 Service Procedure Disassembly of the Rotor Lightbarrier Replaceable Components Pull cable 60 Remove screws 57 and washers 58 Measuring chamber 47 Lift out rotor lightbarrier 59 Glass window for fluorimeter 56 Screw 52 is part of the screw set Washer 53 is part of the screw set 4 6 3 3 Wiring Cable 48 is part of the cable set Cable 49 is part of the cable set Cable 48 connects control temp sensor 50 to PCB Control temp sensor 50 controller Monitor temp sensor 51 Cable 49 connects monitor temp sensor 51 to PCB controller Disassembly of the Measuring Chamber and Glass Cable 60 connects rotor lightbarrier 59 to PCB Window for the Fluorimeter controller Disassembly of the housing parts 4 6 3 4 Adjustment see Disassembly of the sample rotor and fan wheel see see Disassembly of the heating element see Disassembly of the chamber lid see Disassembly of the tooth belt see chapter 4 6 1 Disassembly of the fan motor see chapter 4 6 2 Pull cable 48 and cable 49 Unscrew control temp sensor 50 Unscrew monitor temp sensor 51 Remove screws 52 and washers 53 Lift out measuring chamber 47 Remove spring washer 54 Remove glass
5. essr 5H ul ars 5 L1 Is a L 185H M ase 5 12 Final 1 0 January 1999 Fig main f Light Cycler 5 4 PCB Driver 5 41 Location Functional Description of the LightCycler Power Board The LightCycler power board houses the following functions Driver for the stepper motor of the rotor Driver for the linear stepper motor of the fluorimeter drive Linear controller for driving the chamber fan setting the actual setpoint value by means of a serial 12 bit digital to analog converter The speed of the chamber fan which is equipped with an encoder is controlled by means of a frequency converter and one comparator each for minimum and maximum speed releasing or blocking of the heating voltage depends on this Service Manual PCB Driver Fig 221298k2 Final 1 0 January 1999 Page 13 Chapter 5 Service Manual 5 4 2 Block Diagram PCB Driver Light Cycler lar 100 in 13 it di E dols 9 gi 2 E id 9df 2170611 E 4 JeAugAejonuo addas
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8. 41 Overview Chapter 4 2 part of housing set cpl Z ID No Chapter 4 4 heating element ID No 2024004001 Chapter 4 4 part of cable set ID No Chapter 4 4 part of screwset ID No Chapter 4 2 gasket for chamber lid ID No 2023962001 Chapter 4 5 p chamber lid Chapter 4 2 part of housing set cpl ID No 99999999999999999999999 ID No d Chapter 4 10 Chapter 4 6 Chapter 4 2 22 rotor PCB status LED ID No 2024012001 ID No Chapter 4 3 sampler rotor ID No 1909282001 Chapter 4 3 fan wheel Charter 4 8 ID No 2024039001 lightbarrier interlock Chapter 4 6 g No tooth belt ID No 202989001 Chapter 4 8 lightbarrier rotor jd ID No 4 as Chapter 4 8 excess temp switch 27 SL ID No p P Chapter 4 2 part of housing set cpl TE Chapter 4 6 measuring chamber ID No 2023954001 Chapter 4 6 window fluorimeter cpl ID No 2023997001 69 light barrier fluorimeter ID No A Chapter 4 1 temp sensor control ID No ID No Chapter 4 8 gt Chapter 4 10 f m se monitor battery Fig 160798k1 Final 1 0 January 1999 Page 3 Chapter 4 Light Cycler Service Manual 4 2 Disassembly of the Housing Parts 4
9. i ubapwo T 06 10 38 2 ddas gt ge Chapter 5 14 Final 1 0 January 1999 Fig cap5 4 2 Light Cycler Service Manual 5 4 3 Printed Circuit Diagram PCB Driver 1 of 3 3 20 RH E i ip n E 5 d 1 44 NEUE e M m T 1 we T i 88 88 8 8 44 95 5 ES 2 T 31 89 12 8187 sel get 4 TRE a a of 8388 1 1 lt gt 8 2 8 l 728 E Fig power a Final 1 0 January 1999 Page 15 Chapter 5 Service Manual Light Cycler 5 4 3 Printed Circuit Diagram PCB Driver Page 2 of 3 OO0Z ZZAAB edt 81 Ave 95262071 dois 5 O APC gt dois uonow 205 0 2 SCL9OAd Q WAS XOL Oza PLY GAS O 971d OH 8208 9 VAS VAS 9 Ld8 LSO LSG LSO S Lda tsa Fig power b Chapter 5 Page 16 Final 1 0 January 1999 Service Manual Light Cycler 5 4 3 Printed Circuit Diagram PCB Driver of 3 XOL 854 808 95149 91 ZOSI 022 Su O LZOHPL o s 9 or zL 9621
10. the blue LED dosent work check the blue LED from Photometer check the interlock sensor Final 1 0 January 1999 Page 1 cap7 tbl Chapter 7 Light Cycler Service Manual 8 Spare Parts 2 8 1 Part Identification 2 8 2 Complete Spare Part List 3 8 3 Tools 4 Final 1 0 January 1999 Page 1 Chapter 8 Light Cycler Service Manual 8 Spare Parts 81 Part Identification part of housing set S 2 4 ID No KS 16 heating element part of cable set ID No 2024004001 ID No part of screwset ID No 27 61 gasket for chamber lid part of housing set cpl ID No 2023962001 ID No Doogoggggggggggggggosse 33 9200009 chamber lid 90009 ID No 80 4 9 ID No stepmotor rotor PGB status LED ID No 2024012001 PCB driver 8 ID No 13 sampler rotor ID No 1909282001 15 fan wheel 66 ID No 2024039001 lightbarrier interlock 42 ID No tooth belt ID No cpt 8 lightbarrier rotor 5 ID No 74 excess temp switch 27 ID No if part of housing set cpl ID No 47 measuring chamber ID No 2023954001 window fluorimeter cpl ID No 2023997001 44 fan motor ID No 2023946001 temp sensor control ID No 51 temp sensor monitor lt Fig 8 1 Final 1 0
11. Disconnect the RS 232 and power cables Clean according to the chapter on service and decontaminate if necessary 3 Dispatch instrument in its original packaging Tab cap2 7 Final 1 0 January 1999 Page 6 Chapter 2 Light Cycler Service Manual 2 5 Operation and Maintenance of the LightCycler Guidelines for Operation The instrument may be operated only if protected from the weather It may not be operated in buildings without temperature regulation facilities If necessary additional drying agents may be used to eliminate humidity The instrument should not be operated near dripping spraying splashing or running water The instrument is thus suitable for use according to classification 3K3 in accordance with Standard EN 60721 3 3 The instrument may be used at locations subject to noticeable or significant vibration however it should not be exposed to higher levels of shock waves The instrument is thus suitable for use according to classification 3M4 in accordance with Standard EN 60721 3 3 The instrument is able to tolerate vibrations up to classification 3M6 However based on expected locations of use no significant and permanent vibrations or shock waves are to be expected Transport and Storage When storing or transporting the instrument it should not be exposed to extreme cold e g as in the case of air freight Temperatures lower than 25 should be avoided damage t
12. Fig 221298k1 Final 1 0 January 1999 PCB Controller Page 5 Service Manual Channel 2 for control of excess temperature EEPROM for storing the device specific calibration data and various parameters as well as the serial numbers of the instrument and the fluorimeter Digital to analog converter and driver for regulating the LED current for the blue fluorimeter LED 12 bit analog to digital converter for converting the voltage analog to the temperature for temperture regulation by means of the temp processor Multi channel 12 bit analog to digital converter for converting the measuring values of the 3 fluorimeter channels and the temperature for the display Data interface with the power supply for transferring the actual set values for the heating voltage this serial interface is also galvanically isolated from the power supply via optocoupler Chapter 5 Chapter 5 6 a gt preog Joy 250 20 250 4 pieogiewog 5 150 d id d D pol eszcosiW gjeuueua Ww pue jouueyo Ljeuueu
13. January 1999 Page 26 Chapter 5 Service Manual Light Cycler 5 9 2 Block Diagram Fluorimeter _ 0651217 521 2 1 cem 404991405 esJJO 10 09 7 E Cui 0651217 SOl 2 Zoey OL A 5 960 0 m ydwy ueg Jeyydury 10 1 2 jep so wjo Lr Fig cap5 9 2 Chapter 5 Page 27 Final 1 0 January 1999 Light Cycler Service Manual 5 9 3 Printed Circuit Diagram PCB Fluorimeter 5 2S 2 5 4 4 tie 23 14 3 lt 4 1 8 262 Fig flour a Final 1 0 January 1999 Page 28 Chapter 5 Light Cycler Service Manual 5 4 4 Layout Diagram PCB Fluorimeter Page 1 of 2 O OO Q O Q H39NIHH30H aw JON Fig flour b Final 1 0 January 1999 Page 29 Chapter 5 Light Cycler Service Manual 544 Layout Diagram PCB Fluorimeter FE 2 ROCA LE 0 mo L_ J 231 2 Final 1 0 January 1999 Page 30 Chapter 5 Light Cycler Service Manual 6 Service Software 2 6 1 Hardware requirements 2 6 2 Installation of Windows NT 2 6 3 BIOS Settings 2 6 4 Basic setup actions 2 6 4 4 Logon as administrator 2 6 4 2 Create directory and set run mode of a program 2 6 4 3
