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Service Manual - Frank`s Hospital Workshop

Contents

1. LEVEL SENSOR BOARD GEPR 113 883 LEVEL SENSOR BOARD gt LEVEL SENSOR BOARD i Jp22 tr 118 815 e SA 604 643 O6 593 DM DOSING DRIVE PCHN teo cue 4 o 0 o lt aaa su 1 nmm L m 25 TEHPERATUAE Ma alee MOTOR TACHO 218447 S Kal aimee CABLE PCHN BOARD EE T P LLO BOARD 1 POWER L 118 818 LP LLD FLEX BOARD x CONDUCTIVE Eran 5v T JP2u P1 M I sander n Ec 1 13 JP20 JP21 Eu Peno ism etc is Pano T H pono 15 ti sto 15 PGND 158 15 PGND pana 22 H Pena 22 i Fre re SPOL Cid nw l 10 H8PS_SDUEEZE 2 so a 3 inn inn 13 END R 13 Hes SLEEVE ILE en i a E i2 5 LsPE ARA 5 n TSPQ 82 5 21 4 PE PSPP ra TSPOATE 7 m asm 5 58 LSPE ELK 25DEG jme
2. NSOR BOARD 1 amp CARRIER SENSOR BOARD 2 9 CARRIER SENSOR BOARD 3 amp CARRIER SENSOR BOARD 4 CARRIER SENSOR BOARD 5 8 2 CARRIER SENSOR BOARD 6 amp E CARRIER SENSOR BOARD 7 Imm SENSOR E P pem 1 1 1 4 1 P i 1 4 1 seams Pd 3 NES MM ES E iu 8 11 Microlab STAR Service Manual 8 3 Master 8 3 1 Function e Controls such actions as Communication with PC Communication with teaching box Controlling Pipetting Arm X Movement Controlling pipetting channels Controlling Autoload Function Controlling all extensions e g iSwap Wash station Temperature controlled carrier Storing Technical Status Adjustment Values Download Status Cycle Counting and Firmware The Master ensures coordination and synchronization of all commands between Service and User software and the ML STAR Instrument 8 12 Microlab STAR Service Manual 8 3 2 Master Block Diagram jndu 1811610 oeg eJunjeupenp 0 yeruas snonuoJuoufis ndug epig
3. P N Description Quantity Spare Part class 173900 X ARM CONNECTOR 2 A 173905 CABLE X ARM CONNECTOR 8C 2 A 173906 CABLE X ARM CONNECTOR 16C 2 A 173911 CABLE FILTER GND 1 A 182103 REPLACEMENT CHANNEL A 1 A 182104 REPLACEMENT CHANNEL B 1 A 182105 REPL PIPETTING HEAD 300ul 1 A 182106 REPL PIPETTING HEAD 1000ul 1 A 182805 EXTENSIONS CONNECTOR 1 A 182820 CABLE MASTER EXTENSIONS 1 A 254167 O RING ID 3 6x1 45 16 A 256141 PRESSURE SPRING 2 A 257056 SPACER PINS M5x20 3 A 257062 SPACER PINS 4 40 I O 5 A 258053 COG BELT MXL Z 83 X 3 16 1 A 258129 COG BELT 10AT5 2875 1 A 258130 COG BELT 10T2 5 480 1 A 258134 COG BELT 10T2 5 3065 1 A 258140 BELT MXL Z 90 3 16 1 A 281401 COVERING CAP D 25 5 2 A 281457 BUTTON BUFFER D 12 F 4 d 8 8 A 355130 CABLE USB TYPE A B 3M 1 A 361004 CABLE CLAMP CFCC 4 1 2 10 A 361025 CABLE CLAMP FCC 2A 5 A 361036 CABLE CLAMP 10 A 363012 FUSE 3 15 AT 4 A 363013 FUSE 6 3 AT 4 A 400002 FLATHEAD SCREW X6 DIN912 10 A 400005 FLAT HEAD SCREW X12 013912 10 A 400012 FLAT HEAD SCREW X30 013912 10 A 400024 FLATHEAD SCREW M4 X8 10 A 400025 FLAT HEAD SCREW M4 X10 013912 10 A 400026 FLAT HEAD SCREW M4 X12 013912 10 A 400028 FLAT HEAD SCREW M4 X16 01 912 10 A 400047 FLAT HEAD SCREW M 5 X16 01 912 10 A 400262 FLAT HEAD SCREW M 3X 6 DIN912 A2 10 A 400301 FLAT HEAD
4. 12 5 1 2 Tools P N Standard Tools Size 239511 ALLEN SCREW DRIVER WITH GRIP 1 5 mm 239512 2mm 239012 2 5 mm 239010 3 mm 239544 PHILLIPS SCREW DRIVER 0 60 239643 ANGLED ALLAN SCREW DRIVER SET 1 5 2 2 5 3 4 239644 TORX SREW DRIVER T 25 239596 ADJUSTABLE WRENCH 0 10 mm 239563 FORK RING WRENCH 7 mm 239564 8 mm 239573 17 mm 239646 TORQUE WRENCH SNAP ON 10 60 cNm 239647 ALLAN BIT s 1 5 mm 239648 snap on for Torque wrench 4 2mm 239649 2 5 mm 239650 HEX NUT BIT 7 mm snap on for Torque wrench 74 239651 ADAPTER PIECE Va for Hex Nut bit 239652 ADAPTER PIECE 14 6 3 MM for Allan bit s 74 239028 FLAT PLIERS 120 mm 239035 BRUSH L 135 239034 PELIKAN BRUSH 25 1 235414 GLOVES 10 pairs 239631 SCALE L 300 239015 VERNIER GAUGE 12 36 Microlab STAR Service Manual Microlab STAR Service Kit Tools continued P N Microlab STAR Special Tools 173950 FRONT WINDOW MAGNET 173956 PIPETTING ARM ALIGMENT TOOL 2 pieces Pipetting Channel Adjustment Tool Set 173952 CHANNEL ADJUSTMENT TOOL 173960 CHANNEL CALIBRATION TOOL Autoload Adjustment Tool Set 173981 AUTOLOAD CALIBRATION TOOL 173980 AUTOLOAD SENSOR TOOL 173953 STOP DISC MOUNTING TOOL P N Microlab STAR Disposables 235920 CO RE TIPS FOR ADJUSTMENT One each of the Microlab
5. 10 2 10 2 3 Investigation of Errors with Trace files 10 2 10 3 SBRROR HANDLING c 2 uu aaa sa eae eae 10 4 10 4 FIRMWARE ERROR CODES ideam ete olet ode 10 13 44 MESTAR ExtensiONS ya t ea er ev car EE ec Oo 11 1 12 ducis Eu t Mata cse Y 12 1 Xelan ent erat eec ote nem rest eot r ocn entem eara 12 1 GIOSSBFV sc EA MEE 12 1 12 2 APPENDIX BS roana H h z heb bagi aqu tuo m 12 7 12 21 Installation Qualification u lad rette eti detention deua 12 7 12 2 1 4 IQ Microlab STAR uu n re bak dd te MR E UR P k bk d k ka 12 7 12 2 1 2 IQ Microlab STAR IVD a ara KA KA K KA 12 9 12 2 2 Mamtenan e Checklist re siy iot KESME Kaba V obo K ba Ve bar d 12 11 12 3 APPENDIX O ZL dz dnd yda daan nai dad asnon t n ntis 12 15 722221 Se ic D WS uuu E 12 15 12 3 2 Parts elah Op p up Me 12 16 12 3 3 Problem report form i iua ixi a o aa do e a ea ER ER k 12 17 124 APPENDIX DO suce geana yada be taa bent editt b kere E Sot
6. ee f eceya um 63 GND 1 terc w E E Fre EL4S FLACHMOTOR 217403 m uw PIPETTING ARM CONNECTOR JP18 sij 4 113 823 as PGND E 8 lt 72 3 SA 604 644 l 2 pouer seen CABLE X ARM 821 1 fav PCHN BOARD 13 1 2 5 3 GND 173 817 a a 1 381 E 18 1 CANTH 1 CANH CANH 1 A x Fre FFC 4 17 PIPETTING CHANNEL BOARD PROG w im t 173 880 1 I ENO 7 mone E o o m 4 I c8 Eus 224 5 MEE pa ceso i cn m Mis PIPETTING CHANNEL BOARD 275 soo 2 5 113 813 ime 5 64 L 53 SA 604 542 gt zJ z j maw i Zad mox iad ie Kun ji an Poe jinan aa a ma hn al la kal Ew 2 lim 255 ems ema a i jaz i an jim jil es jel Hl
7. 7 33 7 8 3 Replacement a aca oC ya 7 34 7 84 Part Numbers for original and replacement Parts 7 36 T9 JAUTIOLQOADUDEDVE ZS tetto Sa lie Ker aw qa a 7 37 AOT Part eva una etn va nl cel n 7 39 Z 9 2 1 P 7 39 Microlab STAR Service Manual 7 9 3 Part Numbers for original and replacement Parts 7 46 710 AUTO LOAD X DRIVE inttr EI ERI I Ide 7 46 T IO T Part List j usu musu 7 47 210 2 EUBDUOE oio i wi jane D na eeu 7 47 7 10 3 Replacement aon co ad eo Ray C GR ERG GO as ERROR n 7 48 Tab JANSERTION GUIDES cote LLL 7 49 Part EiSt a a po do do dde dt 7 50 751152 EUDGUOD n OG OG GR a A OE RR Sus 7 50 711 3 FReplacelnent RV CIA DURER EN XE TA 7 50 212 LOADING TRAY ten Rite tcm tette 7 51 PartDISIy uu iei eDim dum dude 7 52 Tl 2 2 PURCUON ARS UT RE EUER VS ETE RECEN eae ebm 7 52 123 Replace ment sc 7 52 7 13 ADDITIONAL INSTRUMENT COMPONENTS e 7 53 Flat Eeee R T R E R HH 7 53 13 2 Spillage oa oin Loo a er na Ear oce a b da an 7 53 1359
8. 1051 Y S O A Ob B E x a e 2 8 5 2 x x j amp ux i d s gt 55 amp ig T E 78 j x 5 1 5 x 52 f 8 85 12 Ed a 5 5 S be 3 E 1 255 3 o j 5 2 I x j s j d T a cr Rc 4 k p4eoq y yndyng 1811610 2 jndu 1611610 1 2 30 30 ZHWSZ V9 1 42 912 1515 0550904 NYJ 99145 1009 peo umnog 9v rds 8 13 Microlab STAR Service Manual 8 3 3 Replacement Remove Left Deck Panel to access Master Board see section 7 4 2 Deck Panels on page 7 7 Before the Master Board is replaced print a hard copy of all Data from the Board by using Service Software and keep on file e Disconnect all cables and unscrew Master Board Screw P N 400656 5 x Screw P N 400632 1 x INTERFACE METAL PLATE P N 173614 1 x WASHER P N 369026 1 x ISOLATING TAPE P N 369061 1 x 8 3 4 Remounting e I
9. 4 3 4 2 INSTALLATION ac t C at ea o e e e toes 4 4 Microlab STAR Service Manual 4 2 1 Workplace environtlellfivscsseravitakeietvr eure nava taka YER 4 4 4 2 2 Unpacking the 5 4 5 42 21 Accessory DOXES W Kun KEY e Dre pr ve pita au 4 6 4222 u kb Ade e bag e dou He v A Tere ier tuti Roe Se 4 7 422 3 Packing List assaka e he k V k fa b ad aka x a Vek en 4 7 4 2 3 Hooking up the instrument esses sees 4 10 4 2 3 1 Putting the Instrument in 4 10 4232 Power Voltage eee tie en re eee tope e iur kak k Rek k k 4 11 4 2 3 3 4 12 4 2 3 4 Waste station 4 13 4 24 Software Installation i 4 14 4 2 4 1 User Software Installation 000000000000 4 14 4 2 4 2 Check Access rights for 4 15 4 2 4 3 Accessories Installation ML STAR 4 17 4244 Service Software Installation 4 17 42 5 Software
10. Program Files Accessories 4 Adobe Analog Devices Common Files ComPlus Applications CI Connectix amm CI Hamilton Brehm HAMILTON Conzett HAMILTON Conzett2 InstallShield Installation I Intel 1 Internet Explorer 71 micrnenfk Frantnane Ee MAA je object s Disk free space 15 5 GB then click OK j bytes My Computer Hamilton Properties General Sharing Security folder C Do not share this folder YYou can share this folder among other users on your network To enable sharing for this folder click Share this Share this folder Liser limit Maximum allowed Allow E Users To set permissions for how users access this folder over the network click Permissions To configure settings for Offline access to this shared folder click Caching Share name Comment For remote access 00 0 Caching 3 2 Activate Share this folder define Share name and optional Comment 4 25 Microlab STAR Service Manual 4 2 6 Adjustment and Calibration For general information see section 6 Adjustment and Calibration on page 6 1 It is particularly important and necessary to adjust and calibrate the Pipetting Arm the Pipetting Channels and the
11. ees 8 16 Microlab STAR Service Manual 8 4 3 Replacement See section 7 7 Pipetting Channels on page 7 26 Before a Pipetting Channel is replaced print a hardcopy of all Data from the Channel by using Service Software 8 4 4 Remounting Instructions are basically the reverse of those for replacement See section 7 7 Pipetting Channels on page 7 26 e With Service Software e Check Pipetting Channel settings e Check for accurate Firmware 8 4 5 Adjustment It is absolutely necessary to run the PIP AUTOADJUSTMENT MCR to generate new calibration values for the Pipetting Channel A Attention Do not restore any Data to Pipetting Channel if previously copied from replaced Pipetting Channel The Calibration values are no longer valid since the Pipetting Channel is physically replaced by another one 8 17 Microlab STAR Service Manual 8 5 Autoload 8 5 1 Function e Controls Autoload Function e Stores Technical Status Adjustment Values Download Status Cycle Counting and Firmware 23 Microlab STAR Instrument with Autoload Option only 8 18 Microlab STAR Service Manual 8 5 2 Autoload Block Diagram Load X Drive Load Y Drive Load Z Drive Load Identification Load Support E Be 24 Actuators Sensors EM EC Motor BR Barco e Reader z DM DC Motor EC Encoder lt FA Fan Vent lator FS Force Sensor HE Heating Element HS Hall Sensor a
12. 25085 83 LSPC_CLK_LS a H ee Sv scaceo res SV SERLEG 5 s 314 7 LSPE RF jw e Lser 10 PRESSURE REESE CENE SEVA 5 5 erpa 11 LEVEL Ow 5 5 ERPD EHA paca 2 2 1234 Sout 24 pee Fae u SMPS R u sya HI E 4 C3 3 SMPSTR lu 3 eo Suse 2 155 SMPS BY 1 1 04207 8428 8 16 5v FFE 1690 l eese Fre FFC l Fre TFC i Pip m D m m m D Um Sann CHN BOARD BOARD 2 p me F mm PROCESSOR D 12 BIT MICROCONTROLLER DMPZ cm N SIEMENS K wawawa SZ 0 can 2 5 2 s LEX DOSINC DRIVE I pum TRIER m MOTOR TACHO GEAR 218545 Mt JP15 JP38 wv 8 je gg d wa Fi Wc 7 5 zig 95 YORIVE pou 58755 s Y SENSOR BOARD sa ST u l 173 841 ren 2 END T 2 2 604 758 i i KT 961 L FFC oL DET inn m inn E S0UEEZE DR IVE ws DESI P s va Y IRIYE Gf vet Pi 18 EEPY E 2 LA 9 A a
13. The Spare Part Class SPC appears as a column of each part list in this manual 2 3 1 Service Assemblies Parts labeled with framed part numbers on the 3D drawings are Service Assemblies and may not disassembled by the Service Technician If a part of the assembly is defective the whole assembly must be replaced See section 12 6 Appendix F on page 12 38 for a complete List of all available Spare Parts 2 3 2 Exchange for Parts and Assemblies Hamilton will exchange assemblies and replace defective Parts with repaired Parts for a reduced price subject to the defective Part or Assembly being sent to Hamilton Bonaduz AG To arrange this contact Hamilton Technical Support see section 1 10 Contacting Hamilton on page 1 8 Microlab STAR Service Manual 2 4 ML STAR Service Kit P N 173970 Overview The Service Case contains all tools required to maintain a Microlab STAR Instrument as well as spare parts which may be required when servicing the instrument For your comfort and convenience the case is equipped with a set of wheels which makes it easy to carry around at customer sites See also section 12 5 Appendix E on page 12 27 for a complete Part List Microlab STAR Service Manual 2 4 1 Service Tool Maintenance In order to provide best service and maintenance to the components of the Microlab STAR instrument the following maintenance procedures should apply to these service tools at the specified intervals
14. A Attention Beware of the Pipetting Arm when it is moving on the Instrument Do not forget Front window Magnet on the customer s ML STAR Instrument This item is intended for use by trained Service Technicians only Alternatively if you deselected the front window in the configuration settings be sure to re select it now 6 7 Microlab STAR Service Manual 6 2 2 Tools for Autoload Adjustment Tool Description Autoload Calibration Tool P N 173981 Groove for automatic positioning in X Y and Z Direction of Autoload drive Tia Cog rail only for mechanical Cog wheel synchronization Supports mechanical Cock wheel synchronization and automatically positioning in X Y and Z Direction of Autoload drive Autoload Sensors Adjustment Tool P N 173980 Reference Barcode Tube Set P N 173986 Label P N 173985 Checks Barcode reading Cup Presence sensor adjustment and the quality of Carrier loading and unloading Reading Height from Deck e for Plates 118 mm e for Tubes 30 110 mm Included with Autoload Sensors Adjustment Tool are e Label P N 173985 for Barcode Reader alignment e Reference Barcode Tube Set P N 173986 6 8 Microlab STAR Service Manual 6 2 3 Tools for Verification of ML STAR IVD Tool Description Barcode Carrier P N 185270 Supports verification of Barcode reading of
15. If necessary decontaminate and clean surfaces of Autoload ribbon underneath Clean Flat Band Cables Groove and ensure collision free movement of Flat Band Cables All belts drives and cables for any damage or loose screws Recover Autoload Deck Panels Pipetting Arm 12 12 27 Microlab STAR Instrument with Autoload Option only 3 dito Microlab STAR Service Manual Maintenance Checklist continued Check all available Carriers REMARKS For signs of liquid spillage and damage If necessary decontaminate and clean Carriers Ensure smooth gliding on Deck Panels and Loading Trays Replace damaged carriers Autoload Check Needles if available For signs of damage If necessary decontaminate and clean Needles Replace damaged Needles Check and Adjust Pipetting Arm Pipetting Channels Autoload Verify instrument Perform a test run 12 13 Microlab STAR Service Manual Maintenance Checklist continued Removal of Trace files OK REMARKS Together with the Laboratory Supervisor check for trace files witch may deleted from the Operating PC Check for Traces files such as method system trace files communication trace files Check for old methods which n may be removed from
