MagCore Plus II Troubleshooting Manual
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MagCore Plus II Troubleshooting Manual

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MagCore® Plus II
Troubleshooting guide
Ver. 2020.1230
www.rbcbioscience.com

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Summary of Contents for MagCore Plus II

  • Page 1 MagCore® Plus II Troubleshooting guide Ver. 2020.1230 www.rbcbioscience.com...
  • Page 2 RBC Bioscience Corp. TEL : +886-2-8912-1200 FAX : +886-2-8912-1300 3F., No.132, Ln. 235, Baoqiao Rd., Xindian Dist., New Taipei City 23145, TAIWAN. http : //www.rbcbioscience.com...
  • Page 3 If the problem you are experiencing is not covered by this guide, let us know: fill in the Instrument malfunction form and send it to us along with the instrument's serial number! To see RBC training videos click or copy in your browser the link below: MagCore Plus II Training Files (https://drive.google.com/drive/folders/1ORi-jZ3MWz0-2S4b4-8wEud7sLbADD0-)

  • Page 4: Table Of Contents

    CONTENTS Safety Precautions Specification ━ Operating Parameters ............5 ━...
  • Page 5 MagCore® Plus II Bending Cartridges ━ Cartridge Installation............45 ━...

  • Page 6: Safety Precautions

    14. Overloading – Do not overload wall outlets, extension cords, or integral convenience Do not place metal objects inside the MagCore® System and wipe away all spilled receptacles as this can result in a risk of fire or electric shock.

  • Page 7: Specification

    MagCore® Plus II Specification Model Plus II System Method Cellulose Coated Magnetic Beads System Components 1. Pipetting Unit: Dispensing, transferring, X -Y two axis movements. 2. Electric Control: PLC module and Arm-based main board embedded in. 3. UV Light: Power 8W, life duration 11,000 hrs .

  • Page 8: Pcb Configuration

    PCB Configuration www.rbcbioscience.com...

  • Page 9: Plc Configuration

    MagCore® Plus II PLC Configuration Y Motor Encoder Signal(A) Y Motor Drive(A) Y Motor Encoder Signal(B) Y Motor Drive(B) Y Home Sensor Signal V Motor Drive(A) V Motor Drive(B) V Motor Encoder Signal A X Motor Drive(A) V Motor Encoder Signal B...

  • Page 10: Accessories

    Accessories T-Rack X 1 Cartridge Rack X 1 Power Cable X 2 (Europe standard and U.S.A standard) Grease X 1 3mm O-Rings X 16 5mm O-Rings X 16 Empty Cartridge X 10 Sample Tube /Elution Tube X 20 Pipette Tip X 20 10.

  • Page 11: Unpacking Plus Ll

    MagCore® Plus II Unpacking Plus ll ━ Removing Packaging Installation For Restricted Person Remove all the screws on the button of the wooden case (a total of 14 screws). Then take off the cover. Open the Front Door Remove cushioning material Remove the and take out accessory box.
  • Page 12 ersonnel Use sonnel Use Remove the brackets and cable ties then Remove the brackets and cable ties then pull out the touch panel. pull out the touch panel. Remove the two brackets Remove the two brackets Close the front door. Close the front door.

  • Page 13: Activating All The Menu Buttons

    MagCore® Plus II ━ Activating All the Menu Buttons Sterilization Replace O-Ring Eject Tip Piston Clean Needles Motor Test Back Select 07/13/2020 09:25:32 If some buttons of the Maintenance menu remain inactive after installation, switch off the machine, close the door, turn the machine on and let it run automatic initialization.

  • Page 14: X-Axis Calibration

    ━ X-Axis Calibration 1. Put the Tips (200 μ l) at the W4 in the positions 1 and 16 on the T-rack. 2. Run W4 piston test and observe the distance between real position and correct position. 3. X position: 1 mm = 92 Pulse;...

  • Page 15: Y-Axis Calibration

    MagCore® Plus II ━ Y-Axis calibration 1. Put the Pipette Tips (1200 μ l) at the W3 at in the positions 1 and 16 on the T-rack. 2. Do W3 piston test and observe the distance between real position and correct position.

  • Page 16: Pistons

    Pistons ━ Noise during Pipetting If you hear noise during pipetting, this means the grease on the pistons wore off. Lubricate the rods inside the pistons. If lubricating the piston does not help, replace the piston (you can send us pistons for maintenance or install new ones).
  • Page 17 MagCore® Plus II 3. There is a hole on the metal rod, fix the metal rod with a hex key, then unscrew the upper screw. 4. Move the V axis to highest position manually or by JOG mode.
  • Page 18 5. Take the piston out, you can pull out the metal rod and clean the inner side with a cotton swab, but do not screw the cap and nut, and do not disassemble the piston, or the tensile strength might be altered and lose accuracy. 6.