14. A 3 channel fluorescence photometer is used for detection purposes Sample excitation is initiated by a blue LED with an emission maximum of 470 nm Fluorescence is detected by means of a separate photo hybrid for each wavelength Final 1 0 January 1999 Page 10 Chapter 1 Light Cycler Service Manual 1 44 Introduction 1 41 Instrument 1 4 1 1 Principle of the LightCycler Technology System Description The LightCycler comprises two different instrument components a cycler component and a fluorescence detection component The combination of both components allows complex applications such as product analysis quantification and mutation analysis The cycler component has been optimized for rapid PCR applications Compared with classical PCR where typical cycling programs take several hours PCR analyses carried out in the LightCycler can be completed in only 15 30 min This considerable time saving effect is due to very short temperature transfer times the so called ramping times of the LightCycler instrument Ramping times are the time periods necessary to reach the next pre set temperature of a cycling protocol in a PCR experiment An example is the transition from 94 C to 55 C after sample denaturation for primer hybridization during the annealing phase This sort of high speed cycling is made possible by an optimized surface volume ratio of the samples and the use of air as a temperature transfer medium Fluorim
15. SION E P4159 Fig power e Chapter 5 Page 19 Final 1 0 January 1999 Light Cycler Service Manual 5 5 Status Board 5 5 1 Location Statusboard Fig 221298k3 Final 1 0 January 1999 Page 20 Chapter 5 Light Cycler Service Manual 5 5 2 Printed Circuit Diagram Status Board Fig c5 5 3 Final 1 0 January 1999 Page 21 Chapter 5 Light Cycler Service Manual 5 5 3 Layout Diagram Status Board Fig c5 5 4 Final 1 0 January 1999 Page 22 Chapter 5 Light Cycler 5 6 Lightbarriers and Sensors 5 6 1 Location Rotor Lightbarrier The rotor lightbarrier controls the rotations of the rotor Interlock Lightbarrier The interlock lightbarrier is a reflection lightbarrier It senses whether the housing lid is open or closed Fluorimeter Lightbarrier The fluorimeter lightbarrier controls the fluorimeter movements Monitor Temperature Sensor The monitor temperature sensor controls the measuring chamber temperature and prevents excess temperature Excess temperature switch Lightbarrier home position Rotor Control temperature ae d sensor a sensor Fig cap5 6 Final 1 0 January 1999 Page 23 Service Manual Conirol Temperature Sensor The control temperature sensor controls excess temperature in the measuring chamber Excess Temperature Switch The excess temperature switch is a bimetal switch which protect
16. customer software Logon as LC Service CTRL ALT DEL gt Logon window Logon User name LC Service Password After logon process is ready insert LightCycler service CD ROM The setup routine of ServiceTools starts after some seconds automaticallly gt Next gt Next gt Finish Please copy the links of the little LC Service window to the desktop TestAdj and LcEdit The setup of the customer software must be started with the command Drive LightCycler Setup exe Final 1 0 January 1999 Page4 Service Manual Chapter 6 Light Cycler 7 Troubleshooting Error Description Possible Reason s Service Manual What To Do Chanber fan or rotor stepper are not running Interlock sensor not adjusted reflex area at the lid is not shiny Sensor defect check output from sensor voltage on pin3 from JP6 must be 0 2V 0 2 if the lid if open then 5V control the reflex are and clean it if necessery change and adjust the light barrier is closed no heating function seeabove about interlock sensor the heating coil is broken the power supply for heating is out of order the overheat latch is seted see above change the heating coil check pin8 from 14 must be 5V if the cover is closed if not then check pin7 from IC23 and IC24 both must be low if not a overheat is detected no flourimeter signal on all channel s
17. 2 1 Housing Lid 4 2 1 1 Location 4 8 n Fig 140798k2 Final 1 0 January 1999 Page 4 Chapter 4 Light Cycler 4 2 1 2 Service Procedure Replaceable Components Housing lid 1 is part of the housing set Screw 2 is part of the screw set Gasket 61 Disassembly of the Housing Cover Flap housing lid 1 backwards Remove all screws 2 Remove housing lid 1 Disassembly of Gasket Flap housing lid 1 backwards Remove gasket 61 Final 1 0 January 1999 Page 5 Service Manual Chapter 4 Service Manual Light Cycler amp VSssssssssssssssssssssso VWSsssSssesssssssssssssss VSsssssssssssssssssssssso VWSSSsssSssssssssssssssss VWSSSsssSsesssssssssssssss WSSSssssssssssssssssssss 4 2 2 Housing 4 2 2 1 Location Fig 151298k1 Chapter 4 Page 6 Final 1 0 January 1999 Light Cycler 4 2 2 2 Service Procedure Replaceable Components 3 is part of the housing set i Screw 4 is part of the srew set Washer 5 is part of the screw set P Disassembly of the Housing Remove all the screw
18. 45 cm It weighs approximately 20 kg Voltage requirements The LightCycler operates on 120 240 V 50 60 Hz and need not be adjusted Power consumption The LightCycler requires approximately 800 W PC and printer require a further 500 W Tab cap2 1 The LightCycler must not be opened by the user The fuse may only be replaced if the instrument has been switched off at the mains Environmental Requirements Please refer to the following table for the environmental requirements Ambient temperature 15 35 all specifications maintained between 15 and 30 C Humidity 20 80 no condensation Altitude Sea level to 2000 m Excess voltage category Il Degree of contamination 2 Final 1 0 January 1999 Tab cap2 2 Page 2 Chapter 2 Light Cycler Storage Conditions The LightCycler can be stored on5 the following conditions Ambient temperature 20 60 C Service Manual Humidity 20 80 no condensation Final 1 0 January 1999 Page 3 Tab cap2 3 Chapter 2 Light Cycler Service Manual 2 2 Installation of the LightCycler Installation of the Instrument Please refer to the following table for the installation of the LightCycler instrument Step Action 1 Unpack the instrument 2 Position instrument on bench working surface Allow 10 cm space left right and behind 3 Electri
19. 79 from the PCB controller 78 4 10 2 1 Wiring Aufzahlung der Kabel die zum PCB Controller gehen 4 10 3 PCB Driver was macht dieses Replaceable Components PCB Driver 80 Screws 82 are part of the screw set Washers 83 are part of the screw set Disassembly Disassembly of the housing see Ehapter 4 2 2 Pullallthe connecting cables from the PCB driver 80 Remove screws 82 and washers 82 Lift out PCB driver 80 4 10 3 1Wiring Aufz hlung der Kabel die zum PCB Controller gehen Final 1 0 January 1999 Page 31 Service Manual 4 10 4 Status Board was macht dieses Disassembly Disassembly of the panel 8 see chapter 4 2 3 Remove nuts 11 with washers 10 Remove status board 9 Pull cable 12 4 10 4 1 Wiring Cable 12 connects status board 9 to PCB controller JP12 see chapter 4 10 2 Chapter 4 Light Cycler 5 Electronics 5 1 Overview 5 2 Cable Connections 5 3 PCB Controller 5 31 Location 5 3 2 Block Diagram PCB Controller 5 3 3 Printed Circuit Diagram PCB Controller 5 3 4 Layout Diagram PCB Coniroller 5 4 Driver 5 4 1 Location 5 4 2 Block Diagram PCB Driver 5 4 3 Printed Circuit Diagram PCB Driver 5 4 4 Layout Diagram PCB Driver 5 5 Status Board 5 5 1 Location 5 5 2 Printed Circuit Diagram Status Board 5 5 3 Layout Diagram Status Board 5 6 Lightbarriers and Sensors 5 6 1 Location 5 7 Power Supply 5 7 1 Location Fina