16. Tool for Stop disk removal STOP DISC MOUNTING TOOL P N 173953 j A Attention Use this tool only for loosening the stop disk Tighten stop disks always by hand A Attention Do not mistakenly tighten Stop Disk when loosening is intended This may damage the Pipetting Head Note Replace Stop disk rather than reusing it if pliers were used to unscrew it Even if only small scratches are visible replace Stop disk 7 35 Removal continued A disposable tip gripped with a pair of pliers may also used to open the stop disk The diposable Tip prevents any scratches to the stop disk After removal of the Stop disk throw used disposable tip away Nothing more than the above mentioned items may replaced or repaired If any drive or other function are defective replace the Pipetting Head Reassembly Instructions are basically the reverse of disassembly instructions e Carefully tighten the Stop Disk by hand Do not use any Tool e g Pliers and do not use excessive force just turn it into place Drawing above tighten 3 screws with 30 cNm and one screw with 20 cNm the second from above A Attention Check for appropriate Dip Switch setting on channels 300 or 1000 ul Pipetting Heads Refer to section 8 1 6 Node settings on page 8 5 Adjustment After replacment run the necessary Adjustment procedures as described in section 6 Adjustment and Calibration on page 6 1 7 8 4 Part
17. soot EVER 4 17 4 2 5 1 eT Mee ted D RE up uum ARE ARE adnate 4 17 4252 nstr ment CODTIQUEGllOD uuu ner cia Ka l dak bi edat 4 17 42 5 9 User Software settings roe i flue d e ekla en 4 18 4 2 5 4 User Software settings ML STAR 4 19 4 2 5 5 Defining Access Rights ML STAR 4 20 4 2 5 6 Remote 4 24 4 2 6 Adjustment and Calibration 4 26 4 2 6 1 Instrument Check Procedure K kk enne 4 27 4 2 6 2 Automatic Adjustment u kek k rka a BRL k k e k 4 28 427 Weekly Maintenance STAR 4 28 428 MOnlCQuOrin csi INERMIS dn 4 28 429 oes A oa etude Qe cuti e Fc du e uu apun cdr bal 4 28 4 2 10 Service Sollware Removal METTE 4 28 5 5 1 5 1 OVERVIEW the EE Hebe 5 1 52 CHECKLIST FOR DEINSTALLATION ducet terrd o d eret 5 1 S21 Decontamination uc esc a y k Q na a vice RO dia v vice eR AN Nak 5 2 5 2 2 Removing Tips or 222 22 000 0 5 2 5 2 3 Disconnect ML STAR Instr
18. The Master Board additionally generates 24V This is also distributed to specific Modules Each Module then generates locally its own voltages depending on their necessary digital and analog circuits 8 2 2 Power Components Line Filter P N 395023 e Function Mains Cable Interface and Fuse Power supply P N 396155 Function transforms Alternating voltage 230 115 VAC to 41 VDC Power Distribution Board P N 173835 e Function Distributes Power between Power Supply Master Board Pipetting Arm and Autoload Board Extension PCB P N 182805 e Function Cable Interface between Master PCB and Extensions such as Wash station and Temperature Controlled Carrier 22 Microlab STAR Instrument with Autoload Option only 8 9 Microlab STAR Service Manual 8 2 3 Replacement Remove Left Deck Panel for access See section 7 4 2 Deck Panels on page 7 7 e Line Filter e Disconnect all cables then unscrew Line Filter and replace Screw P N 400301 3 x Screw P N 257062 2 x Screw P N 400301 2 x Lock Disc P N 411002 2 x e Power supply e Disconnect all cables unscrew sheet metal from chassis then unscrew Power supply from sheet metal and replace Power supply Screw P N 400656 4 x The sheet metal is mounted with Screw P N 400301 4 x to Power supply e Power Distribution Board e Disconnect all cables then unscrew Power Distribution Board and replace Power Distribution Board Screw P N Screw P N 400656 6 x e
19. TIP EJECTOR 173332 STOP DISK 173520 U DISC 2 173600 SLIDE BLOCK 173602 SLIDE BLOCK WEDGE 173817 CABLE X ARM PCHN BOARD 173823 PIPETTING ARM CONNECTOR 173833 CARRIER SENSOR BOARD 173835 POWER DISTRIBUTION BOARD 173843 LOAD DISPLAY BOARD 173845 LOAD X CONNECTOR 173849 CABLE X MOVEMENTS 173850 CABLE FILTER POWER SUPPLY 173851 CABLE POWER SUPPLY 40VDC 173852 CABLE POWER SUPPLY GND 173854 CABLE POWER AUTO LOAD 173856 OS AUTO LOAD X INIT 173858 CABLE SSC 173860 HS COVER CONTROL 173863 CABLE DM X DRIVE PIP ARM 173864 OS PIPETTING ARM X INIT 173874 DM ROTATE DRIVE 173875 HS H V POSITION 173877 HS LOAD DETECT 173878 OS TUBE DETECT 173881 MASTER BOARD PROG 173882 AUTO LOAD BOARD PROG 173890 CABLE POWER SUPPLY GND 173891 CABLE EC AUTO LOAD X POS 173895 EC PIPETTING ARM X POSITION 173898 CABLE RS232 03 ZIN J SAZ Z Z I 5 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 12 33 Microlab STAR Service Manual Microlab STAR Service Kit Parts continued
20. 173861 TEACHING BOX 7 53 Microlab STAR Service Manual Additional Instrument Components continued 7 13 5 Teaching Station P N Description SPC 182174 TEACHING STATION C 182176 TEACHING NEEDLE 7 14 Accessories Accessories such as Carriers Disposables Needles etc are described in User Manual 7 54 Microlab STAR Service Manual 8 Electronics 8 1 Overview This section describes the electronics architecture and electrical Components such as PCBs and cables General note When removing PCBs such as Master Autoload or Pipetting Channels perform automatic adjustment according to section 6 Adjustment and Calibration on page 6 1 8 1 8 1 1 Functional Overview Teaching optional Extensions Master Communication with PC Command Buffer Microlab STAR Service Manual Pipetting Channel Y Drive Makro Control Z Dive Stop Button opt Teaching Box opt XO Module Pipotting Arm X Drivo Carrier Detection on Deck Cover Extensions Actuators Sensors 1x DM EC 1 08 55 HS BD 614 183 WD 604 451 Dosing Drive Squeozo Drivo Capacitivo LLD Pressure LLD Actuators Sensors 1 EM 2x DM EC 1x SM 3x HS 1x OS 2x 15 Power Supply Primary 94 to 254 VAC Auto Load Load X Y Z Drive Scanner Rotato Drivo Copt Scannor Sekundary 40 VDC 600W op
21. 182274 COVER RIGHT C 250016 BALL BEARING ID 6 OD 13 15 258140 COG BELT MXL Z 90X3 16 281401 COVERING CAP 400262 SCREW 6 403452 SUNK SCREW M3X6 DIN7991 403453 SUNK SCREW 403499 SUNK SCREW M4x30 409200 DISC M3 gt 7 9 2 Function The Autoload component e loads and unloads all Types of Carriers automatically Recognizes the presence of carriers ready to load e While loading e Recognizes Carrier Type Reads Carrier Barcodes e Recognizes Plate or Tube Barcodes Recognizes the presence or absence of Tubes Removal A Attention Never switch on ML STAR Instrument while cables such as those to Microlab STAR Service Manual Autoload drive are not plugged in when replacing Autoload drive as short circuits are possible Unscrew remove 182264 BLACK COVER LEFT Screws 2 x 403453 and 182266 COVER LEFT Screws 4 x 403453 Unscrew and remove 182263 BLACK COVER RIGHT Screws 2 x 403453 and 182274 COVER RIGHT Screws 4 x 403453 7 40 Microlab STAR Service Manual Removal continued Detach ribbon P N 182120 Screws 2 x 400262 on the left side of Autoload Drive Detach Ribbon Screws 2 x 403453 on the right side of Autoload Drive Remove Covering Cap 281401 7 41 Microlab STAR Service Manual Removal continued Unscrew and remove the first two Inserti
22. STAR Service Manual ML STAR packaging continued A Attention Prior to any transportation or movement Instrument must be packed with its original supporting and protective foam placed onto the original Pallet and finally packed into its protective box General notes The following Procedure is described for a ML STAR Instrument with Autoload option Disregard these sections if a Manual Load Instrument is to be packed When the left or the right side of the ML STAR Instrument is mentioned in these instructions the point of view is always from the front of the Instrument the operator s viewpoint 1 Lift Instrument onto Pallet shown here is Hamiltons ML STAR Fork Lift N Attention Spillage Trays must be removed prior to placing onto pallet Auto Load must be placed moved either onto the right or left side of the Instrument Pipetting arm U shaped protective foam bars go on X linear guide Microlab STAR Instrument with Autoload Option only 5 5 Microlab STAR Service Manual ML STAR packaging continued 2 Uncover pipetting arm s top housing and carefully place the protective foam blocks between the channels as shown in picture To insert these protective foam blocks into place you have to move the channels Move them gently by hand to the appropriate position and insert the foam blocks between them If an iSWAP is present push it gently towards rear protect it with the iSWAP protecti
23. X Drive Position hardware Position software Init sensor 0 000119979 11998 Initialize Off Repeat Position Position B Repeat cycles 2000 j 2000 0 Automatic request N Attention since any stress on the Pipetting Arm is now relieved do not move it by pushing or pulling it in the front If the Pipetting Arm must be moved hold it by the rear 6 26 Microlab STAR Service Manual Pipetting Arm X Alignment continued e Then start ARM X DIFFERENCE MCR Adjustment Macro Program from Service Software and carefully follow the instructions given in the program STARService fe 4 Put the adjustment tool 173960 to slot position 5 Cancel e Adjustment must performed if difference criteria are not met STARService 1 gt back front difference left channel 19932 19956 24 rihgt channel 19926 19968 42 Arm X correction 33 5 in 0 01 mm ATTENTION Do not moove the arm from front of Frame Repeat the measurement Interpretation of Result of Adjustment procedure Adjusting Pipetting Arm in X Direction which would be necessary in the result window shown above 6 27 Microlab STAR Service Manual Corrective Actions Seeing as the back of the Pipetting Arm connected onto the slides as pivot point in Z Axis the Pipetting Arm may only turn in X Direction counterclockwise In this example the corrective action would be turning the Pip
24. channels 1t016 1011111111111111 concentrically positioned and have therefore no electronic contact with the calibration tool LLD sensors status Repeat the measurement Here in the example only Channel 2 actually passed the check procedure STARService 3 X d ATTENTION Don t Forget to remove the tips from adjustment tool 6 7 Pressure adjustment values of TADM ML STAR IVD Connect the tubing of the pressure transmitter as shown to the ML STAR IVD tip waste Connect the RS 232 Cable to the Computer any Port where the Service software is installed PIP PRESSURE SIGNALS CR 6 39 Microlab STAR Service Manual 6 8 Adjusting Autoload drive For proper loading and unloading of Carriers and Barcode reading By using the Autoload Adjustment Tool and the Service Program Autoload Calibration Loading Tray adjustment Cog wheel synchronization Barcode reader and Tube presence Sensor adjustment are of a mechanical nature adjustment and calibration are totally automatic The cogwheel synchronization is of a pure mechanical procedure therefore no macro program is available for it Note the cogwheels are synchronized with the cog rail of the tool P N 173981 When using the Autoload Adjustment Program the Cog rail of this Tool is not used however the grooves of the tool must face the Cog Wheels The Program asks you during the procedure to put
25. 002 002 x3 Do you wish to readjust the incorrect channels Interpretion of Results from Adjustment procedure Adjusting Pipetting Channels 3 11 and 12 in X Direction which would be necessary in the result window shown above The Y Deviation is given by the straightness of the Channel and by the quality of adjustment with the Channel Adjustment Tool P N 173952 therefore no action can be taken here to improve these values they are for recognition only If the Y Deviation Values are bad or out of Range start adjusting according to section 6 3 Adjusting Pipetting Channel on page 6 14 Corrective Actions Focus only on the Channel with the most deviation resp the Channel which is out of range in X Axis In this example this would be Channel 12 Turn the Channel counterclockwise around its Y Axis to improve the alignment and lower the deviation and run the Adjustment Program again A Attention corrective actions take place within the macro adjustment procedure Therefore focus on Pipetting channel to be corrected Do not switch off instrument do not shift Pipetting Arm etc The macro will continue after you have corrected the Pipetting channel 6 31 Microlab STAR Service Manual Corrective Actions continued Z Axis X Deviation on first Level If no Channel positioning Tool P N 182960 is available then use upper Fixing screw as pivot point and tilt Channel counterclockwise X Axis X D
26. 86528 bytes Documents and Settings A 2002 10 25 14 00 File 3 Files 0 Folders A 2001 08 30 05 35 File Folde 2001 08 30 05 39 File Created Freitag 9 August 2002 10 22 26 2002 10 28 07 05 File Folde A 2002 06 20 12 51 File Folde Attributes i Advanced A 2001 09 1807 48 File Folde Hidden A 2001 08 30 05 33 File Folde A 2002 05 22 07 40 File Folde A 2002 04 16 07 53 File Folde b j1 object s selected my Computer 2 select Security Tab General Sharing Security Check if Users have Modify and Read amp Execute rights as shown here Administrators REQ0185Administrators fT Domain Admins HAMILTON Domain Adm __Bemove Power Users REQ018 Power Users If not see next page Permissions Allow Den Full Control Modify Read amp Execute List Folder Contents Read Write Advanced r Allow inheritable permissions from parent to propagate to this object Cancel Apply 4 15 Microlab STAR Service Manual Check Access rights for C Barcodes continued Users do not have the permissions needed click e Ensure current is selected in Look in e Select Users click and then OK Look in REQ018 Nm me EP Everyone Guests REQ018 Authenticated Users Power Users REQ018 2 ANONYMOUS LOGON BAT
27. A record of every step in the method executed from information supplied by the run editor Each Method started creates a Trace File which is named with the name of the Method plus the extension trc It will be found in Program Files HAMILTON Methods V trc Example If Method name is Trace File will appear as DNASEC trc Every time the Method is started an already existing Trace file will be opened otherwise it will be created and information will be appended to the last entries Accordingly it may be helpful to delete Trace files from time to time simply to avoid large files on the hard drive 10 2 3 Investigation of Errors with Trace files When an Error with the instrument has occurred Open the COM Trace e g ComTrace20010612 trc a file from the 12 June 2001 with an Editor e g NotePad Due to the Master Slave Architecture always search for er99 which indicates an SLAVE error However every possible Error reported by the Firmware may be found this way dj HxUsbComm20020207 trc Notepad File Edit Format Help 934 944 944 954 954 964 964 964 974 974 425 435 435 505 MAN AY AY A AT T18888 16 36 28 545 685 615 685 695 766 766 846 976 VA 395 405 638 lt gt lt gt lt gt lt 2 lt gt gt lt lt gt lt gt S F 8000H08 S F 8000H 08 S F 8000H080 S F 8S8000H 08 S F 80