  • Page 19: V-Axis Immobilization

    MagCore® Plus II ━ V-Axis Immobilization If instrument is showing Error14 (V Position Over Pulse) and it is impossible to run jog test for V-axis or move it manually, this indicates that the X-rings inside the pistons have worn off.

  • Page 20: Detaching Housing

    Detaching Housing ━ Tools List 1. Hex wrench, 3 mm and 4 mm 2. Philips screwdriver ━ Procedure 1. Turn off the power and unplug the power cable. 2. Unscrew the 8 screws marked with red circles, loosen the 2 screws marked with green circles (no need to take out the 2 screws), then disassemble the back cover.
  • Page 21 MagCore® Plus II 3. Unscrew the 4 screws (marked with red circles) with hex wrench. 4. Push the rack base (X axis) all the way inside, loosen the 2 screws on the power cord socket stand (no need to take out the two screws, marked with red circles), then...
  • Page 22 5. See the picture below, put your thumbs on the base (black part), put the other four fingers on the white bar and hold it, then pull the white bar gently and disassemble the housing. www.rbcbioscience.com...

  • Page 23: Non-Responsive Hmi

    MagCore® Plus II Non-Responsive HMI ━ Replacing HMI Frame (Only for P26R0001xxxxx- P26R0069xxxxx) 1. Remove the housing. 2. Unscrew the screw marked with red circle.
  • Page 24 3. Cut off the cable tie on LED cable, loosen the screws on sockets 3 and 4, unplug all the cables on HMI. 4. Unscrew the three screws on the top of the frame (marked with red circles), hold the frame during unscrewing the last screw, then detach the frame.
  • Page 25 MagCore® Plus II 5. Detach HMI, acrylic board, LED strip, and all the components marked with red circles, the two metal sheets marked with green arrows. 6. Install the fixing plates on the four positions marked with red circles, install HMI,...
  • Page 26 7. Follow the reversed steps to restore the frame. Refer to the picture below, one washer on each side of the screw hole (marked with red arrows), the tightness of the screw (marked with a green arrow) is related with the smoothness of the touch screen panel movement, push and pull the panel for testing and tighten the nut (on the inner side) when the panel is under adequate smoothness.

  • Page 27: Replacing Touch Panel Screen Pad

    MagCore® Plus II ━ Replacing Touch Panel Screen Pad 1. Detach the housing. 2. Unplug 5 plugs on the HMI, you can take a photo as a record before unplugging the connectors. 3. Remove the nuts at the four corners (marked with red circles) and the two metal sheets (marked with red arrows);...
  • Page 28 4. Remove the film on the new pad, paste it on the frame, the inner side is larger; do not screw the four inner nuts behind the metal sheets (marked with red arrows). 5. Follow the reversed steps to restore the machine (install HMI, plug the five cables, install the housing).

  • Page 29: Calibrating Hmi Screen

    MagCore® Plus II ━ Calibrating HMI Screen 1. Press the touchscreen and turn the power on. 2. Touch each crosshair target as it appears (at four corners and in the center). 3. Tap "Ok" ━ Adjusting HMI Screen Position 1. Remove the housing and open the door.
  • Page 30 3. Adjust the gap between HMI frame and the door, by pushing HMI frame forward or backward. 4. To adjust HMI frame angle loosen 3 screws on the side of the main frame. Push the holder to the front 5. Push the holder forward/backward. 6.

  • Page 31: Replacing Touch Panel Sliding Component

    MagCore® Plus II ━ Replacing Touch Panel Sliding Component 1. Detach the housing. 2. Unscrew the screw marked with red arrow. 3. Unscrew the two screws and detach the metal bar (the track).

  • Page 32: Door

    Door ━ Door Touching the Cartridge Rack 1. If the cartridge rack is not installed properly it will protrude and some parts of the door will touch it. To install cartridge rack properly put it inside by sliding all the way into the machine. There are magnets at the back of the axis;...
  • Page 33 MagCore® Plus II Remove back lid and check the gap at the back of the machine. There should be no gap! If the rack is pushed all the way but there is still a gap, adjust the position of the...