20. 95 C for dynamic cycles 72 95 50 C Os maintained 3 0 C 1 0 C range Temperature homogeneity in capillary 20 ul 70 C 1 0 C range 15 ul 70 C 0 5 C range Tab cap1 7 Final 1 0 January 1999 Page 6 Chapter 1 Light Cycler 1 2 3 Detector Specifications Service Manual Illumination Type LED Median wavelength 470 nm Output at 470 490 nm 0 1 mW Tab 1 8 Detector Type Photohybrid Receptor surface 2 5 2 5 mm Sensitivity at 520 nm 20 ul sample volume 15 nM fluorescein 1s Sensitivity at 650 nm 20 ul sample volume x nM fluorescein LightCycler Red 640 Sensitivity at 700 nm 20 ul sample volume x nM fluorescein n d Electronic dynamic 12 bit Electronic bandwidth 1 kHz Integration time 20 ms Alteration of amplification range Factor 1 256 Filter Tab 1 9 Detector 1 Bandpass 520 nm HBW 20 nm dichroitic Detector 2 Bandpass 645 nm HBW 30 nm dichroitic Detector 3 Bandpass 710 nm HBW 40 nm dichroitic Tab 1 10 Time Measuring time for 32 capillaries lt 5s Tab cap1 11 Final 1 0 January1999 Page 7 Chapter 1 Service Manual Light Cycler 1 3 System Description 1 31 The LightCycler Scheme of the Instrument Sealed 20 ul sample capillary with superior surface to volume ratio Air heating and cooling for rapid temperature ramping
21. LightCycler Workstation Contents of the Workstation The LightCycler components are listed in the following table Component Description System component 1 LightCycler Instrument Sample Carousel for 1 5 mm capillary premounted in LightCycler Instrument System component 2 Capillaries 96 capillaries and caps box 32 Centrifuge adapters with 1 cooling block in an aluminium cooling block LightCycler Operator s Manual Software Package Cable to connect LC to computer Power cord German plug Power cord U S plug Mouse Pad Recommended PC Hardware 8 98 Vectra VE4 5 200 MMX Model 3200 Desktop Intel Pentium MMX processor 200 MHz 64 MB SDRAM DIMM 3 2 GB ultra ATA 33 hard disk On board PCI vide S3 Trio 64 V2 2MB 50 ns DRAM 24x speed DIE CD ROM disk drive Keyboard and PS 2 mouse Operating system Windows NT 4 0 including service pack III ZIP drive Internal lomega ZIP drive DIE interface ATAPI Monitor HP Ergo 1280 17 monitor HP D2840A Printer HP Deskjet 890C Color Inkjet Printer Tab cap1 1 Final 1 0 January 1999 Page 2 Chapter 1 Light Cycler Service Manual Marks of Conformity The LightCycler has been manufactured in accordance with EN 61010 1 Safety Regulations for Measuring Control and Laboratory Instruments Part 1 General Requirements IEC 1010 1 A1 1992 modified and has been checked according to all relevant s
22. Start gt Settings gt Control Panel gt System Startup Shutdown gt System startup gt Show list for 3 seconds Recovery Write an event to the system log Automatically reboot Chapter 6 Light Cycler 6 4 6 Set administrator password create LC_Service and LC_User account Start gt Programs gt Administrative Tools Common gt User Manager 6 4 6 1 Change Administrator password Double click Administrator gt kkkkkk Password Confirm Password kkkkkk gt OK 6 4 6 2 Create LC_Service account Select Administrator gt User gt Copy Username LC_Service Full name LightCycler Service Description Password kkkkk Confirm password Only Password never expires should be marked gt Groups gt Member of Administrators gt OK gt Profile gt Home directory gt Local Path C LC_Service gt OK gt OK 6 4 6 3 Create LC_User account gt User gt New User Username LC_User Full name LightCycler User Description Password side KEKE Confirm password Only Password never expires should be marked gt Groups gt Member of Poweruser gt OK gt Profile gt Home directory gt Local Path C Users LC_User gt OK gt OK gt Exit Start gt Shutdown gt Close all programs and logon as different user gt YES Final 1 0 January 1999 Page 3 Service Manual 6 5 Setup LC_User
23. mm PCR analysis carried out in these specially manufactured glass capillaries reduces the reaction volume to only 5 to 20 ml max The optimized surface to volume ratio thus obtained allows for very short cycle times of only 15 to 20 seconds per cycle The very favorable surface to volume ratio also guarantees an extremely rapid temperature change in the reaction mixture during each PCR cycle At the same time the glass capillaries serve as cuvettes for the fluorimetric determination of the PCR products formed Air heating and cooling for rapid temperature ramping Heating coil IU Service Manual Thermal Chamber The cylindrical thermal chamber is supplied with hot air and air at ambient temperature by means of a fan with coupledheating coils The incoming airishomogeneously distributed by a high velocity fan at the base of the instrument thus creating an eventemperature throughout the reaction chamber Surplus air is vented through an opening at the side of the chamber The temperature is controlled by using an integrated measuring system with atemperature sensor installed in the direct vicinity of the sample capillaries of the sample carousel The PCR thermal chamberis directly coupled to the optical system of the fluorimeter Sealed 20 ul sample capillary with superior surface to volume ratio Carousel with capacity for 32 samples Stepper motor to position fluorimeter Thermal Chamber Stepper
24. motor to position samples Fan over optics Filters Photohybrids Maintenance free LED light source Microvolume fluorimeter with Fig scheme1 Rodenstock quality optics Chapter 1 Final 1 0 January 1999 Page 12 Light Cycler 1 4 2 2 The Fluorimeter Component Optics The fluorescent optical components of the LightCycler are schematically illustrated in Ehapter 1 3 1 The Light Cycler A blue high performance diode blue LED serves as energy source for sample excitation The diode emits radiation which is spectrally filtered to a wavelength of 470 nm and an energy of 1 mW and is collimated brought to the same wavelength by means of a special optical system The homogeneous light beam of 470 nm generated is subsequently focused onto the individual glass capillaries and then onto the samples to be measured in the sample carousel The glass capillaries are moved by a high precision stepper motor and placed in the optimal position for excitation and measurement According to the spectral properties of the fluorophore used the light emitted from the excited samples is guided into one of three channels see drawing in chapter 1 3 1 The Light Cycler via dichroitic mirrors for subsequent evaluation In this channel the emitted light beam is further collimated and spectrally concentrated by means of a special filter optical system For final evaluation the light beam is then focused onto a photomultiplier The three evaluation channel
25. parts can be distinguished from each other by different material numbers language version e g new part 1234567 001 repaired part 1234567 984 Repaired parts should be ordered together with new parts via the order processing department in Mann heim OU VDG Defective parts should be returned together with order of repair including the filled out RA form giving full details of the defect and marked choice box with repair to Logistic Instruments Incoming Goods in Mannheim Wohlgelegen LI LV Repair of Instruments Complete instruments are accepted only if the problem is definitety located in the photometer unit The replacement should have been agreed with the Technical Product Management or with the responsible person of the Roche Diagnostics Technical Support Terms of Delivery Shipments to countries with the routine truck are c i f other shipments are ex works Mannheim Emergency shipments incur additional charges Charges Repaired parts material no 1234567 984 are supplied at a repair price There will be a subse quent charge consisting of the price difference between a new and repaired part should the defective parts not be returned within 3 weeks for European countries and 8 weeks for Overseas countries Chapter 1 Light Cycler After receipt of a warranty claim for A parts BMG will credit 100 of the currently effective ex MA price In case the manufacturer does not ac