28. Check Needles if available N A A Attention Items for ML STAR and ML STAR IVD may vary therefore ensure correct parts are being used on the Instrument 29 Microlab STAR Instrument with Autoload Option only 9 dito 9 7 Microlab STAR Service Manual Half yearly Maintenance continued Action Available Program 12 Removal of old files e Together with the Laboratory Supervisor check for trace files witch may deleted from the Operating PC e Check for Traces files such as method system trace files communication trace files e Check for old methods which may be removed from PC Back them up if necessary else delete e Check for available disk space onto hard drive 500 MB minimum are needed N A ML STAR IVD additionally 13 e Test tightness of seal for all Pipetting Heads Maintenance Procedure according to ML STAR IVD Operators Manual 14 e Check the pressure adjustment values of PIP PRESSURE SIG TADM NALS_ CHECK MCR 9 8 Microlab STAR Service Manual 10 Troubleshooting and Error Handling 10 1 Overview This chapter is about how to respond to problems and errors identified by the software which the user himself cannot resolve The solution of the problem may require the Service Technician to open up a component of the instrument This chapter takes the form of a list of such errors and instructions how to handle them Problem
29. Do not install new software version over existing software First Back up Macros Firmware etc then remove current software After removal of current software the new software version may be installed e Put Service Software CD into CD ROM Drive e Start Setup exe Program File from the CD ROM and carefully follow the installation instructions N Attention Do not leave the Service Software installed on a Customer s PC as this will enable any user of that PC to play with the system with potentially damaging results 3 1 Microlab STAR Service Manual 3 1 2 Service Software Root Directory structure C Program Files HAMILTON STAR 181 Fie Edt View Favorites Tools Back Forward Up Search Folders History Move To Copy Delete Undo Views Address ja C Program Files HAMILTON STARService Go Folders FP 11 J Bin r CI Firmware File Folder 08 02 2002 08 34 C Config File Folder 30 01 2002 11 40 C Graphic STARService File Folder 08 02 2002 08 27 C Labware C Language File Folder 30 01 2002 11 40 E Language Select an item to view its C Macros File Folder 07 02 2002 14 28 C Library description ServiceDaten File Folder 15 01 2002 16 57 C Logfiles See also File Folder 15 01 2002 16 57 Methods My Documents CJ data2 cab 3885 WinZip File 26 04 2001 15
30. LB LED bive LS Liquid Level Sensor LG lt LED green MS Mico Swiich LR LED red OS Optical Sensor LY lt LED yelow PS Pressure Sensor SM Stepper Motor TS Temperature Sensor SN Solenoid VS Volume Sensor Microlab STAR Service Manual 8 5 3 Autoload Wiring Diagram esau L 4 4 Saee ee ON J i i rm g iE EL 1341 538 135 221 322 11 2 is 2 245 Letts 8 20 Microlab STAR Service Manual 8 5 4 Replacement Remove Left Deck Panel to access Autoload Board see section 7 4 2 Deck Panels on page 7 7 Before the Autoload Board is replaced print a hardcopy of all Data from the Board by using Service Software e Disconnect all cables and unscrew Autoload Board Screw P N 400656 5 x 8 5 5 Remounting e Instructions are basically the reverse of those for disassembly Data may restored if copied from replaced Autoload PCB e With Service Software e Check Autoload settings e Check for correct Firmware 8 5 6 Adjustment e It is highly recommended that you run the AUTOLOAD AUTOADJUSTMENT MCR to generate new calibration values for Autoload drive Microlab STAR Service Manual 8 6 Cables Cables are generally replaced in their previous position If necessary fold the ne
31. P N 182506 VFV CONSUMABLE KIT ML STAR 6 47 6 9 3 Verification after replacement or remounting Microlab STAR Service Manual Described below are the necessary actions such as adjustments verification and functional check which have to be undertaken after replacement or remounting for each component x indicates a necessary adjustment volume verification and or functional check Components which are not listed below do not need any action to be undertaken Instrument Adjustment Volume Functional check Instrument Auto Autoload verin cation Check adjustment adjustment Side Panels of ML A _ Check Collision free movement of Pipetting Arm STAR Instrument Front window E x Cover Switch _ _ check locking function ML STAR IVD check stop functionality when opened while method is running Carrier Stops 2 Perform loading of carriers Deck Panels x Perform loading of carriers Docking Station Check Collision free movement of Pipetting Arm No oollision while carriers are loaded Waste station x 6 48 Microlab STAR Service Manual Verification after replacement or remounting continued Pipetting Arm Adjustment Volume Functional check Instrument Auto Autoload adjustment LAZ Check adjustment Covers of Pipetting j S e Check Collision free m
32. Pipetting Arm housing n Autoload ribbon m Spillage trays E Air filter replace if necessary n Uncover Pipetting Arm Check Cable connections n Check and clean Y Spindles g On Pipetting Heads Replace CO RE O Rings n Check Stop Disk s g Check Tip ejection Tubes g On Pipetting Heads clean and only slightly grease Squeezer Spindle B Dispensing Spindle g Clean and slightly grease guide shafts of X Guides Pipetting Arm g X Guide Autoload n Microlab STAR Instrument with Autoload Option only dito 2 only with brass nuts 4 Microlab STAR Instrument with Autoload Option only 12 11 35 Microlab STAR Instrument with Autoload Option only 36 dito Microlab STAR Service Manual Maintenance Checklist continued Remove Deck Panels and check OK REMARKS For signs of liquid spillage underneath deck and inside electronic chamber If necessary decontaminate and clean surfaces of deck underneath and electronic chamber cover Clean Flat Band Cables Groove and ensure collision free movement of Flat Band Cables All belts drives and cables for any damage or loose screws Distance of X measurement Reader on Pipetting Arm to magnetic Band Remove Autoload ribbon and check For signs of liquid spillage underneath
33. STAR Standard and Special Tools is required except in the case of the PIPETTING ARM ALIGMENT TOOL where 2 of them are necessary 12 5 2 ML STAR Verification Kit P N Microlab STAR Special Tools 182501 BASEKIT 230V 50Hz 182502 VFV BASEKIT 115V 60Hz 182503 VFV SUPPLEMENT ML STAR 182506 VFV CONSUMABLE KIT ML STAR 12 37 Microlab STAR Service Manual 12 6 Appendix F Part List Summery 12 6 1 Instrument Cover Part List P N 173712 SIDE PANEL LEFT 173713 SIDE PANEL RIGHT 173774 173860 281401 COVERING CAP D 25 5 400047 CYL SCR M5X16 DIN912 400619 CYL SCR M2 5X8 DIN912 420560 SCREW 4 10 A2 1507380 420561 SCREW 5 12 12 6 2 Covers over electronics Description 173743 EL COVER LINE FILTER 173748 EL COVER MASTER 173750 EL COVER POWER 7279443 EDGE PROTECTION SECTION ELF ADHESIVE GASKIT 12 6 3 Deck Panel Part List SPC 12 38 Microlab STAR Service Manual 12 6 4 Pipetting Arm Cover Part List PIN 173555 PANEL 173557 173559 173568 173607 H PROFILE 173609 173615 420560 SCREW M4X10 A2 ISO7380 12 6 5 Pipetting Arm Part List 173371 HOLDING PLATE LEFT 173605 CLAMPING BRACKET P Depending on instrument configuration 41 ditto 12 39 Microlab STAR Service Manual Pipetting Arm Part List continued P N Description SPC 400012 CYL SCR M3X30 DIN912 A 400024 CYL SCR M4X8 4000
34. V or flat Work area The area on the Microlab STAR IVD to which access is provided during processing Elements to be pipetted can be placed in this area Work list Information sent from outside the system as to what method s is or are to be executed on the Microlab STAR IVD and with what liquid 12 6 Microlab STAR Service Manual 12 2 Appendix B 12 2 1 Installation Qualification 12 2 1 1 IQ Microlab STAR HAMILTON 06 of Ref Service Manual P N 610754 Installation Date Contact Person Microlab STAR Installation Qualification IQ Installation Report ER eee Extensions Serial Work Place Environment Instrument Check Procedure Inspect workplace environment for accor Perform instrument check procedure dance to technical specifications Verification Inspect table or workbench for supporting the Volume weight of the Microlab STAR and providing gt the minimum space needed Print out verification reports Unpacking the Instrument Service Software Inspect instrument and accessories for ship Print out instrument configuration ping damage or missing parts Uninstall service software Use packing list to verify contents If any Documentation items are missing contact Customer Service Hooking up the Instrument Attach instrument configuration and verifica tion reports to this IQ form Set up the instrument Cu
35. gt HAMILTON Microlab STAR Service gt Unlnstall Microlab STAR Service then follow the Instructions given in the Program 23 Ulead PhotoImpact 6 23 WinZip En 53 Zubeh r von Dell Internet Explorer 2 Microsoft Access Microsoft Excel Microsoft Outlook lej Ld 23 OLYMPUS 2 Acrobat Reader 5 0 Microlab STAR Service 25 Uninstall Microlab STAR Service Professional Windows 200 d 4 3 7 Microlab STAR Service Manual Deinstallation of Service Software continued After deinstallation of Service Software ensure that no components are left on the PC Select START gt SETTINGS 3 SYSTEM gt ADD REMOVE SOFTWARE and search for ML STAR Service Components removing them if still present Eg Add Remove Programs Oj x E Currently installed programs Sort by amp v Change or Adobe Acrobat 5 0 Size 12 4MB 4 Corel Uninstaller Fiery Downloader Size 628KB S McAfee VirusScan Size 19 1MB Add New Microlab STAR Size 3 22 Microlab STAR Service Size 1 84MB Used occasionally Last Used On 07 02 2002 AddjRemove To change this program or remove it From your computer Change Remove Windows click Change Remove Components Close 3 8 Microlab STAR Service Manual 4 Installation of the instrument 4 1 Overview The initial unpacking installation and setup of the Microlab STA
36. 03423 Tips and needles on the same pipetting head Flexible use of tips and needles during the same run 300 ul channel low and standard volume tips or needles when volumes lt 5 ul must pipetted 1000 ul channel standard and high volume tips or needles when volumes gt 5 ul must pipetted Soft tip drop off minimized aerosol 2 2 Microlab STAR Service Manual Key Features continued Pipetting Heads Pressure and capacitive Liquid Level Detection Totally accessible deck each head each well for an 8 channel ML STAR Instrument Aspiration monitoring e 2types of pipetting heads available e 300 ul 0 5 300 ul and 1000 ul 5 1000 Tips and Needles The types of tips and needles currently available are 10 300 and 1000 ul disposable tips with or without filter and 50 300 and 1000 ul washable steel needles For ordering refer to User Manual General Precautions The pipetting channels are the heart of the Microlab STAR The instrument will not function properly if these are damaged or are incorrectly adjusted Therefore you should exercise great care whenever you have to touch the channels when unpacking or repacking the instrument dismantling or re assembling the pipetting arm replacing channels etc The instrument is provided with a front window This window is equipped with a sensor that stops any movement immediately and abo
37. 12 6 2 Covers over electronios uuo adeste odi ore wel RR 12 38 12 6 9 DECK Panel Pat user idet e err dala ka alas laqasqa saa 12 38 12 6 4 Pipetting Arm Cover Part 11 12 39 12 6 5 Pipetting Arm Part EISE oe oco Lope eere ino a Ua due 12 39 12 6 6 Replacement Frame Pipetting Arm P N 182108 Part List 12 40 12 6 7 Pipetting Arm s X Drive Part List us a i EE eR 12 41 12 6 8 Pipetting Channels Part 12 41 12 6 9 Pipetting Head as Gini i o A C GEO AA 12 41 12 6 10 Autoload Fart kist ERR at econ NANI 12 42 12 6 11 Autoload s X Drive Part 12 42 12 6 12 Insertion Guide 11 isses 12 43 Fart atout an 12 43 12614 Tp Waste Fam EISE gt sanan nahe naha ha Ra ek EVE k ye 12 43 12 0 19 Trays Part EISE eode POR DOR EH ay 12 44 12 0 T0 IBSUURIGRL E GE Sa Wi i sht r metus 12 44 12 6 17 Teaching Station qu Duque ea ur revere ean URS 12 44 12 619 POACHING BOX svo tiie e ne PO ERR ER RR P RU ER 12 44 12 6 19 Boards Part List and 550 5 12 45 6 20 Cabl s EIC 12 45 de un Z JIN
38. 173499 Y SPI RIDE FLAT CABLE TEEL BAND LAMPING BRACKET 173606 P ARM LINK 173608 P ARM FLAG 173817 CABLE X ARM P CHANNEL BOARD 173849 X MOVEMENT CABLE 173895 PIPETTING ARM X POSITION 173900 CONNECTOR 173905 CABLE X ARM CONNECTOR 8C 173906 CABLE X ARM CONNECTOR 16C 182103 REPLACEMENT CHANNEL A 182104 REPLACEMENT CHANNEL 182105 REPLACE PIPETTING HEAD 300ul 182106 REPLACE PIPETTING HEAD 1000017 182108 REPL FRAME PIP ARM 8 CHANNEL 361025 FCC 2A CABLE GUIDE 400002 CYL SCR M3X6 DIN912 400005 CYL SCR M3X12 DIN912 400012 CYL SCR M3X30 DIN912 400024 CYL SCR M4X8 400047 CYL SCR 5 16 DIN912 400604 CYL SCR 2 8 DIN912 400617 CYL SCR M2 5X5 DIN912 400621 CYL SCR M2 5X12 UNK SCREW M4X8 EX SCREW M 4 DIN934 420013 CYL SCR M3X8 DIN912 511071 OMNI FIT 15M 7279372 ADHESIVE TAPE 1 SIDED D 2 B 12 lt o 0 z g r m UJ TI gt 2 2 02 02 Depending instrument configuration 16 ditto 7 18 Microlab STAR Service Manual 7 5 2 Main Components Pipetting Arm Replacement Frame P N 182108 A amp B Channels Pipetting Heads 300 ul Pipetting Heads 1000 iSwap 7 5 3 Replacement Preliminary tasks e Uncover Pipetting Arm and remove all Pipetting Channels and iSwap if installed Refer to section 7 7 Pipetting Channels on page 7 26 A Attention store and handle Pipetting Chan
39. Autoload drive This item is part of the ML STAR IVD shipment and the barcode verification may performed by the customer See the maintenance menu of ML STAR IVD User Software The waste block is a ML STAR IVD Instrument part and besides its main tip waste function it is needed for checking tightness and positioning of pipetting heads These verifications may be performed by the customer as well Furthermore for the check and adjustment of Pressure Sensors of pipetting heads a coupling section is implemented into the waste block Toghether with the pressure transmitter and the macro programs PIP PRESSURE SIGNALS CHECK MCR and PIP PRESSURE SIGNALS AUTOAD JUSTMENT MCR the Pressure Sensors may be checked and adjusted necessary for TADM 6 9 Microlab STAR Service Manual Tools for Verification of ML STAR IVD continued Tool Description Pressure Transmitter P N 185380 The Pressure Transmitter comes together with an RS 232 serial interface and a 0 3 m long silicon tube P N 7249057 SILICON TUB 4X7 TRANSP Transmitter 5 Mn wra ww 1 mt wl c 6 10 Microlab STAR Service Manual 6 2 4 Adjustment Macro Programs Ensure all Adjustment macro programs are stored on the same path i e program files HAMILTON ML STAR services macros There are two types of Adjustment Macro Programs Measurement and Calibration Ma