  • Page 34: Door Movement Issue

    ━ Door Movement Issue 1. Open the door and wipe with paper towel the four metal rods marked with red arrows. 2. Open the sliding door and find the two screws at the back of the instrument marked with red circles, loosen each one of the two screws with a hex key (2.5 mm), do not loosen two screws at once.

  • Page 35: Door Switch Malfunction

    MagCore® Plus II ━ Door Switch Malfunction 1. Detach the housing. 2. Open the door. 3. Find door sensor: 4. Check the connection. 5. Unscrew 2 screws: screw1 and screw2 on the top of the switch and disconnect the wires.

  • Page 36: Axis Misplacement

    Axis Misplacement Axis Directions www.rbcbioscience.com...

  • Page 37: Y-Axis Manual Adjustment (Complicated Procedure!)

    MagCore® Plus II ━ Y-Axis Manual Adjustment (Complicated Procedure!) Y manual adjustment is needed when Y-axis does not align with X-axis. Check the paint marks on the screws: if the paint has cracked, it is possible that Y-axis shifted. In this case piston module will be shifted sideways, to the front or to the back.
  • Page 38 4. After the screws are loosened Y-axis frame can be moved sideways. 5. Put the tips into the T-rack and adjust the position of the frame until the pistons align with the tips. 6. Tighten the screws back. For the axis tilted forward or backward: 1.
  • Page 39 MagCore® Plus II 2. Detach the housing. 3. Loosen 3 screws on both sides of the machine. After the screws are loosened Y-axis frame can be moved backward and forward. 4. Put the tips into the T-rack and adjust the position of the frame until pistons align with tips.

  • Page 40: X-Axis

    V-Axis Cannot Be Adjusted Manually V-axis is assembled together with Y-axis. If Y-axis is moved, V-axis will be moved with it. V-axis cannot be adjusted on its own. X-Axis Cannot Be Adjusted Manually X-axis cannot be manually adjusted because it acts as a base that supports the whole mechanism.
  • Page 41 MagCore® Plus II 3. Do "X axis JOG test", pressing "JOG +" and "JOG –"check X axis moving direction. If JOG + is outward (toward the front door), JOG – is inward (toward home position), the motor works normally. If the directions are incorrect, inspect the motor cables (the motor is durable and the probability of malfunction is quite low).
  • Page 42 5. Refer to the picture below, switch cable <X.ECD>+<X.HOME>+X motor line with cable <V.ECD>+<V.HOME>+V motor line Turn on the power, check if X axis is homing normally during initialization. If it is, X motor and motor line have no problem, the most likely cause is the malfunction of X axis driver on the motherboard.

  • Page 43: Checking Signal Propagation

    MagCore® Plus II Checking Signal Propagation Signal pathway: Sensor → Sensor Cable → PCB → PLC → PCB → HMI 1. Check if the SENSOR working properly: Machine is turned on. Place an object next to the Remove an object → LED Sensor is working properly, sensor →...
  • Page 44 Check if X12 works properly in I/O: ● When the sensor is on X12 will light up in yellow ● When the sensor is off X12 will stay white X00 Y Motor A CMD Pulse Y00 Y Motor Pulse X01 Y Motor B CMD Pulse Y01 Y Motor Reverse Encoder X02 Y Home Sensor...
  • Page 45 MagCore® Plus II 3. Check your PCB. When machine is on, all 4 (1 red and 3 green) LEDs on PCB should be on. If any of the LEDs is off it means a corresponding part of PCB is not working.
  • Page 46 4. Check PLC: Open I/O; place an object in front of the sensor. Check sensor Response on HMI screen and on PLC to see if they match. If they don't - PLC response time is slow and you may need to replace it. Check wire connections: cable CBL-0032 –...

  • Page 47: Bending Cartridges

    MagCore® Plus II Bending Cartridges Most of the time this problem happens because the cartridges were not installed properly. To avoid it, follow the instructions below: ━ Cartridge Installation ━ Lifted Cartridges Remove the back lid to check if there is a gap between the cartridge rack and the base...
  • Page 48 1. Loosen the two screws shown in the picture; 2. Move the plate back and forth until the perfect position is found; 3. Tighten the screws back. If the cartridge rack and cartridges get jammed with heating module do the following: 1.

  • Page 49: Cartridges Alignment

    MagCore® Plus II ━ Cartridges alignment If cartridges misalign with the heating module, heater will push them up during the X-axis movement. To check, put the cartridges in the cartridge rack, but don't install the T-rack. Put cartridge rack inside the machine, make sure that all the cartridges are properly placed and run M-motor test –...
  • Page 50 2. Make sure the heating wells of the cartridges are properly aligned with the holes of the heating module, and nothing is loose anywhere along the M-axis. 3. If the distance is not the same on two sides, loosen 4 screws: 4.