26. 17 is part of the cable set Cable 90 is part of the cable set Cable 91 is part of the cable set Screw 88 is part of the screw set Screw 89 is part of the screw set Disassembly of the Power Supply Disassembly of the housing parts Pull cable 17 Pull cable 90 Pull cable 91 Remove screws 88 Remove screw 89 Pull out the power supply 81 4 9 3 Wiring Cable 17 connects power supply 81 to heating element see chapter 4 4 Cable 90 connects power supply 81 to PCB controller see chapter 4 10 2 Cable 91 connects power supply 81 to PCB driver see chapter 4 10 23 Final 1 0 January 1999 Page 29 Service Manual Chapter 4 Light Cycler Service Manual 4 10 PCBs 4 10 1 Location 78 7 5 Fig 100898 1 Final 1 0 January 1999 Page 30 Chapter 4 Light Cycler 4 10 2 PCB Coniroller und Battery The PCB controller of the Light Cycler houses the essen tial control functions data recording and communication with the PC via interface RS232 Replaceable Components PCB controller 78 Battery 79 Disassembly of the PCB Controller Disassembly of the housing see chapter 4 2 2 Pull all the connecting cables from the PCB controller 78 Remove the PCB controller 78 located on the side Disassembly of the Battery Disassembly of the housing see chapter 4 2 2 Remove battery
27. 39001 AZL WOvZL194W1 NV Q SUOOL O 92 Q peede an eco 700 e g ASL Eza 1 54001 922 I 621 GAS XOL 694 Nehe NVA Fig power c Chapter 5 Page 17 Final 1 0 January 1999 Light Cycler Service Manual 544 Layout Diagram PCB Driver Page 1 of 2 1506 1503 1504 1505 ecce ecce ecce a Light Cycler Power Board Rev 3 1 meee 0006 eee 1507 1502 1501 4 09 98 BS P4 p DIO 09 r4 5 JP3 JP5 R33 R34 57 2 co lt ks ue Bohringer Mannheim GmbH Fig power d Final 1 0 January 1999 Page 18 Chapter 5 Service Manual Light Cycler 5 4 4 Layout Diagram PCB Driver Page 2 of 2 KIT esrul E Wozu W e UN eccull B rd N SZ comme gt 5200 SS Secum ISHE W BLUE W Sum 2 onam ycul N e 92 ON gt W m 7 C2 131 5 sje Lou M m evi 020 e E
28. 99 Page 1 Service Manual Chapter 10
29. Check desktop properties 2 6 4 4 Change the reginonal settings 2 6 4 5 Set system parameters 2 6 4 6 Set administrator password create LC Service and LC User account 3 6 4 6 1 Change Administrator password 3 6 4 6 2 Create LC Service account 3 6 4 6 3 Create LC User account 3 6 5 Setup LC User account 3 6 5 1 Desktop properties 3 6 5 2 Regional settings 3 6 6 Setup LC Service account 3 6 6 1 Desktop properties 3 6 6 2 Reginonal settings 4 6 7 Install LightCycler service and customer software 4 Final 1 0 January 1999 Page 1 Chapter 6 Light Cycler 6 Service Software 6 1 Hardware requirements This chapter descripes the minimal system to control the LightCycler Vectra VE4 5 200 MMX Modell 3200 Desktop HP D5606N Intel Pentium MMX Processor 200 MHz 64 SDRAM DIMM 3 2 GB Ultra ATA 33 Hard disk On board PCI Video S3 Trio 64 V2 2MB 50ns DRAM 24 times Speed IDE CD ROM drive Keyboard and PS 2 Mouse Operatingd system Windows NT 4 0 inclusive service pack 3 and hotfixes english version Internal lomega ZIP drive IDE interface ATAPI HP Ergo 1280 17 Monitor D2840A Optional component not generally supplied with the instrument HP DeskJet 890C Color InkJet printer 6 2 Installation of Windows NT During installation of Windows NT the following parameters should be set Display mode settings 1024 768 pixels 256 colors small fonts Hard disk format one NTFS partition 6 3 BIOS Sett
30. January 1999 2 Light Cycler Service Manual 8 2 Complete Spare Part List mnn 1909282001 Samplerotor 13 2024039001 Fan Wheel 15 2024004001 Heating Element 16 2023962001 Gasket for Chamber Lid 61 Chamber Lid X 33 2024012001 Stepmotor Rotor 43 2023989001 Tooth Belt 42 PCB Driver 80 PCB Controler 78 Power Supply 81 Fluorimeter Drive 64 2023946001 Fan Motor 44 Temperature Sensor Control 50 Temperature Sensor Monitor 51 2023954001 Measuring Chamber 47 2023997001 Window Fluorimeter 56 PCB Status LED 9 Lightbarrier Rotor 59 Lightbarrier Interlock 66 Excess Temperature Switch 74 Lightbarrier Fluorimeter 70 Battery 79 Damper 84 Housing Set cpl Screwset Cable Set Fig cap8 2 Final 1 0 January 1999 Page 3 Chapter 8 Light Cycler 8 3 Tools Allan key Wrench Socket spanner Phillips screwdriver Snap ring pliers Final 1 0 January 1999 4 5 5 5 size 1 length 100 mm size 0 length 100 mm 10 25 mm for window photometer mm mm mm mm mm mm mm mm mm mm Page 4 Service Manual Chapter 8 Light Cycler 10 Maintenance The Light Cycler is a maintenance free instrument Keep the instrument surface and the outer parts of the instrument clean for hygienic reasons Use a commercial detergent or disinfectant preferably 70 isopropanol if necessary Final 1 0 January 19
31. Service Manual Light Cycler S8sssssssssssssssssssssS Ssssssssssssssssssssssss 88Ssssssssssssssssssssss S8ssssssssssssssssssssssS S8ssssssssssssssssssssss Ssssssssssssssssssssssss S8ssssssssssssssssssssss Ssssssssssssssssssssssss 8899999999899999S8S8999ssss Final 1 0 January 1999 Light Cycler Final 1 0 January 1999 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Service Manual Application Introduction Installation omitted Mechanics Electronics Note In some wiring diagrams the fluorimeter is termed photometer Software Trouble Shooting Spare Parts omitted Maintenance Light Cycler 1 Application Introduction 11 LightCycler Workstation 1 2 Technical Data 1 2 1 Instrument Specifications 1 2 2 Application Specifications 1 2 3 Detector Specifications 1 3 System Description 1 31 The LightCycler 1 4 Introduction 1 4 4 Instrument 1 4 1 1 Principle of the LightCycler Technology 1 4 22 Instrument Components of the LightCycler 1 4 2 1 The Cycler Component 1 4 2 2 The Fluorimeter Component 1 5 Warranty Final 1 0 January1999 Page 1 Service Manual 11 11 11 12 12 13 14 Chapter 1 Light Cycler Service Manual 1 Application Introduction 11
32. account Logon as LC_User CTRL ALT DEL gt Logon window Logon User name LC_User Password 6 5 1 Desktop properties Display properties Background gt None ScreenSaver gt Starfield Simulation No Password protection Wait 15 min 6 5 2 Regional settings Start gt Settings gt Control Panel gt Regional Settings Reginal settings properties Regional settings english United States Number gt Measurement System Metric Time gt Time style HH mm ss Date Short date style dd MMM yy Long date style dddd dd MMMM yyyy gt OK 6 6 Setup LC Service account Logon as LC Service CTRL ALT DEL Logon window Logon User name LC Service Password 6 61 Desktop properties Display properties Background gt Pattern gt None Wallpaper LcService Display Tile ScreenSaver gt Logon Screen Saver Password protected Wait 15 min Settings gt Color palette 256 colors Desktop area 1024 by 768 pixels Font size Small fonts Refresh frequency 75 Hertz Chapter 6 Light Cycler 6 62 Reginonal settings Start gt Settings gt Control Panel gt Regional Settings Reginal settings properties Regional settings english United States Number gt Measurement System Metric Time gt Time style 55 Date gt Short date style dd MMM yy Long date style dddd dd MMMM yyyy gt OK 6 7 Install LightCycler service and
33. aceable Components Stepper motor rotor 43 Tooth belt 42 Cable 38 is part of the cable set Screw 39 is part of the screw set Washer 40 is part of the screw set Set screw 41 is part of the screw set Disassembly of the Tooth Belt Disassembly of the housing parts see chapter 4 2 Disassembly of the heating element see Disassembly of the chamber lid see chapter 4 5 Pull cable 38 from PCB driver Remove screws 39 and washers 40 Turn set screw 41 in order to reduce tooth belt 42 tension Lift out tooth belt 42 Disassembly of the Stepper Motor Rotor Disassembly of the tooth belt Lift out stepper motor rotor 43 4 6 1 3 Wiring Cable 38 connects stepper motor rotor 43 to PCB driver see chapter 4 10 3 4 6 1 4 Adiustments Belt tension of the sample rotor drive An adjustment of the belt tension is necessary if one of the following components is removed or replaced stepper motor rotor 43 tooth belt 42 measuring chamber 47 Proper adjustment of the belt tension ensures a minimum of friction between motor belt and rotor To adjust the belt tension please proceed as follows Open the fixation screws 39 of the stepper motor rotor 43 about 1 4 of a turn so that the motor can be moved in a horizontal direction Adjustthe tension with the adjustment screw 41 until the teeth of the belt fit properly into the grooves of