40. Contact Person Extensions Serial Always wear required personal protection equipment Work Place Environment inspect workplace environment for accor dance to technical specifications Inspect table or workbench for supporting the weight of the Microlab STAR and providing the minimum space needed Unpacking the Instrument Inspect instrument and accessories for ship ping damage or missing parts Q Use packing list to verify contents If any items are missing contact Customer Service Hooking up the Instrument Set up the instrument Connect communication and power cables If included inspect install extensions iSWAP Yes No AVS Yes No TCC s Yes LJ No LJ WS s Yes No Recommended Uninterruptible Power Supply UPS installed Yes No Software Installation ML STAR software Service software Labware definitions of carriers Remote access Yes No P N 610911 00 Instrument Check Procedure Perform instrument check procedure Verification Volume Print out verification reports Service Software Print out instrument configuration Un install service software Documentation Attach instrument configuration and verifica tion reports to this IO form Customer Summary Explain how to request technical and service assistance Address any other concerns Comments Customer Acceptance Date Ins
41. DM X DRIVE PIPETTING ARM Pu 173 883 ha papers ES ORE AS A MASTER BOARD H EEND 7 ws D Ua ic dne Ae 173 825 aN mine 391 123 SA 604 751 E L queas voor Lou une 5 T RD DE ERI SE mi i a Saree 06 PIPETTING AR X INIT igi lt EW 5 173 864 Em T Z 5 edd 5l ken eee FT 4 1 5 kz TENSIONS 1 0 1 um EXTENSIONS CONNECTOR eco gt a ee 182 805 n 2 c e SA 604 998 Sewer H 5 EXT our L Ext puris FL STO SEE r mi EIU r lt 18 Beran 4 E L w ass LN MES e __ ipsi see Foo E 2 3 3 m E L Ra L8 I LI 0 293 ss W A i Wc m cai E f 4 f s Li 1 as publi em ME i 1 5182 Saebeegansas n 1 FP MEET ES j EE ATSE Li HH i ane r Sia toe POWER DISTRIBUTION BOARD CABLE SSC MASTER 20 20 NUS L mme d FT mas aN 1
42. Hint If Possible switch on Instrument as this will result in a smoother motion when Channels have to be moved on Pipetting Arm However do this only if all cables are plugged in correctly and no short circuit is possible 7 29 Microlab STAR Service Manual Remounting e Instructions are basically the reverse of disassembly instructions e Turn Y Spindle completely in by hand not using much force e Using a Torque wrench tighten the M4 Hex Nut with 60 cNm A Attention Check for correct Dip Switch setting on new channels Refer to section 8 1 6 Node settings on page 8 5 Also check for correct Firmware Version because all Pipetting Channels must using the same Firmware Version e f necessary download the latest firmware onto the new Pipetting Channel e Adjust Channel according to section 6 Adjustment and Calibration on page 6 1 Order of Pipetting Channel placement Front of Pipetting Arm Back of gt Pipetting Arm Shown above are the location of all Channels and their numbering 7 30 Microlab STAR Service Manual 7 7 4 Part Numbers for original and replacement Parts Note Microlab STAR instruments when shipped carry Channels with the following Part Numbers Label on Channels P N 173301 CHANNEL A with 300ul PIPETTING Head P N 173302 CHANNEL B with 300ul PIPETTING Head P N 173305 CHANNEL A with 1000ul PIPETTING Head P N 173306 CHANNEL B with 1000ul PIPETTIN
43. Instrament oa DRUMS 7 53 7 13 4 Teaching BOX u unu usia aetna ee 7 53 LABS Teaching Station oiii i er e bine ix a e a jina aa 7 54 ACCESSORIES bebes beide bebes 7 54 8 NBIGCUORICS 8 1 BE G 4 en zi e e e e e e EEE EEEE EEEE SERER 8 1 8 1 1 Functional rE bA bank 8 2 P unclional DescrpliOn iii en yaya ERR 8 3 8 12 tenaces oem aki oe eite tudo tuna ride tte tae stc 8 3 8 1 2 2 ML STAR Instrument communication architecture 8 3 amp 12 3 Firmware and eterne kan Een ehe akan LO P eT 8 3 8 1 3 Boards QVerviIgW ss o Gods Gen dd ir e od rr a 8 4 8 1 4 Location of electronically 8 5 81 41 EISU ice E tu Susa kuu PURO DR NER 8 6 8 1 5 COVErS OVereleCH DI6S su uuu pag men enel eue ba tv 8 6 8 1 6 Node settings Dip 5 8 8 9 2 POWEFFS2 Susu uyanan Nn od 8 9 8 2 1 aaa AM SEER uyay aa attese cta ce uyay h aa 8 9 8 2 2 Power ped dere enu bid 8 9 vi Microlab
44. Load display board by loosening three screws and replace with a new one Disk is located between Insertion Guides and Load display board Reassembly Instructions are basically the reverse of those for disassembly 7 50 Microlab STAR Service Manual 7 12 Loading tray Replacement Table right ELLE B BG Bg GG 2n E ETPEBRES Replacement Table left Ir EE ELE ELLE EL BG 400026 408006 173700 403453 nderit rd 21 Microlab STAR Instrument with Autoload Option only 173701 7 51 Microlab STAR Service Manual 7 12 1 Part List P N 173600 SLIDE BLOCK 173602 173700 173701 182112 REPLACEMENT TABLE RIGHT 182113 400026 403453 C SUNK SCR M3X8 DIN7991 403453 408006 re 7 12 2 Function holds carriers ready for transfer to Autoload Positions carriers in relation to deck 7 12 3 Replacement Slide Blocks with Slide Blocks Wedges See section 7 4 2 Deck Panels on page 7 7 7 52 Microlab STAR Service Manual 7 13 Additional Instrument Components 7 13 1 Tip Waste 173736 WASTE CONTAINER IP WASTE LID 173738 WASTE HANDLE 420561 TORX SCREW M5x12 gt 7 13 2 Spillage Trays 173195 TRAY LEFT 173196 TRAY RIGHT 147683 AIR FILTER B 148248 FAME VELCRO B 7 13 3 Instrument Parts 281111 FOOT M10x50 W CAP 173508 STOP BAR C 173509 FENDER BAR 7 13 4 Teaching Box
45. Manual P N 610889 For ML STAR IVD Instruments only 1 5 3 Programmers Guide P N 610888 For ML STAR IVD Instruments only 1 5 4 Service Manual P N 610754 The basic reference for the Service Technician is the present volume the Microlab STAR Service Manual 1 5 5 Firmware Reference Guides The Firmware Reference Guide lists all the commands that can be sent to the firmware of the instrument and lists all the status messages that the firmware returns for a particular module Firmware commands are used when sending a single instruction to the instrument rather than the series of instructions which constitutes a method The knowledge of firmware commands is therefore very useful for the Service Technician when testing particular aspects of an instrument s performance Note This documentation is not included as an appendix to the present volume It will be distributed during ML STAR Service Training Courses Service Technicians trained and or authorized by HAMILTON Bonaduz AG may request it from Technical Support at Hamilton Bonaduz Copies of Firmware reference guides may be filed in Section 12 4 3 Firmware Reference Guides on page 12 19 ff 1 5 6 Verification Reference Guide This guide accompanies the Verification Kit which provides the means to verify instrument function against specific acceptance criteria 1 5 Microlab STAR Service Manual 1 6 Software Overview 1 6 1 User Software P N 911004 This is the software opera
46. RP PER Pee PRAE PD era dn V 8 21 85 9 SEInOUhig a suu anu an ATA us au dv a uU asuy Du ui 8 21 8 9 0 Adjustment msr u EH HHH Hev 8 21 8 6 CABLES prira SORORE ana u eee de mc md a 8 22 8 6 1 lel HEND PER Susana 8 22 8 6 2 Cables Part lit uy a N Kaba Vetus puta Vp 8 22 1 xi l EE 9 1 OVERVIEW NE t p NOKE ND NEN bet NANE NO KEWO NEK 9 1 9 2 ITEMS NEEDED u uu ehe pU xan s n nana qu Eee etd 9 2 PU 6 9 2 OP EET ct ie tet Emm 9 2 93 DECONTAMINATION ccc oii as Se Se Se ores Se acids Se orden Gc ede s 9 3 WIL RIG PTOI cca ci yau cuy NER RR RR DE EAR LA ra RT aaah 9 4 95 HALE YEARLY MAINTENANCE rasa 9 5 vii Microlab STAR Service Manual 10 Troubleshooting and Error Handling 10 1 1051 ma amana b e Eke Ey a eb A 10 1 Version u xi xun ane din lan a v dae 10 1 TRACE uyan cused oue canet ces d r eed dined dined at 10 1 10 2 1 Communication Trace Tias aee o awe e a e a e e e EE 10 1 10 224 System Tace THOS o edo
47. SCR 4 6 DIN912 10 A 400650 FLAT HEAD SCR 4 16 DIN912 10 A 400302 FLAT HEAD SCREWM 4X 8 DIN912 A2 10 A 400602 FLAT HEAD SCREWM2X 5 DIN912 40 A 400604 FLAT HEAD SCREWM2X 8 DIN912 50 A 400617 FLAT HEAD SCREWM2 5X 5 DIN912 50 A 12 34 Microlab STAR Service Manual Microlab STAR Service Kit Parts continued P N Description Quantity Spare Part class 400619 FLAT HEAD SCREWM2 5X 8 DIN912 50 A 400621 FLAT HEAD SCREWM2 5X12 DIN912 50 A 400632 FLAT HEAD 8 DIN912 50 A 403452 SUNK SCREW 6 DIN7991 10 A 403453 SUNK SCREW M 3X8 01 7991 10 A 403491 SUNK SCREW M 4X8 DIN7991 10 A 403499 SUNK SCREW M4x30 10 A 405082 SET SCREW M 5X 5 DIN913 10 A 405445 SET SCREW M3 X8 DIN916 10 A 408006 HEX NUT M4 01 934 10 A 409103 U DISCM2 DIN125A 20 A 409200 U DISC DIN9021B 10 A 413005 LOCK DISC 4 DIN6799 10 A 413008 LOCK DISC 7 DIN6799 10 A 420010 ZYL SCHR M2 5X8 DIN912 A4 10 A 420013 FLAT HEAD SCREW M 3 X8 DIN912 10 A 420074 FLAT HEAD SCREWM 4X16 DIN912 A2 10 A 420560 SCREW 4 10 2 1507380 20 A 420561 TORX SCREW 5 12 10 A 420564 PASSCHULTERSCHRAUBE 6x20 M5 4 A 511000 LOCTITE 222 10ML 1 A 511071 OMNI FIT 15M 1 A 7249025 PVC TUBING 3 X5 TRANSP 0 5m A 7279372 TAPE 0 2 B 12 0 5m A 12 35 Microlab STAR Service Manual Microlab STAR Service Kit continued
48. STAR Service Manual 8 23 8 10 824 Jeoedssembly 0W e T 8 10 8 2 5 Wiring Diagram Power 8 11 83 MAST Ren r NEDEN EO EH eO E eter ec t 8 12 8 3 1 EFUh GtOD ois aa e o o de ASS RR A y 8 12 8 3 2 Master Block Diagram so t ee ERR RN X ee eens 8 13 8 3 3 brevets 8 14 8 3 4 Remounting iioii i ara yasa 8 14 0 3 9 e 1 7S 44 2741 QQ Saga ONA DK Du SSS hisa Sus 8 14 84 PIPETTING CHANNEL i rixi peyi ENA HWR KER HER KERO ER KENI GENA KERO Rapes 8 15 8 4 1 Pipetting Channel Block Diagram 8 15 8 4 2 Pipetting Channel Wiring Diagram 8 16 8 4 3 Replacement Deyab ea bete Sba VE 8 17 Bd ReEMO N NG so 5 KAD AA OU da RI E ued dahan a N DR NEAR ayat 8 17 alii Si ebbe te DA a beats 8 17 AUTOL OAD a DD n dg gg dg 8 18 8 5 1 FUGO us Ay iye hae en SUG s cor re GSE GEG A EWANA 8 18 8 5 2 Autoload Block Diagram teer rere dvd c deed 8 19 8 5 3 Autoload esee 8 20 8 54 Replac m nt et E A or
49. System Tools uj Storage Services and Applications Event Viewer ijJ System Information 9 48 Performance Logs and Alerts Hg Shared Folders 19 Device Manager EH Local Users and Groups Sg Storage 222 411 Disk Management Disk Defragmenter Logical Drives El 2 4 Damouashla Starana 2 Open Local Users and Groups 3 Click on Groups and see the List of defined Groups You will find groups such as Lab Operator Lab Operator2 Lab Method programmer Lab Service ZERA 1 Action View aa 2 E 2 Name _ Description Administrators Administrators have complete and unresl Backup Operators Backup Operators can override security 1 Guests Guests have the same access as membeli Power Llsers Power Llsers possess most administrative Replicator Supports File replication in a domain Users Users are prevented From making accidei Debugger Llsers Debugger users can debug processes Lab Method programmer Method programmers may modify metho Tree Computer Management Local El E System Tools Event Viewer System Information Performance Logs and Alei 2 1 Shared Folders A Device Manager Local Users and Groups 6 6 EH Users Lab Operator Operators may run any method They m Groups Lab Operator
50. Temperature controlled carrier Automated vacuum system All pipetting heads mounted on channels are either of 300 or 1000 ul type A mixture 2 1 4 Pipetting Head and Tip Needle Combinations of these two types is not allowable the user software will not support a configuration with both types of pipetting heads 300 ul Pipetting Head 1000 ul Pipetting Head v v Low Volume Standard Volume High Volume Tip Needle Tip or Needle Tip or Needle v v v v 0 5 10nl 0 5 50 ul 1 300 ul 10 1000 ul Microlab STAR Service Manual 2 2 Technical Specifications Item Value maximum weight of instrument with the Autoload option and trays installed 8 Channel Version 145 kg 16 Channel Version 155 kg ML STAR Instrument packed for transportation total weight including shipping crate 200 kg electrical requirements maximum power consumption 600W Voltage 115 230 V 15 10 95 Frequency 50 60 Hz 5 Delayed action fuse 115 V 6 3 A 230 V 3 15 A Operating temperature range 15 35 C relative humidity 30 85 with no condensation Storage temperature range 0 55 C relative humidity at a maximum of 95 with no condensation 2 6 Microlab STAR Service Manual Technical Specifications continued Item Value maximum outer dimensions Instrument Width 1670 mm Height 868 mm Depth 780 mm Instrument incl attached Autoload
51. The torque wrench P N 239646 must be subject to an annual check and calibration Calibration may performed by any calibration authority Hamilton Bonaduz AG offers a calibration service The Adjustment Tools such as the Channel Adjustment Tool P N 173952 may be returned periodically to Hamilton Bonaduz AG where a check service is offered Note Adjustment Tools can not be calibrated If an Adjustment Tool is found to be out of range it must be replaced with a new one N Attention the Microlab STAR Special Tools are precision tools and must be handled with due care to provide the best results in adjustment work on the Instrument 2 5 Disposal of ML STAR Instruments After the life cycle of the instrument has terminated the Microlab STAR may be shipped back to Hamilton Bonaduz AG Otherwise local disposal regulations are to be observed Microlab STAR Service Manual 3 Service Software 3 1 Overview The Service Software supports the identification and correction of malfunctions in the ML STAR instrument The Service Software e Configures the Microlab STAR Instrument e Downloads Firmware e Updates the Technical Status Performs calibration and adjustments Macro Programs e Controls all single movements of the instrument Checks Sensor status e Gathers all Trace information e Features both Single Commands and Macro Programs refer to firmware reference guide How to Install the Service Software A Attention
52. and Power compartment To stabilize them the self adhesive gasket P N 7369085 must be placed as shown over the covers 6 items each 3 cm long 8 6 Microlab STAR Service Manual Covers over electronics continued A To prevent any vibration of the covers the bottom line of the Master and the power compartment cover must equipped with rubber edge protective strips 6 items each 2 cm long 3 rubber edge protective strips 3 rubber edge protective strips Covers over electronics to prevent against liquid falling onto components Description SPC 173743 EL COVER LINE FILTER C 73748 EL COVER MASTER 73750 EL COVER POWER C 279443 EDGE PROTECTION SECTION C 7369085 SELF ADHESIVE GASKIT C 8 7 Microlab STAR Service Manual 8 1 6 Node settings Dip Switches The node settings address multiple components modules via the CAN Bus system CAN Module switch 6 switch 5 switch 4 switch 3 switch 2 switch 1 Node Abbrev Name Type Address 0 CO Master b Off Off Off Off Off 1 XO X Motor b Off Off Off Off ON 2 lO Auto Load b Off Off Off ON Off 3 W1 Wash station 1 3 b Off Off Off ON ON 4 W2 Wash station 4 6 b Off Off ON Off Off 5 T1 Temperature carrier 1 b Off Off ON Off ON 6 T2 gt carrier2 b
53. e g by selecting the ABORT Button in the Run Screen or by opening the front window while running the method which has the same effect This Information could be found in the System Trace File by checking the same time when the Error occurred 10 3 10 3 Error Handling Microlab STAR Service Manual The following listing of activities will help you to locate defective parts It is recommended that Service Technicians make an in depth examination of the assemblies before replacing any parts Also check the Versions of Firmware Adjustment Macro Programs Service and User Software Ensure the latest current Versions are being used Incident Corrective Action No communication Check if Power switch is on Listen for the Fan working inside Microlab STAR instrument Check Power and Interface Cables Fuses e g does the PC work on the same electrical outlet Are all cables plugged in correctly Cables may not be damaged e g broken lines Check the COM Port in the Configuration Settings in Service and User Software and physically on the PC Is USB being used or the RS 232 Interface If RS 2323 Interface is being used Is the original Microlab STAR Interface Cable being used RS 232 Check the Lines according to section 4 2 3 Hooking up the instrument on page 4 10 If USB Interface is being used Check USB Controller in the Add Remove Hardware Wizard start gt