  • Page 51: Rails (X-Axis Inspection)

    MagCore® Plus II Rails (X-Axis Inspection) ━ Noise during the Rack Movement If machine makes noise during the operation, check the rails and sliders and lubricate them. If the axis is stuck, makes loud noise and triggers an error on the screen check:...

  • Page 52: Rusting

    ━ Rusting Buffers contain high concentrations of GuSCN and GuHCl, which crystalize over time as the liquid evaporates. They are strong deteriorating agents and lead to corrosion and rusting. To prevent rusting strictly follow the direction for Preventive Maintenance: Maintenance after Each Run: - Clean operational area (check for spillage, clean the inside the machine) - Clean the spillage if occurred - Clean waste box...

  • Page 53: Motors

    MagCore® Plus II Motors: Y motor cable Y-motor V-motor V motor power cable M – DC motor M – DC motor power cable X-motor X motor power cable ━ Motor Test Motor Axis test is a test that is designed to check motors movement and is a part of Preventive Maintenance;...

  • Page 54: Directions To Run The Test

    Directions to Run the Test Sterilization Replace O-Ring Motor Test Eject Tip Piston M Axis Up M Axis Dn Clean Needles X Axis V Axis Y Axis M Axis Motor Test Back Back Motor Test Select 07/13/2020 09:25:32 07/13/2020 09:25:32 Select Maintenance from Select Motor Test Select X-Axis...

  • Page 55: Jog Test

    MagCore® Plus II ━ Jog Test Jog test helps to identify issues with axis movements, encoder condition and function and check the motors. The two values, the Encoder and the Pulse, should be the same or +-10. If they are not, clean the encoder disc.

  • Page 56: Encoders

    Encoders Only X, Y and V motors have encoders: Y motor encoder V motor encoder X motor encoder Cleaning Encoder Disc Remover the cover of Use napkin to clean Put the cover back and encoder (counterclock the dust (without any connect the cable.

  • Page 57: Rd Mode

    MagCore® Plus II RD Mode ━ Activating RD Mode Heater Test Sterilization Replace O-Ring Eject Tip Piston Program Update Saved Maintenance Pairing Protocols Start Clean Needles Alarm History Motor Test Advanced Report Eject Tip Setup Back Back Select Select 08/08/2019 08:08:08...

  • Page 58: Heating Test

    ━ Heating Test Select Heater Test button. Heater Test Program Update Saved Pairing Maintenance Protocols Start Alarm History Advanced Report Eject Tip Setup Back Select 08/08/2019 08:08:08 07/13/2020 09:25:32 Use a digital thermometer to get more precise measurements. Put it into the separate Heat Block Wells and press Next.
  • Page 59 MagCore® Plus II Underlined value is the actual temperature and should be very close to what your thermometer shows. T.D1 - Actual temperature T.D2 - The temperature the heater should reach (preset) T.D4 - Relay Power 44 ºC / 111 ºF...
  • Page 60 R<4.11Ω The heater is broken R=0Ω The heater is broken R>4.11Ω The module is aging. The smaller R is the bigger power will be, it is better to replace the part. 2. Check if all SSR connections are tight: 3. If connections are loose, tighten them and make sure no cables drop off. 4.
  • Page 61 MagCore® Plus II Measure heater voltage:...

  • Page 62: Software Update

    ━ PLC Prepare your Software Update Tools one USB to RS232 adapter one RS232-PLC one USB to RS232 for DVP ES/EX/EH programing cable converter Download PLC software update tool "EasyClient" from the link below and install. https://download.rbcbioscience.com/MagCore%C2%AE/MagCore%C2%AE%20 Automated%20Nucleic%20Acid%20Extractor/MagCore%20SUPER/Software/ EasyDownload_v1.83/EasyClient.exe www.rbcbioscience.com...
  • Page 63 MagCore® Plus II 1. Turn off the power, find the PLC and unplug the black interface cable. 2. Turn the switch on PLC (marked with white frame) from "Run" to "Stop", plug the PLC-RS232 connection cable and connect with computer, then turn on the power.
  • Page 64 4. Click the folder (marked with blue circle), then select PLC software for update, the filename extension is .dvz. 5. Select "Local (PLC COM Port)" and "COM Port", Baud Rate is 9600 bps, then click "Download". www.rbcbioscience.com...
  • Page 65 MagCore® Plus II Check COM Port number in device manager: Go to "device manager" and check the RS232-usb converter cable is the same as the "PLC COM Port" while updating (see below figure). 6. Download progress bar will be displayed if connected successfully, download...
  • Page 66 7. After download is completed, turn off the power, turn the switch on PLC (marked with white frame) from "Stop" to "Run", unplug the PLC-RS232 connection cable (the cable linked with computer) and plug the original interface cable. 8. Go to "System Status" and check the PLC version. www.rbcbioscience.com...