34. afety standards prior to leaving the factory The instrument has been approved for use by recognized testing institutions This is confirmed by the following test conformity symbols GS Certificated by VDE institute Association of German Electrotechnical Engineers CE The instrument conforms to current directives as issued by the European Union UL 0 Certificated by Underwriters Laboratories Inc CUL Certificated by Underwriters Laboratories for Canada testing facility recognized by the Standards Council of Canada SSC Tab cap1 2 All equipment to be connected must fulfill the standards set by IEC 950 Safety of Information of Technology Equipment Including Electrical Business Equipment Final 1 0 January1999 Page 3 Chapter 1 Light Cycler Classification ISM instrument medium sized for industrial laboratory and domestic use The instrument is designed for stationary operation Any false measurements produced are irrelevant from the safety point of view Theinstrumentis designated for worldwide marketing Itis intended for evaluating pre processed biological material The following should be noted The instrument may not be used in conjunction with infectious material without additional safety measures being taken Final 1 0 January 1999 Page 4 Service Manual Chapter 1 Light Cycler 1 2 Technical Data 1 2 1 Instrument Specifications Genera
35. cal connections Connect LightCycler to the PC using an R 232 cable serial inter face Connect LightCycler PC monitor and printer to same distributor plug Tab cap2 4 Ensure that printer monitor and PC have been set to the correct voltage Final 1 0 January 1999 Page 4 Chapter 2 Light Cycler Service Manual 2 3 Computer and Software Installation Installation of the PC After unpacking the computer carry out the following steps Step Action 1 Connect mouse keyboard and monitor to the computer 2 Connect the LightCycler to the computer with an R 232 cable serial interface 3 Connect computer monitor and LightCycler to the distributor plug The computer is now ready for operation Tab cap2 5 Software The complete software package is installed by Roche Diagnostics Installation of Updates Reinstallation In the following table you find information about the reinstallation and loading of updates Step Action 1 Store any data e g DATA PROFILES and PROTOCOLS 2 Place LightCycler CD ROM in appropriate disk drive e g F 3 Start set up program e g F SETUP EXE Tab cap2 6 Final 1 0 January 1999 Page 5 Chapter 2 Light Cycler Service Manual 2 4 LightCycler De installation De installation of the Instrument Please refer to the following table for the de installation of the instrument Step Action 1 Switch off the instrument 2
36. cept the warranty claim each country s respective service center will be charged the for parts and the new price for non R parts RA Form Return Authorization Please answer all the questions on the RA form with the greatest care and sign the form Country code Problem date Type of instrument Serial no of the instrument Installation date of instrument Defective instrument or spare part Part number and material number of the spare part Old new serial no Fault description Alarm code Service workshop report no Instruments Not Under Warranty Installation date of spare part All returned parts should be individually labeled with the corresponding RA no and shipped together with the completed RA form to Roche Diagnostics Logistic Instruments RA Management Friedrich Ebert Str 100 D 68167 Mannheim Germany Final 1 0 January1999 Page 15 Service Manual Chapter 1 Light Cycler Service Manual RA Form Example ROCHE DIAGNOSTICS GmbH Friedrich E bert Strasse 100 Telefon 49 621 759 81 84 D 68167 Mannheim Fax 49 621 759 80 93 Germany Return Authorization Country code Date Instrument Serial No Installation date Spare Part Customer Address will be filled in by BM Part No Qty Part Name Repair Comments Mat No Warranty Installation date of Spare Part Warranty Repair OLD serial No Modificati
37. er 3 i 8 1 77 100 Zt 881 L JP hat 100 Z 51 881 eyejdgng 1 100 IE SI 884 100 EL ZI 881 Xoopeju 108496 00 pieog BunBiosue 100 FL SI 881 Jayawoyoug 100 69 60 881 Josuag 100 Z0 SL 881 pyeog 100 8L P1 881 100 88 981 nl Jawwey Jojoulleyn1 Jojouupuuos 100 SL SL 881 10595 9qex Fig cap5 2 Chapter 5 Page4 Final 1 0 January 1999 Light Cycler 5 3 Controller 5 3 1 Location Functional Description of the PCB Controller of the LightCycler The PCB controller of the Light Cycler houses the essen tial control functions data recording and communication with the PC via RS232 These functions are Interface 85232 galvanically isolated via optocoupler serves for communication with the PC Interface management between PC and temp and or step processor by means of a PIC processor 2 microprocessors temp processor and step processor for temperature regulation positioning of the stepper motors and recording of the measuring values 2temperature measuring channels Channel 1 for regulating the chamber temperature by means of the temp processor indication of the actual temperature in the measuring chamber and control of excess temperature
38. etric Detection The combination of an optimized thermocycler and a fluorimeter not only enables online presentation of the PCR data obtained and efficient analysis of results but also offers the user utmost flexibility To meet individual requirements different detection formats can be used by choosing and combining fluorescent dyes and detection probes Fluorimetric detection of the PCR products formed consists of two different procedures Sequence specific detection by the double stranded DNA binding dye Green or Sequence specific oligonucleotides are coupled to suitable fluorophores as hybridization probes Analysis of Results By means of the special LightCycler software the data obtained from fluorimetric analysis can be evaluated and displayed Additional cumbersome analytical procedures subsequent to PCR e g restriction and gel analysis as well as blotting and hybridization experiments are no longer necessary The direct and simple analysis of results also minimizes the contamination risk posed by samples and working materials due to a reduction of working steps required Final 1 0 January1999 Page 11 Chapter 1 Light Cycler Instrument Components of the 1 4 2 LightCycler 1 4 2 1 The Cycler Component Sample Carousel The central element of the cylindrical thermal chamber is the sample rotor The rotor takes 32 samples in glass capillaries with a diameter of 1 55 mm and a length of 35
39. ge 22 by lifting it out Disassembly of the Grounding Remove screw 27 with washer 28 Remove grounding 29 4 4 3 Wiring Cable 17 connects heating element 16 to power supply see chapter 4 9 Ground cable 29 connects base plate 30 to lower part of the housing 31 Final 1 0 January 1999 13 Service Manual Chapter 4 Light Cycler Service Manual 4 5 Chamber Lid 4 5 1 Location wo 33 W Fig 140798k3 Final 1 0 January 1999 Page 14 Chapter 4 Light Cycler 4 5 2 Service Procedure Replaceable Components Chamber lid 33 Damper 84 Screw 34 is part of the screw set Screw 35 is part of the screw set Washer 85 is part of the screw set Nut 65 is part of the screw set Disassembly of the Chamber Lid Disassembly of the housing parts Disassembly of the heating element see chapter 4 4 Remove screws 34 Remove nut 86 and washer 85 Push damper 84 slightly to the side Lift out base plate 36 with chamber lid 33 and damper 84 Remove screws 35 and base plate 36 Unscrew damper 84 from base plate 36 Final 1 0 January 1999 Page 15 Service Manual Chapter 4 Light Cycler Service Manual 4 6 Rotor 4 61 Stepper Motor Rotor 4 6 1 1 Location check here Fig 151298k2 Final 1 0 January 1999 Page 16 Chapter 4 Light Cycler 4 6 1 2 Service Procedure Repl