54. ette 12 18 12 4 1 Microlab STAR Firmware 200002200 0 000000 12 18 12 4 2 Microlab STAR Firmware Files eese 12 18 12 4 3 Firmware Reference 2 000 100 000 000100000 12 19 12 4 3 1 Master Module Command Specification 12 19 12 4 3 2 Module Command Specification 12 21 12 4 3 3 Pipetting Channel Module Command Specification 12 23 12 4 3 4 Auto Load Module Command Specification 12 25 12 4 3 5 Wash Station Module Command Specification 12 27 12 4 3 6 Temperature Controlled Carrier Module Command Specification 12 29 12 4 3 7 iSwap Module Command Specification 2 12 31 12 5 APPEND Ea Send nel Kin n k n 12 33 12 5 1 Microlab STAR Service Kit 12 33 1253421 n u mus a IO eben ma itii utut 12 33 Microlab STAR Service Manual e BM MMMMMMDMMM 12 36 12 5 2 ML STAR Verification i e e ee eite 12 37 12 6 APPENDIX F PART LIST SUMMERY kk kk KK st 12 38 12 6 1 Instrument Cover Part uri has aieo 12 38
55. holding the Y Motor Drive The Y Nut Bore must be rectangular to the Channel no signs of bending A bent sheet metal indicates too much friction between Y Spindle and nut which may lead to steps lost The Y Motor metal plate nose must fit into the groove If not too much friction between Y Spindle and Nut which may lead to step lost Check if the Belt is still in place Check all the cable connections of the channel focussing on y motor cable Perform an Auto adjustment and check visually the linearity of all Channels Turning the Y Motor by hand no hardware based friction is recognized e g signs of damaged bearing broken parts inside etc except the electromechanical resistant If no improvement check Y Spindle for possible damage and replace Channel Decide if Y Spindle should be replaced as well Pipetting Head loss of seal Ensure Stop Disk has no scratches the smallest scratches may lead to an loss of seal If there are scratches replace Stop Disk Check CO RE O Ring for signs of wear and tear Black abrasions may be found around O Ring and Stop disk if so replace O Ring 10 10 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Pipetting Head cLLD problems _ Ensure conductive liquid is used Run the PIP AUTOADJUSTMENT MCR Check if the O Ring is squeezed when the program is started Using Service Softwar
56. instructions on the cover page and then file the cover page in the appropriate section 1 4 Service News Service news are sent to inform the Service Technician of new developments without delay File the service news in the appropriate section of the Service Manual 1 4 1 Upgrades Will be announced via Service News Basically all information will be found in Service News After replacing upgrading of any component refer to section 6 9 3 Verification after replacement or remounting on page 6 48 1 4 1 1 Firmware upgrade Refer to section 1 6 6 Updates on page 1 7 1 4 1 2 Service Software upgrade Refer to section 3 1 1 How to Install the Service Software on page 3 1 and section 3 4 Deinstallation of Service Software on page 3 7 1 4 1 3 User Software upgrade Refer to section 4 2 4 1 User Software Installation on page 4 14 and section 5 2 7 User Software Deinstallation on page 5 13 1 4 Microlab STAR Service Manual 1 5 Manuals Overview 1 5 1 User Manual P N 610766 The basic reference for the user is the Microlab STAR User Manual It contains all the information required to operate the instrument to carry out routine maintenance and to solve the more straightforward problems the user may encounter when operating the instrument The Microlab STAR User Manual describes the software used to operate the Instrument In the User Manual will also be found instructions on how to create and run methods 1 5 2 Operators
57. macro programs ensures perfect alignment of Pipetting Arm and all Channels All Pipetting Channels must be mounted and adjusted with Channel Adjustment Tool first then calibration with Channel Calibration Tool can take place A Pointer Z Tool P N 173968 is included with the Channel Calibration Tool CO RE Tips for Adjustment P N 235920 can be used with Macro PIP ALIGNMENT WITH LLD MCR 6 5 Microlab STAR Service Manual Tools for Pipetting Arm and Channels continued Tool Description Channel Positioning Tool P N 182960 For mechanical Channel Adjustment on Pipetting Arm According to the results from the PIP XY MANUAL ADJUSTMENT MCR this tool helps in adjusting fine tuning channels 6 6 Microlab STAR Service Manual Tools for Pipetting Arm and Channels continued Tool Description Pipetting Arm Alignment Tool P N 173956 Together with Channel Calibration Tool this facilitates Pipetting Arm alignment in X Direction Two Pipetting Arm Alignment Tools are placed on the X Guide on the left and right sides of the uncovered Pipetting Arm Front window Magnet P N 173950 Bridges the Front window switch and enables the Microlab STAR Instrument to be run with Front window open It is mounted on the left vertical Post Hint The front window may also deselected in the configuration settings use Service Software
58. movement check voltage check Hardware positioning counter 13 Perform Pipetting Arm Auto adjustment 10 7 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Pipetting Channels Step loss Dispensing Drive In General try to run the specific drive with service software to determine the degree of malfunction 1 Ensure the Pipetting Head fixing screws are mounted with the exact torque tension defined in section 7 8 Pipetting Heads on page 7 32 2 Clean Dispensing Spindle by removing all old grease and slightly grease it with new grease 3 By using Movement Sensors Pipetting Channel Menu from Service Software perform a whole stroke run in approx 10 times Use Service Software CONTROL gt MOVEMENTS SENSORS gt PIPETTING CHANNEL and RUN in Dispensing Drive from corresponding Channel 4 If dispensing Drive is blocked at its lower end Dispensing Spindle is not visible the spindle is down then send single command P DSds00500dv05000dr200dw7dt0O The Spindle must come up otherwise no recovery is possible Note when the Spindle is down not visible then parameter dt0 must be used 5 If dispensing Drive is blocked on its upper end Dispensing Spindle is visible the spindle is up then send single command P DSds00500dt1dv05000dr200dw7 The Spindle must go down otherwise no recovery is possible Note when the Spindle is up vi
59. tray Depth 780 220 mm 1000 mm ML STAR Instrument packed for Width 1820 mm transportation shipping crate dimensions Height 1000 mm Depth 900 mm 7 M A etl JJ d v 44444444 vi Microlab STAR Service Manual Technical Specifications continued Item Value Work area The Deck has space for 55 Tracks Track Number 55 the rightmost Track is reserved for Waste Station Therefore 54 Sample carriers 9 Plate Carriers or a mixture of both may be loaded onto the ML STAR Instrument A ML STAR Instrument with up to 8 Pipetting Channels has full sequential access This means that every Pipetting Channel reaches any HAMILTON standard Labware A ML STAR Instrument with up to 16 Pipetting Channels is limited in its Y direction movements Movement Refer to Firmware Reference Guides Increments for x y z drives 2 8 Microlab STAR Service Manual Technical Specifications continued Criteria Value Barcode Types Specification The following types of bar code symbol can ISBT standard be recognized by the system See also user software Menu Tools gt ML STAR Configuration Editor gt Advanced settings Code 128 subset B and C Code 39 Codabar Code 2 of 5 Interleaved UPC A E JAN EAN 8 Bar Code Density and Resolution Up to 32 characters excluding start stop and check characters can be read and decoded Code
60. 00H080 S F 8000H08 S F 8000H080 S F 8000H 08 S F 8000H080 S F 8000H 08 S F 80001H080 S F 8000H08 S F 8000H08 P58888 P68888 P76666 P88888 8000 06 S F 8S8000H 08 S F 80008H08 S F 8000H08 S F 8000H080 S F 8000H080 8006 06 8000 06 S F 8S8000H 08 10 x PGRJid8835 PGRJid8835 jd2802 02 07 j51 W1RFid8836 WRFid8836rf1 1E 2002 01 18 V1RJid8837 418100037 jd8800 08 08j51 T1RFid8038 TiRFid8038rf1 8P 2294 na T1RJid8039 718 140039142002 COCEid0058 COCEid00n08er88 00 CORMid0051 CORMid0051er88 00 P90000 Match case E 21 xl Find what esa Find Next Direction Cance C Up Down C8Quid8852 C 8QUid8852er88 88qu1 C8uIid8853unium1 CauIid8853er88 88 CauIid8854unium2 CauIid8855er88 88 CauIid8855uniun3 COW1id6645er 66 66 0 1 5 8 3925 3800 3675 3550 3425 3300 3175 3850 2558 2425 2388 2175tp1976t2187 6te245 8 18 SAF 8 SAF 8 S F 80008H 00 S F 8000H 08 S F 8000H080 S FH 80008H00 S F 80001H080 S F 8000H08 C 6HDid6647er 66 66 C6D1idb646er99 66 X663 66 C6AZid 6648 P1RVid 6649 P1RVid 6649na 6660661 2 64nb 6660661 164nc 6660662586nd 6660663942 P2RUid8858 P2RUid0050na0000001200nb0000001163nc 0000002587nd0000003939 Refer also to section 12 4 3 2 X0 Module Command Specification on page 12 21 for further inf
61. 173195 SPILLAGE TRAY LEFT 173196 SPILLAGE TRAY RIGHT 147683 FAME AIR FILTER 148248 VELCRO O 12 6 16 Instrument Parts U P N Description 281111 173508 173509 12 6 17 Teaching Station P N 182174 TEACHING STATION 182176 TEACHING NEEDLE 12 6 18 PIN 173861 TEACHING BOX o O 12 44 Microlab STAR Service Manual 12 6 19 Boards Part List and accessories PIN Description SPC 146242 ELECTRONIC RACK FAN C 173614 METALPLATE 1 C 173835 POWER DISTRIBUTION BOARD 71 173881 MASTERBOARDPROG 7 N Q2 N gt AUTO LOAD BOARD PROG 82805 EXTENSIONS CONNECTOR 57062 369026 69061 95023 96155 00640 00301 00632 8 om O gt ISOLATING TAPE INE FILTER OWER SUPPLY 41V 600W CYL SCR M4x10 DIN912 TUFLOK CYL SCR M4X6 DIN912 CYL SCR M3X8 DIN912 00656 CYL SCR M4X8 DIN912 A2 TUFLOK 03606 C SUNK SCR M3X8 DIN7991 A2 TUFLOK 11002 DISC M4 UL gt m A gt O0 gt 369061 395023 396155 400640 400301 400632 400656 403606 411002 _ 12 6 20 Cables Part list Description SPC 146355 W65 173817 CABLE X ARM PCHN B 173849 CABLE X MOVEMENTS 173850 CABLE FILTER POWER SUPPLY 173851 CABLE POWER SUPPLY 40VDC 173852 CABLE POWER SUPPLY GND 173853 CABLE POWER MASTER 17
62. 2 22 Microlab STAR Service Manual 12 4 3 3 Pipetting Channel Module Command Specification File the corresponding Firmware reference guide after this page 12 23 Microlab STAR Service Manual 12 24 Microlab STAR Service Manual 12 4 3 4 Auto Load Module Command Specification File the corresponding Firmware reference guide after this page 12 25 Microlab STAR Service Manual 12 26 Microlab STAR Service Manual 12 4 3 5 Wash Station Module Command Specification File the corresponding Firmware reference guide after this page 12 27 Microlab STAR Service Manual 12 28 Microlab STAR Service Manual 12 4 3 6 Temperature Controlled Carrier Module Command Specification File the corresponding Firmware reference guide after this page 12 29 Microlab STAR Service Manual 12 30 Microlab STAR Service Manual 12 4 3 7 iSwap Module Command Specification File the corresponding Firmware reference guide after this page 12 31 Microlab STAR Service Manual 12 32 Microlab STAR Service Manual 12 5 Appendix E 12 5 1 Microlab STAR Service Kit All items listed below come in the Microlab STAR Service Kit P N 173970 Note The Service Kit Microlab STAR contains items such as parts and Tools 12 5 1 1 Parts P N Description Quantity Spare Part class 146355 FAME CABLE W65 173293 STOP HOOK 173300 DISC 173310 GREASE 100 GR TOPAS AK50 173330
63. 2 Operators 2 may run any method and mc 24 Storage Lab Remote Service Service technician For Hamilton s laborat 1 Disk Management Service which may check content of Har b Here we want to enter all users who are engaged in routine laboratory work members of the Lab Operator group 4 20 Microlab STAR Service Manual Defining Access Rights continued 4 Double click on Lab Operator and click Add General Lab Description Jany method They must not modify any method definition Members Add Remove Cancel Apply Decide if the User is to defined only locally also to domain in case the PC is in a network environment 5 If so select the domain out of Look in this step is not necessary for local Users Look in E 0018 lt lt names separated by semicolons choose from list gt gt BK Cancel 2 4 21 Microlab STAR Service Manual Defining Access Rights continued 6 Select User from name column and click Add The User will then be inserted into list Repeat this Step for all Lab Operator Users then click OK Select Users or Groups J 2 Look in 29 hamilton ch Boegel Stefan sboegel amp hamilton ch on ch Medical Users R amp D Bognar Rodolfo rbognar hamilton ch hamilton ch H amilton Bonaduz Dealer Product M Bombis Dan
64. 3 4 Deinstallation of Service Software on page 3 7 A Attention Do not leave the Service Software permanently installed on a Customer s PC as this will enable any user of that PC to play with the system with potentially damaging results 4 28 Microlab STAR Service Manual 5 Disassembly 5 1 Overview The initial deinstallation and packing of the Microlab STAR may only be carried out by Service Technicians trained and or authorized by HAMILTON Bonaduz AG For proper deinstallation follow the order of instructions given in this section A Attention Exercise great care if touching the Channels when packing the Instrument 5 2 Checklist for Deinstallation To ensure a fast and proper deinstallation process follow the checklist For detailed descriptions see the subsequent chapters of this manual A Attention Do not skip any of the items in the checklist below as this may lead to an unsuccessful deinstallation 1 Decontaminate ML STAR Instrument and its components 2 Ensure no Tips or needles are left on Pipetting Channels e Remove any still present Dispose of Tips Decontaminate Needles 3 Disconnect ML STAR Instrument 4 Remove all Carriers Spillage Trays Loading Trays and the Waste Station from ML STAR Instrument e Remove from ML STAR Instrument and decontaminate them 5 Remove ML STAR Instruments Panels 6 Pack ML STAR Instrument into Shipping Crate 7 Carry out Software deinstallation A Atten