  • Page 67: Hmi

    MagCore® Plus II ━ HMI 1. Copy HMI software to root directory of USB flash drive, insert the USB drive to the USB port, then HMI software update interface will open automatically after USB flash drive is detected, tap "Download".
  • Page 68 3. Tap "usbdisk", then select the HMI software for update, the filename is "PLUS II- HMI (6 numbers) .cxob", filename extension is .cxob, the 6 numbers is software version. 4. Tap "Download", then reboot, unplug USB flash drive and go to homepage.

  • Page 69: Program

    MagCore® Plus II ━ Program 1. Download the latest version of program from RBC website, unzip the file on computer. There are 3 em files in the folder, use the notepad to open the file em2, type the machine's S/N and one space.
  • Page 70 You can find the S/N# → On the silver label beside the power button. → Page "System Status". → System teaching data sheet. 2. Copy the 3 files (em0, 1, 2) to the root directory of a FAT32 formatted USB Flash Drive.
  • Page 71 MagCore® Plus II 5. Tap "Program Update" → "Execute". Cancel Execute Program Update 07/13/2020 09:25:32 6. Do not turn off power and wait a few seconds. Do not turn off power during update Please Wait a moment... Cancel Execute Program Update 07/13/2020 09:25:32 7.
  • Page 72 8. Go to page System Status and check the Program Ver. www.rbcbioscience.com...

  • Page 73: Error Alarm Codes

    MagCore® Plus II Error Alarm Codes DC M Motor Up Time Out • DC M Motor or DOWN Sensor do not function properly 1 Run M-axis test to see if the axis moves properly, if not check if the DOWN...
  • Page 74 Y_Encoder no change • No signal response from the Encoder • Encoder cap is aging and can't read the encoder disc anymore (always caused by encoder malfunction) 1 Check PLC X00 terminal – make sure the cable (CBL-0031) is not loose 2 Clean encoder disc 3 Check encoder cap Open it and see if the red LED inside is on If the light is off Encoder needs to be replaced...
  • Page 75 MagCore® Plus II V_Encoder no change • No signal response from the Encoder 1 Check PLC X00 terminal – make sure the cable (CBL-0031) is not loose 2 Check if encoder is functioning properly 3 Clean encoder disc 4 Check encoder cap Open it and see if the red LED inside is on If the light is off Encoder needs to be...
  • Page 76 X_SoftLimt- • Encoder pulse count exceeds the value set by the software; the distance from the motor moving backward does not match the distance from encoder • Encoder cap is aging and can't read the encoder disc anymore 1 Restart the instrument 2 Clean encoder disc 3 Check cables CBL-M002 (encoder signal) and Power CBL-M001 4 Check encoder cap Open it and see if the red LED inside is on If it is off, ecoder needs to be...
  • Page 77 MagCore® Plus II X_Home Sensor Fail • No response from X-Home sensor 1 Check if the sliders are blocked Check if X-axis can move smoothly Clean sliders and rails 2 Check if the sensor is functioning properly 3 Check sensor block plates position 4 Check if the motor is functioning properly 5 Check PLC X10 terminal –...

  • Page 78: Common Problems

    Common Problems The tips are not taken properly • Y-axis is not calibrated properly; • There is too much grease on the piston tips; • Pistons need maintenance 1 Recalibrate Y-axis accordingly 2 Remove extra grease and examine the condition of pistons Cartridges are bending • Cartridge rack is not installed properly;...
  • Page 79 MagCore® Plus II Instrument is dropping tips • Y-axis is not calibrated properly; • There is too much grease on the piston tips; • X-rings and O-rings wore off and pistons need maintenance or replacement; Loose axis coupling 1 Recalibrate Y-axis accordingly...
  • Page 80 Message on Screen: the door is opened during the run • The door is opened 1 Close the door: It has to be pushed down to lock It slides up and down, but it does not lock automatically It is done for safety reasons, so make sure the door is locked before they start a run A click sound will indicate that the door closed Wrong elution volume/Magnetic beads in the final eluate • Wrong pretreatment, error in the code;...

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