40. he price list are generally accepted under warranty Return only parts marked with in the spare parts price list Warranty claim for R parts will be accepted if the part has been returned to Mannheim defective parts and parts should be kept for a period of 7 months should the manufacturer need to investigate the part in which case it will be requested All parts unduly returned to Mannheim will be sent back at the expense of each country s respective Service center RA warranty claims are accepted no later than 8 weeks after the problem date Exclusion from Warranty The aforementioned warranties do not apply in case of improper use handling transportation or storage faulty installation repair or maintenance chemical influence or contamination as well as damages resulting from that failure to follow operating instructions alterations or modifications of instruments or parts thereof not authorized or recommended by Roche Diagnostics and resulting damages normal wear and tear and in case of other circumstances beyond the control of Roche Diagnostics Final 1 0 January 1999 Page 14 Service Manual Repairs As a general rule all instrument repairs should be carried out by authorized and trained personnel only Repair of Parts Marked with Parts which are worth repairing are marked with in the spare parts price list New and repaired
41. ings This parameters are recommended The changed boot priority is the best protection against boot viruses Advanced gt Boot time diagnostic screen disabled Boot gt Boot device priority gt 1 Hard disk 2 Removable devices 3 ATAPI CD ROM device Final 1 0 January 1999 2 Service Manual 6 4 Basic setup actions 6 4 1 Logon as administrator Logon User name Administrator Password Only Password never expires should be marked 6 4 2 Create directory and set run mode of a program Start the explorer and create folder C Users select file C Winnt Profiles AllUsers Start Menu Programs Startup lomega Quick Tools NT with right mouse button gt Properties gt Shortcut gt Run Mininized gt OK 6 4 3 Check desktop properties Display properties Background gt Pattern gt Weave ScreenSaver gt Logon Screen Saver Password protected Wait 10 min Color palette 256 colors Desktop area 1024 by 768 pixels Font size Small fonts Refresh frequency 75 Hertz Settings gt 6 4 4 Change the settings Start gt Settings gt Control Panel gt Regional Settings Reginal settings properties Regional settings english United States Number gt Measurement System Metric Time gt Time style HH mm ss Date Short date style dd MMM yy Long date style dd yyyy gt OK 6 4 5 Setsystem parameters
42. l 1 0 January 1999 Page 1 Service Manual 3 11 13 13 14 15 18 20 20 21 22 23 23 24 24 Chapter 5 Light Cycler Service Manual 5 8 Heating Element 25 5 8 1 Location 25 5 9 Fluorimeter 26 5 9 1 Location 26 5 9 2 Block Diagram Fluorimeter 27 5 9 3 Printed Circuit Diagram PCB Fluorimeter 28 5 4 44 Layout Diagram PCB Fluorimeter 29 Final 1 0 January 1999 Page 2 Chapter 5 Service Manual Light Cycler Electronics 5 Overview 5 1 A ddng samo ndul Jamo 2 4 0 0015 1 244 2 08 nd pJeog 5 T a 5 ays ARE ASH J quieuo geri pJeog _ 108495 Jeddejs J9 0 osuss pren e LO LL Chapter 5 Page 3 Final 1 0 January 1999 Service Manual Light Cycler Cable Connections 5 2 100 99 SL 981 100 06 2 881 pieog E 21 zr 100 Z1 91 881 ndo 100 IS 92 981 wayu 22254 09 95 91 88 5 s 100 6 881 30972 pueog pieog snes 100 92 881 2 1 2 C 100 69 1 881 MU 4 Z Jejupjouueu 12170 E
43. l Data Dimensions Weight Height 45 cm Width 30 cm Depth 45 cm 20 kg Service Manual Power supply 110 240 V 10 47 63 Hz Wattage 800W Noise acc to DIN 43635 80 dBA Heat emission including PC monitor and printer Max 860 kcal h Safety symbols CE GS UL CSA or CUL Environmental Parameters Tab 1 3 Temperature during operation 15 35 Temperature required during operation to maintain 15 30 specifications Temperature during transport storage packaging 20 60 Relative humidity 20 80 Altitude pressure 0 2000 m above sea level1030 850 hp Samples Tab cap1 4 No of samples 32 Sample volume 2 20 ul Tab cap1 5 Final 1 0 January1999 Page 5 Chapter 1 Light Cycler 1 2 2 Application Specifications PCR Temperatures Service Manual Temperature range 40 98 Temperature accuracy of measuring system 0 3 C Heating rate Heating rate 40 95 C step 40 95 C time 10 90 8s Heating rate 50 72 C step 50 72 C time 10 90 4s Heating rate 72 98 C step 72 95 C time 10 90 5s Cooling rate Cooling rate 95 40 C step 95 40 C time 10 90 8s Cooling rate 95 60 C step 95 60 C time 10 90 4s Temperature stability Temperature stability with respect to time 95 1 0 5 C ra
44. n 3122 29 89 6121 889 ziszaw 8151 P z LES 413 OL 3400 30001 EdW 980 9 red ovd 34001 rm E zs z YASH Fig main b Chapter 5 Page 9 Final 1 0 January 1999 Service Manual Light Cycler 41831 41831 p rid 28 an 0L M ZN aNd V 22 YAS 1 di Quod 51 ZN Q ovadwai 621911 F c e c 321 OrOFWT 39001 anzz 3218 H NU M 020 619 DENY t Diagram PCB Controller V VAST 5 3 3 Printed Page 4 of 4 Fig main d Chapter 5 Page 10 Final 1 0 January 1999 Service Manual Light Cycler 5 3 4 Layout Diagram PCB Controller Page 1 of 2 21440 Ottan 293 Olden OSV 14d LLI m 8 m Kz CD 201 221 NIVW H3 JAJ 1 811 uiaquueyw SJIISONSVIGO 3HJOH O O LOHddN Fig main e Chapter 5 Page 11 Final 1 0 January 1999 Service Manual 5 3 4 Layout Diagram PCB Controller Light Cycler Page 2 of 2 GEH u 937 1 D azu m in L_J6 24 CO CONC 48 gay L 1E JL 1533
45. nge Temperature stability with respect to time 65 1 1 0 C range Temperature stability with respect to time 40 Temperature homogeneity 1 0 3 range Temperature homogeneity over all capillaries and time 95 C 1 5 C range Temperature homogeneity over all capillaries and time 65 C 0 7 1 5 range Temperature homogeneity over all capillaries and time 45 C 1 5 0 5 C range Temperature Gradients Temperature gradient 0 1 C s 0 2 C s Tab cap1 6 Temperature homogeneity for one capillary 70 95 C 1 5 C range Temperature homogeneity for one capillary 50 70 C 1 0 C range Temperature homogeneity for one capillary all positions 70 95 C 2 09 range Temperature homogeneity for one capillary all positions 50 70 C 1 5 C range Temperature gradient 1 0 C s Temperature homogeneity for one capillary 70 95 C 2 0 C range Temperature homogeneity for one capillary 50 70 C 2 0 C range Temperature homogeneity for one capillary all positions 70 95 C 3 0 C range Temperature homogeneity for one capillary all positions 50 70 C 3 0 C range Temperature homogeneity for control of temperat ure peaks Stability at 95 C for dynamic cycles 72 95 50 C Os maintained 2 0 C 1 0 range Homogeneity of capillary capillary at
46. nitor Temperature Sensor The monitor temperature sensor monitors the measuring chambertemperature and prevents excess temperature Replaceable Components Monitor temperature sensor 51 Cable 49 is part of the cable set Disassembly Disassembly of the panel Pull cable 49 Unscrew monitor temperature sensor 51 4 8 5 1 Adjustment see chapter 4 8 6 1 4 8 5 2 Wiring Cable 49 connects monitor temperature sensor 51 to PCB controller see chapter 4 10 2 Chapter 4 Light Cycler 4 8 6 Control Temperature Sensor The control temperature sensor controls excess temperature in the measuring chamber Replaceable Components Control temperature sensor 50 Cable 48 is part of the cable set Disassembly Disassembly of the panel Pull cable 48 Unscrew control temperature sensor 50 4 8 6 1 Adjustment Temperature Sensors Two temperature sensors for temperature control and temperature monitoring are located in the measuring chamber of the light cycler The sensors should be placed close to the capillaries in the sample rotor so that the temperature can be monitored as accurately as possible However the sensors must not touch the capillaries when the rotor is moving For this reason the height of these sensors needs to be adjusted See drawing below 11 9mm 0 5 Fig 030898 1 The height can be adjusted by turning the sens
47. ntroller Ircul 5 3 3 Printed C Page 3 of 4 917808 18H QNS Azt 817828 E dads 11144150 6u 3409 0 0 34001 sida tsa lt __ SH ES Prot 418 1804 s 82698 zl ano 4015 NOHOW ONS i a 3 gt ood 150 any 827808 ane ane aLreo8 2 m ZN VAS vAs 558 30001 ven 199 Som atot anok 90A eld 24y ZNOJ 30 4378 D a E D b 927808 p 5 1 S 301 HENT T 291 duni LEENT 7201 D 4 1 AOL 90 881971 888 888 39001 V __ gt 204150 ae 952 34001 ACT 69H gt rod 158 gt 504192 028 2 yo E 168 s V ZN 5 zn 2 4800 Me 5 anoo LHS 001 e 189 LS x wiyt 1 41831 A cia Ne xp ben 2201 bed 201 1 X 06 8 zed 1504 ___ TUNI or s 42601 1 NI EN 82 VERD uO zs vza 150 84180 7 8i