65. 3712 SIDEPANELLEFT 173713 SIDE PANEL RIGHT 173774 FRONTWINDOW C 173860 HS COVER CONIROL 1 gt 7 4 7 4 1 2 Function The Front window and side Panels left amp right protect the user from the moving Pipetting Arm and from any contamination inside the instrument A Cover Control switch located inside the left vertical post controls the closed Front window and will stop any movement of the instrument and also will abort a started Method if the Front window is opened during a Run However it is still possible to access all Carriers loading and unloading with the Front window closed Opening is necessary for maintenance Tasks i e deck surface cleaning access to waste station etc The Microlab STAR Instrument can be run without side Panels when the optional ML STAR Plate Handler and or the ML SWAP require access to the deck 7 4 1 3 Replacement this section describes the replacement of e Front window Cover Switch e Panels left amp right side A Attention Handle with care to avoid scratches on cover and panels e Front window Remove 6 screws P N 420561 First remove outer screws then holding the Front window by hand the two remaining screws in middle Carefully lift Front window away and store on appropriate surface A black sheet metal to protect the front guide bar from dust is located behind the Front window fixed with screws P N 400047 first the outer screws
66. 3854 CABLE POWER AUTO LOAD 173858 CABLE SSC 173863 CABLE DM X DRIVE PIPETTING ARM 173890 CABLE POWER SUPPLY EARTH gt gt gt 173891 CABLE EC AUTO LOAD X POSITION 173898 CABLE RS232 173905 CABLE X ARM CONNECTOR 8C 173906 CABLE X ARM CONNECTOR 16C 173911 CABLE FILTER EARTH 182820 CABLE MASTER EXTENSIONS 355130 CABLE USB TYPE A B 3M O gt A gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 12 45 Microlab STAR Service Manual 12 7 Index Aspirate 12 1 Autoload 1 1 1 6 2 6 2 7 4 9 4 21 4 23 5 2 5 5 6 1 6 3 6 9 6 10 6 14 6 42 6 43 6 44 6 45 6 46 6 49 6 53 6 54 7 1 7 4 7 6 7 36 7 38 7 39 7 40 7 41 7 42 7 43 7 44 7 45 7 46 7 47 7 48 7 50 7 51 8 1 8 3 8 9 8 12 8 18 8 19 8 20 9 2 9 4 9 5 9 6 10 7 10 13 10 14 12 1 12 3 12 11 12 12 12 13 12 19 12 39 12 44 Automated Vacuum System 12 1 Barcode 2 9 4 5 6 9 6 10 6 14 6 42 6 43 6 50 10 14 12 1 12 2 12 5 Carrier 1 6 4 23 6 10 6 14 6 15 6 47 6 48 6 49 6 51 7 8 7 9 7 10 7 12 7 13 7 38 10 14 10 15 12 1 12 2 12 3 12 20 12 31 Container 5 1 9 2 12 2 12 3 12 4 12 5 12 6 Cover 4 9 5 3 5 11 6 38 6 51 7 4 7 5 7 6 7 15 7 16 7 19 9 2 10 8 12 2 12 40 12 41 Deck 2 8 2 9 5 11 6 9 6 13 6 20 6 51 7 4 7 6 7 7 7 8 7 9 7 11 7 12 7 13 7 19 7 24 7 51 8 10 8 14 8 18 9 2 9 4 9
67. 4 fixing screws tilting around X Axis is enabled Torque Tension fixing screws M3 x 8 P N 420013 110 cNm or M2 x 8 P N 400604 50 cNm 6 15 Microlab STAR Service Manual 6 3 2 Pipetting Channel Adjustment Tool Remove Y Spindles first Gently drive Pipetting Head all the Pipetting Arm s left upper Y Guide shaft way down then gently push Channels Z Guide Shaft into Adjustment Tool If not possible release locking and fixing screws Channel Adjustment Tool placed approx In the middle onto Pipetting Arm s upper Y Guides Check visually there may be no Gaps between Z Guide and reference grooves of Adjustment Tool Freeze Adjustment Position by carefully tightening the fixing screws Pipetting Channels Z Guide shaf Adjustment Tool reference grooves No Gap visible indicates a perfect adjustment For a better understanding only two Channels with the adjustment Tool are shown here 6 16 Microlab STAR Service Manual 6 3 3 Pipetting Channel Alignment By placing the adjustment Tool once two channels at a time may be adjusted For providing best adjustment results the Design of the Adjustment Tool is to avoid the need to turn it around which may cause a shift from the theoretical Y Axis between Channels from the left and the right side of pipetting Arm Note During adjustment use always the same orientation with the adjustment Tool i e left side of adjustment Tool always t
68. 42 T lt lt Carrier Sensor Board 3 Load Display Board 3 Level Sensor Board 2 j 173 896 173 897 173 883 Carrier Sensor Board 1 Load Display Board Level Sensor Board 173 833 173 843 173 815 j 604 755 604 763 SA 804 643 7 Teilpletinen L T Tellolat _ Load X Connector 4 173 845 SA 604 764 Y Sensor Board 173 841 SA 604 758 Load X Connector SMD 173 847 u a a a LP LLD Flex Board 173 888 SA 604 946 y TO hM s J Microlab STAR Service Manual 8 1 4 Location of electronically components 8 5 Microlab STAR Service Manual 8 1 4 1 Part List Description SPC 46242 ELECTRONIC RACK 73614 INTERFACE METAL PLATE 400640 CYL SCR M4x10 DIN912 TUFLOK A 403606 C SUNK SCR M3X8 DIN7991 A2 TUFLOK A A Attention when replacing a Master Board without an USB Interface the Interface metal plate P N 173614 must be ordered as well This is because all Master PCBs contain RS 232 as well as USB COM Ports 8 1 5 Covers over electronics There are three covers which protect the electronic components against any liquid which may drop from the deck if liquids are spilled The covers are over the Line filter Master
69. 47 CYL SCR M5X16 DIN912 400604 CYL SCR M2x8 DIN912 A 400617 400621 CYL SCR M2 5X12 A 403491 408006 420013 511071 7279372 ADHESIVE TAPE 1 SIDED D 2 B 12 12 6 6 Replacement Frame Pipetting Arm P N 182108 Part List Description 173239 CABLE GUIDE COMPLETE 173490 ROLL HOLDER 173491 GUIDE 173536 REINFORCING ANGLE BRACKET 173537 PAWL 173538 173549 GAP DISC IPETTING ARM CONNECTOR RING ID8 00X2 00 705 256141 PRESSURE SPRING 281281 TRACK ROLLER D 16 281457 BUTTON BUFFER D 12 F 4 d 8 361004 CABLE GUIDE CFCC 7 173357 Y FLAG C U x 400002 CYL SCR M3X6 DIN912 400026 CYL SCR M4X12 400028 CYL SCR M4X16 DIN912 ORX SCREW M5x12 511006 ILOCTITE 222 12 40 Microlab STAR Service Manual 12 6 7 Pipetting Arm s X Drive Part List U P N 173380 OS HOLDER 182111 REPLACEMENT X MOTOR 250007 BEARING ID 8 AD 16 18 B 6 250045 BEARING ID 15 AD 35 11 257056 SPACER PINS M5x20 I O 258129 COG BELT 10AT5 2875 Description 20 258130 BELT 10T2 5 480 396011 MAGN MEASURING TAPE gt 400025 CYL SCR M4X10 DIN912 400026 CYL SCR M4X12 DIN912 400077 CYL SCR M6X60 DIN912 400262 CYL SCR M3X6 DIN912 A2 400302 CYL SCR M4X8 DIN912 A2 ET SCR M5X5 DIN913 OCK DISC 7 DIN6799 ORX SCREW M5x12 rico gt gt gt gt gt gt gt 12 6 8 Pipetting Channels Part List 182103 Replace
70. 48 Microlab STAR Service Manual 7 11 Insertion Guides 7 Segments of Insertion Guides 7 Segments of Insertion Guides are connected together LEDs in the front display user where to load carrier 2 Types of Insertion Guides are applicable e The one outermost right Insertion Guide End P N 173729 and the left Insertion Guide P N 173292 Both types of segments including e P N 173300 disk 7x e Screw P N 403452 Microlab STAR Instrument with Autoload Option only 7 49 Microlab STAR Service Manual 7 11 1 Part List 173292 INSERTION GUIDE 173729 INSERTION GUIDE END 173747 SPRING STRIP 173843 LOAD DISPLAY BOARD 400617 CYL SCR M2 5X5 DIN912 403452 SUNK SCREW 6 DIN7991 gt gt 7 11 2 Function LEDs guide the user as to where to load carriers Entry and exit positioning for carriers to be loaded and unloaded Bottom view e Load display board P N 173843 1x is mounted with 3 screws P N 400617 Sheet Metal P N 173299 1x Stop Hook P N 173293 8x Not shown here is Spring Strip P N 173747 which is mounted on Chassis and pushes the Stop Hooks up DA D se Soo TERES 7 11 3 Replacement e See section 7 10 Auto Load X Drive on page 7 46 Due to its plug design start removing from left to right Replace Stop Hook by removing Load display board and sheet metal e Remove
71. 5 9 6 10 8 10 13 12 2 12 3 12 5 12 11 12 12 12 13 12 40 Dispense 7 32 12 2 Disposable Tip 2 5 2 8 4 23 5 2 6 1 6 51 7 5 7 32 7 35 7 52 9 2 9 4 10 1 10 13 12 11 12 45 Fall Through Tip Waste 12 5 Internal Swivel Arm Plate Handler 12 3 Labware 2 8 6 1 10 11 12 1 12 3 Liquid Level Detection 12 3 liquid level detection LLD 2 2 6 6 6 14 6 39 10 12 10 13 Microtiterplate 12 4 microtiterplate MTP 8 7 10 11 12 4 Pipetting 1 6 2 2 2 3 2 5 2 8 4 8 4 9 4 21 4 23 5 1 5 2 5 4 5 11 6 1 6 3 6 6 6 7 6 8 6 12 6 13 6 14 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 6 29 6 30 6 31 6 32 6 38 6 39 6 52 7 1 7 4 7 5 7 8 7 14 7 15 7 16 7 17 7 19 7 20 7 21 7 22 7 23 7 24 7 25 7 26 7 27 7 28 7 29 7 30 7 31 7 32 7 33 7 34 7 35 8 1 8 3 8 8 8 9 8 14 8 15 8 16 8 17 8 21 9 1 9 2 9 3 9 4 9 5 9 6 9 7 10 3 10 6 10 8 10 9 10 10 10 11 10 12 10 13 12 2 12 3 12 4 12 11 12 12 12 13 12 14 12 19 12 20 12 25 12 39 12 41 12 42 12 43 12 47 rack 12 4 Rack 12 3 12 5 Tip 12 5 Total Aspiration and Dispense Monitoring 2 4 12 5 Tube 6 9 6 42 7 38 9 4 12 2 12 5 12 11 12 44 Wash station 2 5 8 8 8 12 12 20 Waste 2 8 5 1 5 2 6 10 6 51 7 52 9 2 12 6 12 45 12 46 HAMILTON the measure of excellence HAMILTON Bonaduz AG Via Crusch 8 CH 7402 Bonaduz
72. 52 Firmware My Network Places S HxThreadAndSyn 48 KB Application Extension 16 03 2001 15 11 A Br My Computer a ikernel ex_ 332 EX 05 10 2000 16 01 RA info amp install bmp 403KB Ulead PhotoImpact 01 11 2000 14 01 RA Language as layout bin 1KB BIN File 26 04 2001 15 52 RA Macros jD Setup exe 136KB Application 16 05 2000 16 36 RA C ServiceDaten Setup ini 1KB Configuration Settings 26 04 2001 15 51 RA C test a setup inx 115KB INX File 04 04 2001 14 21 RA SWwAPService amp STARService exe 888KB Application 03 12 2001 10 13 A InstallShield Installation In S UsbIoComm dli 84KB Application Extension 11 07 2001 11 06 C Internet Explorer lan win_tus cnt 2KB CNT File 05 01 2001 15 14 A Q microsoft frontpage an Win tus GID 11KB GIDFile 24 01 2002 09 52 C Microsoft Office win tus hlp 34KB HelpFile 05 01 2001 15 19 Q NetMeeting C Network Associates C OfficeUpdate CI ORL Outlook Express C C Ulead Systems Windows Media Player C Windows NT C Winzip Programme C swap C TEMP WINNT 20 object s Disk free space 5 80 GB 5 79 MB 5 My Computer Astart 21 9 El ua 3 Eppos 8 wa Wiser Eco 9 0 38 3 2 Microlab STAR Service Manual 3 2 Starting the Service Software From Start Menu NIC Utilities 28 Be
73. A amp C OLYMPUS Attributes normal amp ikernel ex _ 332KB EX File 05 10 2000 16 01 RA 5 a install bmp 403 KB Ulead PhotoImpact 01 11 2000 14 01 RA a layout 1KB BIN File 26 04 2001 15 52 RA H Accessories o Adobe Setup exe 136 Application 16 05 2000 16 36 RA Common Files Setup ini 1KB Configuration Settings 26 04 2001 15 51 RA ComPlus Applications a setup 115KB INX File 04 04 2001 14 21 RA Corel 888KB Application 03 12 2001 10 13 A Fiery 5 UsbIoComm dll 84KB Application Extension 11 07 2001 11 06 A S I HAMILTON a win tus cnt 2KB CNT File 05 01 2001 15 14 Bin Win_tus GID 11KB GID File 24 01 2002 09 52 Config win tus hlp 34KB Help File 05 01 2001 15 19 A CJ Graphic H Labware Language J Library J Logfiles 71 Methods Ey STARService Firmware O Inf CJ Info Ca Language C Macros 9 ServiceDaten test ewan Application Size 888 ge My Computer KSiroste amp cent amp servi RYDE 07 42 Service Software may also started from desktop if you create shortcut to STARService exe program This will be found in the STARService Folder e g C Program Files HAMILTON STARService 3 4 Microlab STAR Service Manual Starting the Service Software continued a My Documents Microsoft Outlook STAR
74. Autoload Adjustment and Calibration can only be done using the Microlab STAR Service Software and the special adjustment calibration tools 7 Microlab STAR Instrument with Autoload Option only 4 26 Microlab STAR Service Manual 4 2 6 1 Instrument Check Procedure Before running any adjustment programs as described in chapter 6 Adjustment and Calibration on page 6 1 perform an Instrument check procedure with Macro Program INSTRUMENT setup installation of ML STAR instrument 606867 Instrument Check mcr lt passed b yes ic 606827 PIP Autoadjustment mcr Y 606867 Instrument Check mcr X lt passed 3 gt yes no Y 606828 PIP XY Manual Adjustment mcr Perform mechanical positioning adjustment according to result values 606828 PIP XY Manual Adjustment mcr improved gt no if values far out of tolerance then mechanical S p P adjustment with adjustment tools must performed U 606825 Arm Z Difference mcr until passed Passed gt 606826 Arm X Difference mcr yes until passed 606827 PIP Autoadjustment mcr Y 606828 PIP XY Manual Adjustment mcr 606867 Instrument Check mcr no Passed gt yes Y setup sucessful lt continue according to installation qualificatio
75. CH Users REQ018 CREATOR OWNER 7 Debugger Users REQ018 mi CREATOR GROUP 2 Lab Method programmer REQOIS zl Lab Operator REQ018 Add Check Names Add J Check Names lt lt Type names separated by semicolons or choose from list gt gt REQOTS Users Allow Modify for Group Users General Sharing Security Name Administrators REGQO18 Administrators ff Domain Admins HAMILTON Domain Adm _Bemove Power Users REQO18 Power Users eum Add Permissions Allow Full Control Modify Read amp Execute List Folder Contents Read Write Advanced r Allow inheritable permissions from parent to propagate to this object r Kl The Permissions section of the window should then look like this General Shaing Securty Finally click OK Name Administrators REQO18 Administrators Domain Admins HAMILTONSDomain Adm Power Users REQO18 Power Users ffi Users REQO18 Users Permissions Full Control Modify Read amp Execute List Folder Contents Read Write Advanced Allow inheritable permissions from parent to propagate to this object EI KI RI KI Microlab STAR Service Manual 4 2 4 3 Accessories Installation ML STAR IVD e Accessories CD comes together with Carrier Put CD into CD ROM Drive Start Setup exe Program File from the CD RO
76. Channels and Heads on Pipetting Arm must have the same orientation in X Y and Z Direction 4 Adjustment of Autoload e Adjustment synchronization of Cogwheels 5 Calibration of Autoload e Calibration in X Y and Z independently from Pipetting Arm with Channels See section 6 2 Adjustment Tools and Macro Programs on page 6 5 for a complete list of Tools and Macro Programs Note After adjustment and calibration have been completed you should perform a Check Run and a verification General notes Always follow the order of adjustment described above and summarized in section 6 2 Adjustment Tools and Macro Programs on page 6 5 However for installation and quick check procedures the Instrument Check Macro Program INSTRUMENT CHECK MCR should be performed to decide if the instrument is ready to operate If the values according to the Instrument Check Macro Program are out of range then the automatic calibration Macro Program PIP AUTOADJUSTMENT MCR must be started to generate new calibration values with the current state of the hardware In consequence it may necessary to start a complete adjustment and calibration procedure following the order already described 5 Microlab STAR Instrument with Autoload Option only dito 6 3 Microlab STAR Service Manual Order of adjustment and calibration Deadjusted Channel or replaced Channel mechanical adjustment with adjustment tools Y 606825 Arm Z Differ
77. D E KH Ano K r DD n Po TY CY PTY PY CY PV CU 12 46 Microlab STAR Service Manual 1 Introduction 1 1 General Information This Service Manual is a field service guide and is to be used only by Service Technicians trained and or authorized by HAMILTON Bonaduz AG Repaired units must meet the quality standards set by HAMILTON Bonaduz AG No part of this manual may be copied or handed on to a third party Owners of Service Manuals are registered and only they will be issued with update information such as Service Manual Updates and Service Bulletins A Attention You should reaq User Manual Chapter 1 General Information before repairing or servicing the system A Attention Never lift a fully assembled instrument with carriers racks etc from one work bench to another First lock pipetting Arm X movement and channels by using protective covers from packaging Check instrument for level position and adjustments after placing on the new work bench A Attention Good laboratory practice GLP is a must Protect yourself before working on the Microlab STAR Instrument wear safety gloves Ensure that where applicable decontamination has been carried out A Attention Be aware of moving Parts inside the Microlab Star Instruments e g when ever working inside the Instrument e g if not all covers are closed and the Instrument has to be operated e g via serv