48. o optical systems The optical systems are equipped with open ventilation systems and should therefore be protected from dirt and humidity There are no further specifications for transport and storage General Maintenance The instrument is maintenance free Cleaning the Instrument Use 70 ethanol for disinfecting the incubator Use only alcohol and an optical cloth for cleaning the optical window Use a mild commercial detergent for domestic use for cleaning the housing Final 1 0 January 1999 Page 7 Chapter 2 Light Cycler Service Manual 4 Mechanics 3 4 4 Overview 3 4 2 Disassembly of the Housing Parts 4 4 21 Housing Lid 4 4 2 2 Housing 6 4 2 3 Panel 8 4 3 Sample Rotor and Fan Wheel 10 4 4 Heating Element 12 4 5 Chamber Lid 14 4 6 Rotor 16 4 6 1 Stepper Motor Rotor 16 4 6 2 Fan Motor 18 4 6 3 Measuring Chamber 20 4 7 Fluorimeter Drive 22 4 8 Lightbarriers and Sensors 24 4 8 1 Location 24 4 8 2 Rotor Lightbarrier 25 4 8 3 Interlock Lightbarrier 25 4 8 4 Fluorimeter Lightbarrier 26 4 8 5 MonitorTemperature Sensor 26 4 8 6 Control Temperature Sensor 27 4 8 7 ExcessTemperature Switch 27 Final 1 0 January 1999 Page 1 Chapter 4 Light Cycler Service Manual 4 9 Power Supply 28 4 9 1 Location 28 4 10 PCBs 30 4 10 1 Location 30 4 10 2 PCB Controller und Battery 31 4 10 3 PCB Driver 31 4 10 4 Status Board 31 Final 1 0 January 1999 Page 2 Chapter 4 Light Cycler Service Manual 4 Mechanics
49. of melting point temperatures are carried out Structure of the LightCycler The instrument comprises a basic lower and an upper unit Basic Lower Unit Thermo chamber photometer drive units circuit boards and power supply are located in the basic unit The base of the unit is a 10 mm cast aluminum plate onto which the various elements are fixed This guarantees stability especially for the thermo chamber and Service Manual photometer Upper Unit The upper unit contains the heating coil an excess temperature sensor and a cooler with sectional converter Tab cap1 12 Final 1 0 January1999 Page 9 Chapter 1 Light Cycler Service Manual Thermo Chamber Thermostatting Thermostatting is done by using hot and cold air A sensor with thermal time constants identical with those of the capillaries provides reference values for control purposes The process is controlled by varying the heating coil voltage During the heating phase only the ventilator in the thermo chamber is in operation this guarantees a high degree of temperature homogeneity During the cooling phase both the capillaries and the heating coil must be cooled The ventilator is then operated at a higher speed 2 sensors are incorporated in order to prevent excess temperatures Sensor Sensor is responsible for the temperature regulation Sensor Sensor Il monitors the actual temperature Tab cap1 13 Fluorescence Photometer
50. on NEW serial Replacement Fault Description Alarm Code Service Report No Workshop Report No Place Date Signature Remarks will be filled in by BM NOS Credit FC BM Final 1 0 January 1999 Page 16 Chapter 1 Light Cycler 2 Installation 2 1 2 2 2 3 2 4 2 5 Installation Requirements Installation of the LightCycler Computer and Software Installation LightCycler De installation Operation and Maintenance of the LightCycler Final 1 0 January 1999 Page 1 Service Manual 2 Chapter 2 Light Cycler 2 Installation Service Manual 2 1 Installation Requirements Note The LightCycler should not be set up next to instruments that cause electromagnetic interference or have high inductance e g centrifuges or mixers All connected peripheral instruments must fulfill the requirements of Standard IEC 950 UL 1950 All plugs used in the LightCycler workstation PC printer monitor should have the same phasing in order to prevent switch on peaks and electronic noise generated by other instruments or the power supply itself Use of an appropriate distributor plug with the LightCycler workstation is recommended Working Place Requirements See the following table for the working place requirements Dimensions and weight The LightCycler has a width of 30 cm a depth of 45 cm and a height of
51. or fixation screws clockwise or counterclockwise 4 8 6 2 Wiring Cable 48 connects control temperature sensor 50 to PCB controller see chapter 4 10 2 Final 1 0 January 1999 Page 27 Service Manual 4 8 7 Excess Temperature Switch The excess temperature switch is a bimetal switch which protects the Light Cycler from overheating e g due to excess periods of operation Replaceable Components Excess temperature switch 74 Screw 76 is part of the screw set Washer 75 is part of the screw set Cable 77 is part of the cable set Disassembly Disassembly of the housing see chapter 4 2 2 Pull cable 77 Remove screw 76 and washer 75 Lift out excess temperature switch 74 4 8 7 1 Wiring Cable 77 connects excess temperature switch 74 to PCB controller see chapter 4 10 2 Chapter 4 Service Manual Light Cycler Power Supply 4 9 Location 4 9 1 to PCB Driver 9 en O 2 O b w x b E N R N D X X N 8 N 2 T d 3 021 broa Fig 230998k1 Chapter 4 Page 28 Final 1 0 January 1999 Light Cycler 4 9 2 Service Procedure Replaceable Components Power supply 81 Cable
52. s 4 with washers 5 Lift off housing 3 Note Please take care that the edges of the cover 3 do not scratch the front of the cover 3 Final 1 0 January 1999 Page 7 Service Manual Chapter 4 Light Cycler 4 2 3 Panel 4 2 3 1 Location Fig 140798k1 Final 1 0 January 1999 to PCB controller JP12 8 Service Manual Chapter 4 Light Cycler 4 2 3 2 Service Procedure Replaceable Components Screws 6 are part of the screw set Washers 7 are part of the screw set Panel 8 is part of the housing set Status board 9 Washers 10 are part of the screw set Nut 11 is part of the screw set Cable 12 is part of the cable set Disassembly of the Panel Remove housing see Loosen all screws 13 Remove all the screws 6 with washers 7 Pull cable 12 Lift chamber lid 14 Take off panel 8 Disassembly of the Status Board Disassemble the panel 8 Remove nuts 11 with washers 10 Remove status board 9 4 2 3 3 Wiring Cable 12 connects status board 9 to PCB controller JP12 see chapter 4 10 4 Final 1 0 January 1999 Page 9 Service Manual Chapter 4 Light Cycler 4 3 Sample Rotor and Fan Wheel 4 3 1 Location 13 nga n 9000 Fig 140798k7 Final 1 0 January 1999 Page 10 Service Manual Chapter 4 Light Cycler 4 3 2 Ser
53. s of the LightCycler are fitted with filter combinations Thus analysis at the given emission wavelengths is possible and exact sample measurement can be carried out in parallel with the fluorophores given in Tab cap 1 14 Service Manual Fluorophore Excitation Channel Analysis Channel 1 2 3 470 nm 40 530 nm 20 640 nm 20 710 nm 40 Fluorescein 490 nm 525 nm SYBR Green 494 nm 521 LC Red 640 640 nm Tab cap1 14 Table cap 1 14 Specification of excitation and measuring channels of the fluorimeter component of the Roche Diagnostics LightCycler Comparison of the spectral properties of selected fluorophores Abbreviations LC Red Light Cycler Red 640 gt LC Red is not excited by the blue LED but is a FRET partner of fluorescein For further information refer to the Operating Manual Final 1 0 January1999 Page 13 Chapter 1 Light Cycler 1 5 Warranty Processing of Warranty Claims A warranty claim has to be processed by way of the Return Authorization procedure or any accepted equivalent Please answer all the questions on the RA form with the greatest care The warranty claim will only be accepted by the manufacturer if adetailed fault description is supplied Complete instruments are accepted only in agreement with the Technical Product Management or with the responsible person of Roche Diagnostics Technical Support Important Information Only parts marked with in t
54. s the Light Cycler from overheating e g due to excess operating periods Interlock lightbarrier Lightbarrier home position Fluorimeter Monitor temperature Chapter 5 Light Cycler Service Manual 5 7 Power Supply 5 7 1 Location Functional Description of the LightCycler Power Supply The power supply is a functional unit and is accommodated in a metal housing closed on all sides It is connected to the mains by means of an integrated rubber connector Fuses are off limits to the customer because all outputs are short circuit proof A blown fuse is an indication of a defect that cannot and should not be fixed by the customer The power supply has three output plugs 12 pin plug with the following outputs 5 V for the supplying of digital functions on the PCB controller 12V for the supplying of analog switching functions on the PCB controller furthermore for serial data transfer for the supplying of the heating element integrated in the power supply 10 pin plug with the following outputs 5V for the supplying of digital functions on the power board 24V as driver voltage for the stepper motor drivers and the chamber fan driver a2 pin plug for connecting the heating element voltage range of this output 0 90V DC Power supply 8999999999
55. ssembly Pull cable 66 Remove screws 62 and screws 63 Lift out fluorimeter drive 64 Note If the fluorimeter drive is replaced it is necessary to check the distance between stepper motor and the plate When assembling the photometer drive the distance between them should be 18mm 1mm If an adjustment is necessary turn the plate until the required distance is reached 18mm 1mm stepmotor 4 7 3 Wiring Cable 66 connects fluorimeter drive 64 to PCB driver 5 4 10 3 Final 1 0 January 1999 Page 23 Service Manual Chapter 4 Light Cycler Service Manual 4 8 Lightbarriers and Sensors 4 8 1 Location to PCB controller JP6 to PCB controller JP11 to PCB controller JP8 to PCB controller S1 to PCB controller S2 Fig 150798k3 Final 1 0 January 1999 Page 24 Chapter 4 Light Cycler 4 8 2 Rotor Lightbarrier The rotor lightbarrier monitirs the rotations of the rotor Replaceable Components Rotor lightbarrier 59 Screw 57 is part of the screw set Washer 58 is part of the screw set Cable 60 is part of the cable set Disassembly Disassembly of the housing parts see chapter 4 2 Disassembly of the sample rotor and fan wheel see chapter 4 3 Disassembly of the heating element see chapter 4 4 Disassembly of the chamber lid see chapter 4 5 Disassembly of the tooth belt see chapter 4 6 1 Pull cable 60 Remo
56. the rotor drive see drawing Final 1 0 January 1999 Page 17 Service Manual check here Fig 030898k1 Fix the fixation srews 39 of the stepper motor 43 and check again for proper movement Chapter 4 Light Cycler Service Manual 4 6 2 Fan Motor 4 6 2 1 Location 45 to PCB driver to PCB driver JP2 JP7 Fig 151298k3 Final 1 0 January 1999 Page 18 Chapter 4 Light Cycler 4 6 2 2 Service Procedure Replaceable Components Fan motor 44 Screw 45 is part of the screw set Cable 46 is part of the cable set Cable 92 is part of the cable set Disassembly off the Fan Motor Disassembly of the housing parts see chapter 4 2 Disassembly of the sample rotor and fan wheel see chapter 4 3 Pull cable 46 Pull cable 92 Remove screws 45 Remove fan motor 44 by pulling it in a downward direction 4 6 2 3 Wiring Cable 46 and calbe 92 connects fan motor 44 to PCB driver see chapter 4 10 3 4 6 2 4 Adjustmemt When assembling the heat dissipator of the fan motor 44 it is important that its edge is parallel to that of the fluorimeter Please ensure that the dissipator does not touch the fluorimeter dissipator fluorimeter edge should be parallel to the fluorimeter Fig 030898k1 Final 1 0 January 1999 Page 19 Service Manual Chapter 4 Light Cycler Service Manual 4 6 3 Measuring Chamber 4 6 3 1 Location
57. u uon 20 99 Li 49 z dni 20 9221 asss o Chapter 5 5 lt 01 go gt 188250 N 200 20 QN5 1358008 apal ivo rave t QNS s dub 3381 x 248 01 082591 x 220 61 6 031 E P 0S2XVW 01 A ELI ba 2 1901 omm 4 reu 2250 29001 ot SI o 8 1 900002 90 a E otv 42 48 1 1080 ana 198 8rd i 089 i NIACQLDHS Y V eve 5 INS a vast VAS i ave isu 8 2 2 1199 S 41028 5 esa 5 inon 8991918 b axuio ed 180 191 3 34001 28 Y 9991 862180 zs jr L 180 1201 uno o um 2 7039 EL oxusa teo 201 2000228 21 CN 2308005 izounos 2 a 2315 7 INIVUC 54 188 21 5 00082991 92092691 81 598 A N am 601 gt ted 28a L 029 280 zee 280 YEPSNZ NIYHd T gt nee aat E 031 231 gt 1 G ozy TT 1881 E LL LL Service Manual Light Cycler t Diagram PCB Co
58. ve screw 57 and washer 58 Lift out rotor lightbarrier 59 4 8 2 1 Wiring Cable 60 connects rotor lightbarrier 59 to PCB controller see chapter 4 10 2 Final 1 0 January 1999 Page 25 Service Manual 4 8 3 Interlock Lightbarrier The interlock lightbarrier is a reflection lightbarrier It senses whether the housing lid is open or closed Replaceable Components Interlock lightbarrier 66 Screw 68 is part of the screw set Washer 67 is part of the screw set Cable 69 is part of the cable set Disassembly Disassembly of the housing see chapter 4 2 2 Pull cable 69 Remove screw 68 and washer 67 Lift out interlock lightbarrier 66 4 8 3 1 Wiring Cable 66 connects interlock lightbarrier 66 to PCB controller see chapter 4 10 2 Chapter 4 Light Cycler 4 8 4 Fluorimeter Lightbarrier The fluorimeter lightbarrier monitirs the fluorimeter movements Replaceable Components Fluorimeter lightbarrier 70 Screw 72 is part of the cable set Washer 71 is part of the screw set Cable 73 is part of the cable set Disassembly Disassembly of the housing see chapter 4 2 2 Pull cable 73 Remove screw 72 and washer 71 Lift out fluorimeter lightbarrier 70 4 8 4 1 Wiring Cable 73 connects fluorimeter lightbarrier 70 to PCB controller see chapter 4 10 2 Final 1 0 January 1999 Page 26 Service Manual 4 8 5 Mo
59. vice Procedure Replaceable Components Sample rotor 13 Fan wheel 15 Disassembly of the Sample Rotor Flap housing lid 1 backwards Remove sample rotor 13 Disassembly of Fan Wheel Disassemble the sample rotor 13 Remove nut 14 Remove fan wheel 15 by lifting it out Note Do not tighten nut 14 too tight when mounting the fan wheel 15 or this might cause damage to the plastic fan motor thread Final 1 0 January 1999 Page 11 Service Manual Chapter 4 Light Cycler Service Manual 4 4 Heating Element 4 4 1 Location 18 to power supply 17 6 4 25 25 a to base plate 27 21 28 29 Fig 150798k1 Final 1 0 January 1999 Page 12 Chapter 4 Light Cycler 4 4 2 Service Procedure Replaceable Components Heating element 16 Cable 17 is part of the cable set Ground cable 29 is part of the cable set Disassembly of the Heating Element Flap housing lid 1 backwards Disassemble the housing 3 see Remove screw 23 with washer 24 Remove cable clip 25 with washer 26 Remove cable 17 from cable clip 25 Remove screws 18 Remove screw 19 Pull off cover sheet 20 Pull cable 17 Remove heating element 16 by lifting it out Remove sheathing 21 if necessary Disassembly of the Flange Disassemble the heating element 16 Remove screw 23 Remove flan
60. window 55 Attention Do not touch the window 55 with your fingers Afingerprint would generate an additional flourecence signal which would affect the measurement results Carefully clean the window 55 with 70 ethanol polishing it with a lint free tissue afterwards Assembly of the Window Please use the new spring washer 54 in case of a window 55 replacement Ensure that the window 55 is placed in the correct position sping washer window cD Fig 040898k1 Final 1 0 January 1999 Page 21 Chapter 4 Light Cycler 4 7 Fluorimeter Drive The fluorimeter 65 is preadjusted by the manufacturer and is adjusted for the second time when it is assembled in the Light Cycler production plant in Germany In case of a defective fluorimeter the complete instrument is to be sent to Mannheim for repairing Please use the RA procedure for the shipment to Mann heim see chapter 1 5 The repaired instruments will be sent to you as soon as possible Note Please do not touch any of the fluorimeter 65 adjustment screws especially focus screws 4 7 4 Location 62 Fig 150798k2 Final 1 0 January 1999 Page 22 Service Manual to PCB driver JP6 Chapter 4 Light Cycler 4 7 2 Service Procedures Replaceable Components Screw 62 is part of the screw set Screw 64 is part of the screw set Fluorimeter drive 64 Cable 66 is part of the cable set Disa
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