78. ENE H k 7 16 1 Hye zen a aae ipt odit edt dace 7 17 Ped Part a iA Vana aaa aan nayana amu yaaa au ell amici 7 18 2 l u dee in ei den dert at da dan n 7 19 Loss Replacement E EE 7 19 7 5 4 Pipetting Arm Replacement Frame P N 182108 7 21 GOAN EE EEE oot TA 7 22 7 6 PIPETTING ARM X DRIVE 7 23 Part BISE e meten a pe omen Reden ORE Raa 7 24 606 2 ke a app LER 7 24 7 63 Replacement dri Ec rice ln lew ew ew an es Dual awe apas 7 25 ene be a de See dek Salen Stee be eb dek Ge 7 26 ele me ele key dtes cere ctr rrr 7 27 757 2 PMV e o l z pa m o oic ie dica Mat vaca dpud 7 28 a Zm k na ana Adana diana a di 7 29 7 7 4 Part Numbers for original and replacement Parts 7 31 287 PIPETUNGHEADS e A ama 7 32 EISE Lan inti nu de a N 7 33 NN rere te
79. Extension PCB e Disconnect all cables then unscrew Extension PCB and replace Screw P N 403606 2 x 8 2 4 Reassembly Instructions are basically the reverse of those for disassembly 8 10 Microlab STAR Service Manual 8 2 5 Wiring Diagram Power Master us pc vof M WIE es EM 5 173895 us 172 298 SERVE pom Los BOOTSTRAP LONDER ER n A PIPETTING ARM CONNECTOR 173 823 SA 804 644 n ty omE MASTER BOARD PROG ___ 535 COMMUNICATION PIPETTING ARM X ORIVE
80. G Head Ordering The replacement Channels must ordered with Part Numbers as follows P N 182103 is a Channel A without Pipetting Head P N 182104 is a Channel B without Pipetting Head The Label on replacement Channels will show Part Number 182101 for Channel A Part Number 182102 for Channel B 7 31 Microlab STAR Service Manual 7 8 Pipetting Heads Two different Pipetting heads of 300 8 1000 ul are available for the Microlab STAR Due to their absolutely identical outer geometry you need to refer to the Label to identify them as a 300 or 1000 ul Pipetting Head Torque tension fing screws 4 400621 1x20 Ncm q 7 3 30 15 182105 182106 173330 173520 254167 Shown here is an A Channel v s 173332 3 511071 with Pipetting Head Ri Torque tension screw 10 Nem Stop Disk 7 32 7 8 1 Part List 173330 TIPEJECTOR 173332 STOP DISS_________________vV A gt gt i mp 409103 DISCM2DIN1I2A 173310 GREASE 100 GR TOPASAK50 2 gt gt 7 8 2 Function following features implemented the Pipetting Head e Tip coupling with CO RE technology e Tip presence is registered e Capacitive Liquid Level Detection for Aspiration and Dispensing e Pressure Liquid Level Detection for Aspiration only by using a new disposable Tip for each aspiration step e MAD Monitored Air Displacement which monitor
81. Instrument configuration Communication settings lx lx TADM settings instruments Step selection Instrument extensions Barcode settings Error settings Communication settings Instrument configuration Number of channels 12 Default waste wastet 2 Z Autoload Teaching Mode Teaching box Keyboard C Both Teach with channel no s Hamilton Microlab STAR Configuration Editor Select mode for instrument Microlab STAR 4 Aw Differences from the ML STAR User Hep Software are Save e Communication only via USB lt lt Advanced Select Instrument E not selectable Instrument extensions e Channel Type only 1000 ul Instrument configuration n ot se cta b All instruments settings Tab lx Mode Recording Monitoring r TADM Upload Mode C None Error curves only Allcurves 4 19 Microlab STAR Service Manual 4 2 5 5 Defining Access Rights ML STAR IVD After Installation of ML STAR IVD Software Users working with the System must be registered This action can only be done by a PC Administrator 1 Select My Computer and right click on Manage Computer Management loj action view gt am E E 2 Tree 8
82. M and carefully follow the instructions during installation 4 2 4 4 Service Software Installation Generally see section 3 Service Software on page 3 1 A Attention Do not leave the Service Software permanently installed on a Customer s PC as this will enable any user of that PC to play with the system with potentially damaging results 4 2 5 Software Presettings 4 2 5 1 Overview User and Service Software are completely independent of one another Therefore settings such as Com Port settings must be made for both Basically e Using the Service Software you can set the Microlab STAR Instrument Configurations on the Master Board located inside the Instrument e Using the User Software you can set the Microlab STAR Instrument Configurations necessary for programming Methods 4 2 5 2 Instrument Configuration Check the Instrument Configuration by using service software and print out summary Note The Instrument and Software Configurations must match The User Software during Method parsing compares the settings of Instrument and User Software Microlab STAR Service Manual 4 2 5 3 User Software settings e Select ML STAR Menu Tools gt ML STAR Configuration Editor gt Advanced 6 Hamilton Microlab STAR Configuration Editor 3 x 6 Hamilton Microlab STAR Configuration Editor x Instrument Instrument C Simulator C Simulator Save Cancel Advanced Save Cancel tep sele
83. NS 5 201 258129 COG BELT 10AT5 2875 258130 BELT 1012 5 480 396011 MAGN MEASURING TAPE YL SCR M4X10 DIN912 YL SCR M4X12 DIN912 400262 CYL SCR M3X6 DIN912 A2 C C 400077 CYL SCR 6 60 DIN912 C C 400302 CYL SCR M4X8 DIN912 A2 405082 SET SCR M5X5 DIN913 413008 LOCK DISC 7 DIN6799 420561 SCREW M5x12 7 6 2 Function e Moves Pipetting Arm in X Direction SP C A B A A A B A A C A A A A A e Driven by a DC Motor and controlled by a magnetic measurement system optical switch 1 24 Microlab STAR Service Manual 7 6 3 Replacement Preliminary actions Remove deck panels see section 7 4 2 Deck Panels on page 7 7 Hint remove left deck panel first and right side deck panel only if necessary Item Description Replace X Motor P N 182111 Loosen Belt Tension of secondary drive disconnect DC Motor cable from Master PCB and then remove Primary Drive Assembly 2 screws M4 x 8 P N 400025 Loosen Belt Tension of primary drive 2 screws M3 x 6 P N 400262 remove security washer from DC Motor axis and then remove DC Motor from sheet metal 3 screws I6R M5x12 P N 420561 Primary drive belt Cog belt SYN FLEX 10T2 5 480 P N 258130 See DC Motor Additionally loosen 2 set screws P N 405082 from large cogwheel remove axle and large cogwheel Secondary drive belt Cog belt Breco P N 258129 Loosen Belt
84. Numbers for original and replacement Parts Note Original equipped Microlab STAR instruments carry Pipetting Heads with the following Part Numbers Label on Pipetting Heads P N 173303 300 ul PIPETTING Head P N 173304 1000 ul PIPETTING Head Ordering The replacement Pipetting Heads must ordered by Part Number as follows P N 182105 is a 300 ul Pipetting Head P N 182106 is a 1000 ul Pipetting Head The Label on replacement Channels will show Part Number 173303 for 300 ul Pipetting Head Part Number 173304 for 1000 ul Pipetting Head 7 36 7 9 Auto Load drive Drives X Drive positions the Autoload drive to the Track Y Drive The two Cogwheels load and unload Carriers e Z Drive couples the two cogwheels into Carriers for y movement n Barcode Reader Vertical position for Carrier recognition and Tube Barcode Reading e Horizontal position for Plate Barcode Reading 1 Microlab STAR Instrument with Autoload Option only 7 37 Microlab STAR Service Manual Auto Load drive continued e o 19 CN 173297 p x zn 403452 409200 173874 173879 173878 173877 7 38 Microlab STAR Service Manual 7 9 1 Part List o O O D P N Description 173297 PINION MXL Z 32 173845 LOAD X CONNECTOR 173849 CABLE X MOVEMENTS 173874 DM ROTATOR DRIVE 173875 HS H V POSITION 173877 HS LOAD DETECT 173878 05 TUBE DETECT 173879 SCANNER
85. Off Off ON ON Off 7 b Off Off ON ON ON 8 P1 Pipetting channel 1 a Off ON Off Off Off 9 P2 Pipetting channel 2 a Off ON Off Off ON 10 Pipetting channel a Off ON Off ON Off 11 4 channel 4 ON Off ON ON 12 P5 Pipetting channel 5 a Off ON ON Off Off 13 P6 channel 6 a Off ON ON Off ON 14 P7 Pipetting channel 7 a Off ON ON ON Off 15 P8 channel 8 a Off ON ON ON ON 16 P9 Pipetting channel 9 a ON Off Off Off Off 17 Pipetting channel 10 a ON Off Off Off ON 18 PB Pipetting channel 11 a ON Off Off ON Off 19 Pipetting channel 12 a ON Off Off ON ON 20 PD Pipetting channel 13 a ON Off ON Off Off 21 PE Pipetting channel 14 a ON Off ON Off ON 22 PF Pipetting channel 15 a ON Off ON ON Off 23 PG Pipetting channel 16 a ON Off ON ON ON a The Pipetting channel is defined with Dip switch 6 where OFF 300ul and ON 1000Uul b Not currently used 8 8 Microlab STAR Service Manual 8 2 Power 8 2 1 Function Provides the power needed to run the Microlab STAR Instrument with all its applications Through operation of the Net filter Mains power switch the current is distributed to the Power Supply Primary circle On the secondary circle 41 V are available Feeds Current through the Power distribution board to all Modules Each Module has its own self resetting Fuses multi Fuses
86. PC Back them up if necessary else m delete Check for available disk space m onto hard drive 500 MB minimum are needed ML STAR IVD additionally Test tightness of seal for all Pipetting Heads Check the pressure adjustment values of T 12 14 12 3 Appendix C 12 3 1 Service news Microlab STAR Service Manual Subject Date 12 15 Microlab STAR Service Manual 12 3 2 Parts return tag A Tag P N 612554 should be found here 12 16 Microlab STAR Service Manual 12 3 3 Problem report form Name Date Company Operating System User Software version PC RAM PC Processor PC Hard drive size free space Brief description Symptom Q User software hangs Initialization fault u System error Abort u Verification fault Q System error Continue Q Processing fault Exit Q Window dialog box fault Instrument hangs nM Pipetting Arm fault nap E Channel fault EU Pipetting Head fault m Svid MUN Weak waq an Ak ARE T Autoload fault eos ceded aa panpay u doco nu B qatata d Detailed description of problem Attached Q Method Trace Q Com Trace Q Method Q Other Please sign and return to Hamilton Date Signe
87. Pipetting Arm Adjustment Program only provides measurements and helps you to align the Pipetting Channels on the Pipetting arm Note The Adjustment may be performed where the Pipetting Channels have been preadjusted and the X and Z Differernce Macro Procedures are completed succesfully Preliminary actions Hint Run the Adjustment macro Program before removing any Panels of the Instrument After the first run check the result window If the values are out of range corrective Action must take place Run the following macro program together with Channel Calibration Tool P N 173960 PIP XY MANUAL ADJUSTMENT MCR Adjustment Start Adjustment Macro Program PIP XY MANUAL ADJUSTMENT MCR from Service Software and carefully follow the instructions given in that program STARService E x Put the adjustment tool no 173960 to slot position 5 Would you like to measure the alignment off all channels 6 30 Microlab STAR Service Manual Adjustment Pipetting Arm with Channels XY Manual e Adjustment must performed if difference criteria are not met STARService E x Deviation of X positions channels 1 to 16 in 0 01mr D04 003 018 013 0009 0011 005 001 010 0005 0019 0022 0002 0012 009 006 15 Deviation in 2 levels X in 0 01mrm 0008 0018 0002 0012 0003 008 0004 0009 0009 0010 0008 012 0011 0013 0004 0011 25 in counts 0007 004 0004 0006 0005 0009 004 0003 0003 0004 0003 0004 0004 0007
88. R may only be carried out by Service Technicians trained and or authorized by HAMILTON Bonaduz AG For proper installation follow the order of instructions given in this section Deinstallation is described in section 5 Disassembly on page 5 1 A Attention Exercise great care if touching the Channels when unpacking the Instrument Installation Qualification To ensure a fast and proper installation process follow the Installation Qualification For detailed descriptions see the subsequent chapters of this manual An Installation Qualification Form may be found in section for ML STAR see section 12 2 1 1 IQ Microlab STAR on page 12 7 respectively for ML STAR IVD in section 12 2 1 2 IQ Microlab STAR IVD on page 12 9 Note depending if a Microlab STAR or a Microlab STAR IVD is being installed use the corresponding Installation Qualification Form A Attention Do not skip any Chapter this may lead to an unsuccessful installation Note If any of the steps above can not executed successfully refer to section 6 Adjustment and Calibration on page 6 1 and section 10 Troubleshooting and Error Handling on page 10 1 4 1 Microlab STAR Service Manual 4 1 1 1 Microlab STAR Installation Qualification Service Organization eoe ML STAR Software Version Contact Person Microlab STAR Installation Qualification IQ Installation Date Installation Report W Si Gs
89. RUCTURE OF THIS u uu u near n he eret ehe EK n ene ener ehe Eee Eee es 1 3 13 SERVIGE MANUALE UPDATES cbe tct tbt ded 1 4 Tub SERVIGENNEWS ntt tcs ese s kaka Eke kara 1 4 1 4 1 Belege 1 4 TAILL Firmware one oe o prre WAE E xer eee ea eee DE 1 4 14 1 2 Service Software upgrade peo Cpu diei 1 4 1413 User Software upgrade RR E ERE PUER e t KAKA be KA KA KAK de 1 4 1 5 MANUALS OVERVIEW 25 tv zerey ected Pk en Ke Kl eee ER 1 5 1 5 1 User Manual P N 610766 1 5 1 5 2 Operators Manual P N 610889 1 5 1 5 3 Programmers Guide PIN 610888 ene Ge 1 5 1 5 4 Service Manual P N 610764 1 5 1 5 5 Firmware Reference 1 5 1 5 6 Verification Reference 1 5 16 SOFTWARE OVERVIEW a nanan aqa aa uqa aq aquqa Tue sus 1 6 1 6 1 User Software P N 911004 1 6 1 6 2 User Software for Microlab STAR IVD P N 911039 1 6 1 6 3 Service Software P N 911003 1 6 007 mu Corp tau unata 1 6 1 6 5 Adju
90. STAR Service Manual Adjustment Macro Programs continued This List follows the order of Adjustment and Calibration File Name Description INSTRUMENT CHECK MCR With Channel Calibration Tool 173960 checks all calibration values of Pipetting Arm Channels and Heads Measurement Macro Program ARM Z DIFFERENCE MCR With Channel Calibration Tool 173960 checks Z parallelity of Pipetting Arm to Deck in functional dependence on X and Y Axis Measurement Macro Program ARM X DIFFERENCE MCR With Channel Calibration Tool 173960 checks X parallelity of Pipetting Arm to Deck in functional dependence on Y Axis Measurement Macro Program PIP XY MANUAL ADJUSTMENT MCR With Channel Calibration Tool 173960 Shows the linearity and relative positioning of all channels after preadjustment shipping etc Measurement Macro Program PIP AUTOADJUSTMENT MCR With Channel Calibration Tool 173960 Performs an initial Adjustment and calibrates the pipetting Arm in X Axis and its Channels in Y and Z Axis Calibration Macro Program 6 12 Microlab STAR Service Manual Adjustment Macro Programs continued This List follows the order of Adjustment and Calibration File Name Description PIP ALIGNMENT WITH LLD MCR With Channel Calibration Tool 173960 and Low Volume Tips Final visual Pipetting Channel check Checks alignment of all channels with Low Volume T
91. Service Manual Microlab STAR i k gt A 4111441144144 LLL LLL GU I Y P N 610 754 00 HAMILTON the measure 4 excellence Important Notice Reproduction of any part of this manual in any form whatsoever without the express written consent of Hamilton Bonaduz AG is forbidden e contents of this manual are subject to change without notice efforts have been made to ensure the accuracy of the contents of this manual However should any errors be detected Hamilton Bonaduz AG would greatly appreciate being informed of them e above notwithstanding Hamilton Bonaduz AG can assume no responsibility for any errors in this manual or their consequences Copyright 2000 2001 Hamilton Bonaduz AG Bonaduz Switzerland All rights reserved e Windows NT Windows 20007 and Windows are registered trademarks of Microsoft Corporation Microlab is a registered trademark of Hamilton Bonaduz AG Microlab STAR Service Manual Table of Contents 1 u uu I LE aa 1 1 1 1 GENERAL INFORMATIQN irren 1 1 UMESSTAR uu our umanuan yapapi b v ab DEDAT E 1 2 WZ ML STAF IV D xo gt oo odo odo mei 1 2 1 12 a cias Gs o eo e a a ia e o de ra as 1 2 1 1 4 Description of text icons for special notes 1 2 142 ST
92. Service exe Microlab STAR RUN HAMILTON Microlab STAR Service Main menu D xl File Control View Settings Download Traces Help 606827 PIP Autoadjustment none none 606825 Z Difference none none 606826 Arm Difference none none 606828 PIP XY Manual eui none Ione none none 606843 PIP alignment with LLD utoadiustment none none 505832 Autoload cd El 2 E amp jwae RMD 075 By default two windows appear COM Trace and the Main menu window The COM trace window starts when view trace from the view menu is activated It reports all commands sent to and responses received from the ML STAR Instrument The arrows after the time format have the following meaning gt identifies a command from PC to ML STAR Instrument and lt identifies a response from ML STAR Instrument to PC after the command has been executed 3 5 Microlab STAR Service Manual 3 3 Help Menu In this section all Menu Choices of the Service Software are explained E HTML Help Gi x f Hide Back Print Options Contents Index Search programming gt User manual 3 6 Microlab STAR Service Manual 3 4 Deinstallation of Service Software Select Start gt Programs
93. Stop Side Panel 2 4 Insertion Guide with integrated loading display Mains switch Interfaces RS 232 USB Teaching Box loading trays left and right Autoload Drive Spillage Trays 7 2 Microlab STAR Service Manual Side and back panel 7 3 2 ML STAR IVD Front Window with integrated loading display and monitored locking function Loading Trays with extended side guards 7 4 Covers of the Microlab STAR e Front window Panels left and right side e Deck Panels e Pipetting Arm housing e for the Autoload Drive Ribbon refer to section 7 9 Auto Load drive on page 7 37 7 4 1 Front Window and Panels left amp right side side panels left amp right Front window gt I h r zu E j a eee lt hc mi s C e sss ss z d gt Bosse usu amp SS 1 DS kaso n ue LSS gt zar SS 55554 v d E n Men m SS SS es X HS Cover i SERES nsnm Control m 7 4 1 1 Part List 17
94. Switzerland Tel 41 81 660 60 60 Fax 41 81 660 60 70 marketing hamilton ch http www hamiltoncompany com
95. Tension of secondary drive and remove belt from Pipetting arm claw Magnetic Band See picture on previous side 1 25 Microlab STAR Service Manual 7 7 Pipetting Channels Location of Dip switches opposite side as shown here Pipetting Channel B P N 182102 Pipetting Channel A P N 182101 Basically the difference of the Channels may only be found in the lower section of each channel due to their mounting order onto the Pipetting Arm Shown here circled are the brackets which connect the Channels to their corresponding Slides these run either on upper or lower guides and therefore the mounting of the Y Motor to ensure enough spacing between the channels 7 26 Microlab STAR Service Manual 7 7 1 Part List Pipetting Channels P N SPC 182103 Replacement Channel A A Package containing 1 Channel A P N 182101 without Pip Head Mounting accessories A 182104 Replacement Channel B Package containing 1 Channel B P N 182102 without Pip Head e Mounting accessories Note Replacement Channels come without Pipetting Heads These must ordered separately The mounting accessories are 2 types of screws and washers for both types of slides available on ML STAR Instruments For Slides with small threads the small screws CYL SCR M2X8 P N 400604 must be mounted with washers otherwise use CYL SCR M3X8 P N 420013 Nothing may replaced or repaired on Channels if any d
96. a The following PCBs carry Flash Memory which contain the necessary Firmware e Master CO Module Master PCB e The Pipetting Arm s X Drive is the XO Module which is a virtual slave on the Master PCB Note It does not have its own Flash Memory it is controlled by the Master and therefore has no Firmware of its own e Pipetting Channel PX Module on Pipetting Channel PCB X stands for the channel number Note Pipetting Channel Board carries Flash Memory Pipetting heads do not have Flash Memorys but are controlled by their associated Channel Pipetting Heads are passive elements and have therefore no memory of their own e Autoload 10 Module on Autoload PCB e For Extensions see chapter 11 ML STAR Extensions 8 3 Microlab STAR Service Manual 8 1 3 Boards Overview POWER SUPPLY WD 604 454 Extensions Connector 1 Power Distribution Board 1 X Arm Connector 1 182 805 173 835 173 300 SA 604 998 SA 604 756 SA 604 949 9 ARM WD 604 432 Pipetting Arm Connector 1 173 823 SA 604 544 p 7 7 MASTER 0 604 451 AUTO LOAD WD 504 452 8x PIPETTING CHANNEL Pipetting Channel Board 2 173 880 Master Board prog 173 881 Master Board 173 825 SA 604 751 Auto Load Board prog 173 882 Auto Load Board 173 827 SA 604 752 Pipetting Channel Board 173 813 SA 604 6
97. actions Side panels are removed by unscrewing 8 Screws P N 420560 currently 2 screws per panel front and rear Hint If no more uncovering is needed do not remove side panel s lower screw at the back since there are matching indents to join the side panel with the back panel Unscrew the 2 remaining screws and remove Back panel P N 173609 and Panel P N 173555 in the rear Hint If it is all right for the Back panel to remain on the Pipetting Arm do not remove lowest screws since there are indents in Panel to join it with back panel Covering Instructions are the reverse of those for uncovering Ensure shadow gaps and collision free mounting for Pipetting Channels and X Movement of Pipetting Arm Join Panel and Back panel at the rear and place screws loosely in Back panel do not tighten them yet Join Side panels to Back panel and fix them with screws Reassemble Front Panel with 4 screws Tighten all screws Snap Top Cover onto H bars and Side panels 7 16 Microlab STAR Service Manual 7 5 Pipetting Arm 182103 1400504 5107 182104 2420013 Menon 162105 2106 10009 40062 122511071 30 173371 173366 pipetting Arris bel claw P N 173606 Torque tension of the M4 Hex Nut 60 cNm P N 408006 7279372 7 17 Microlab STAR Service Manual 7 5 1 Part List P N 173206 CLAMP AT5 173372 HOLDING PLATE RIGHT 173392 173446
98. actly the instructions given in the adjustment program When the program asks for the Autoload Calibration Tool to be placed from the back onto Track position 1 Ensure the cog rail is facing upwards and push the Tool gently from inside the ML STAR Instrument outwards until the pin from the Tool attaches to the slide block At the end of adjustment procedure after the Autoload Sensors Adjustment Tool is unloaded ensure a gap of approx 1 mm between Stop Hook and the Carrier 6 46 Microlab STAR Service Manual 6 9 Verification 6 9 1 Volume Verification The Verification Kit provides the means to verify instrument functions against specific acceptance criteria The gravimetric verification procedure consists of an easy to follow program called from the user Software The Pipetter s Accuracy and Precision will be verified 6 9 2 Verification Kit s The Verification Kit consists of 3 parts Basekit witch may be used for several Hamilton Instruments next to the ML STAR Instrument however it is current depending for Countries with either 115 VAC or 230 VAC e An Instrument specific SUPPLEMENT Kit witch contents ML STAR Instrument specific items A CONSUMABLE KIT which contains verification fluid disposables Tips etc Countries with 230 VAC Countries with 115 VAC V P N 182501 P N 182502 VFV BASEKIT 230V 50Hz VFV BASEKIT 115V 60Hz N K P N 182503 VFV SUPPLEMENT ML STAR v
99. annels will be placed above calibration Tool and allow a visual check which is prompted with the dialog box below STARService xi Is the alignment of all channels correct 6 36 Microlab STAR Service Manual 6 6 Calibrating Pipetting Arm with Channels Run the following macro program together with Channel Calibration Tool P N 173960 e PIP AUTOADJUSTMENT MCR Automatic Adjustment procedure 1 Channel Calibration Tool P N 173960 placed onto deck as asked for by the program Appropriate Adjustment Program has been started After the successful Adjustment ensure all screws on Pipetting Arm and Pipetting Channels are tight Perform a Check Run Cover pipetting arm and Instrument 6 37 Microlab STAR Service Manual 6 6 1 Pipetting Channel Positioning Check LLD Check Run the following macro program together with Channel Calibration Tool P N 173960 e PIP ALIGNMENT WITH LLD MCR x 4 Put the adjustment tool no 173960 filled up with Low Volume Tips tips to slot position 5 ATTENTION THE INSTRUMENT MUST BE ADJUSTED E Cancel Calibration Tool filled with Low Volume Tips All Low Volume Tips are picked up and positioned inside the small holes of Calibration Tool 6 38 Microlab STAR Service Manual Pipetting Channel Positioning Check continued xj The goal is to have all LLD sensor statuses at 0 This means all Low Volume Tips are absolutely
100. are to be carried out must be adhered to and the work must be documented A Attention The preventive maintenance must only be done by an authorized Service Technician Service Technicians as well as laboratory personnel should be aware of the danger of infection where instruments are used to sample biohazardous materials In such cases the instrument or parts of it are said to be contaminated As Service Technician you should be aware if an instrument you are servicing has been contaminated in this way Contaminated parts to be touched while repairing should be cleaned and sterilized a precautionary measure of the greatest importance Only after cleaning and disinfecting should repairs be carried out A Attention Wear Gloves before repairing the Instrument and decontaminate Microlab STAR prior to taking an y action A Attention before executing any preventive Maintenance empty and decontaminate deck panels A Attention The following Parts may have sharp edges where infringements are possible when not enough attention is paid e Decks under side where slide Blocks are pushed through deck e Electronic covers Cutaways gt above PCB s Fan etc e Magnet Band edges Position Reader Pipetting Arm X Drive 9 1 Microlab STAR Service Manual 9 2 Items Needed Description P N Microlab Detergent amp Disinfectant Kit 281242 Microlab Disinfectant Spray Kit 281243 Microlab Disinfectant St
101. arter Kit 281245 e Service Kit Microlab STAR 173970 Tools e g Adjustment Tools Grease e Cleaning Paper Towels e Microlab STAR Verification Kit 182501 or 182502 with 182503 and 182506 9 2 1 Duration For an 8 channel Microlab STAR it will take approximately 4 to 6 hours to perform a complete maintenance as described below Refer to section 12 2 2 Maintenance Checklist on page 12 11 for a list of items which the Service Technician has to check on the instrument being serviced 9 2 2 Tasks Refer to section 9 5 Half yearly Maintenance on page 9 5 for each Task that should be carried out 9 2 Microlab STAR Service Manual 9 3 Decontamination Spray Carriers and Waste Station with Microlab Disinfectant and wipe them off Clean Deck and loading trays the same way Carefully clean Pipetting Heads Tip Coupling Ejection Tubes with a cloth soaked with Microlab Disinfectant A Attention Do not spray directly onto the Channels or inside the Pipetting Arm Cover as this may damage the Instrument The Covers of the Microlab STAR may by cleaned either by spraying Microlab Disinfectant directly onto surfaces or by wiping them with a cloth soaked with Microlab Disinfectant A Attention Transparent Covers will become stained and clouded if they come into contact with Liquids containing propyl alcohol 24 Microlab STAR Instrument with Autoload Option only 9 3 Microlab STAR Servi
102. ce Manual 9 4 Lubrication Generally lubricate as sparingly as possible Avoid the possibility of grease falling from the spindles as this can badly affect the samples Torque tension thing screws 4 400621 1x20 Ncm 1 Of Pipetting Heads NT N Dispensing Y lt Squeezer Spindle NW 182105 182106 However only if N squeezer nut is brass N A otherwise do not N lubricate i 173330 173520 254167 409103 Shown here is A Chonnel 4 400602 with Pipetiing 173332 5511071 B tighten Torque tension ft ng screw 10 Nem Stop Disk Procedure is as follows set the spindle moving up and down using Service Software then use a paper or cloth to wipe off old grease N Attention Do not use any liquids such as Acetone or alcohols as these may damage the Pipetting Head Housing A Attention Touch Spindles gently Ensure spindles are completely dry and then apply a thin layer of Topas Grease 9 4 Microlab STAR Service Manual 9 5 Half yearly Maintenance Action Available Program 1 Decontaminate and clean exposed Surfaces Deck e Docking Station Loading trays e Instrument Covers e Pipetting Arm housing e Autoload ribbon e Trays Air filter replace if necessary N A A Attention e Do not grease Y Spindles Pipetting Arm Do not use any Clea
103. changed and printed via service software only It is highly recommended that a copy of the current Technical Data Sheet be held by the Service Technician for his own reference 1 see in section 12 4 3 Firmware Reference Guides on page 12 19 2 10 Microlab STAR Service Manual 2 2 2 Computer Requirements Minimum requirements Compatible with Windows NT Windows 20007 and Windows XP Operating Systems CPU with at least 450 MHz Processor approx 1 GB HDD and minimum 64 MB of RAM SVGA Monitor resolution min 600 800 Keyboard Mouse CD ROM Drive 3 5 HD Floppy Drive Serial port s at least 1 USB or RS232 for the ML STAR Instrument Optional requirement Printer port 2 2 3 Software Requirements These Operating Systems can be used for the User and Service Software Windows NTTM Version 4 0 or higher and Service Pack 5 or higher Windows 2000 or Windows Ongoing updates of User and Service Software may also require Operating System updates The Microlab STAR software installed on one PC controls one Microlab STAR instrument Microlab STAR Service Manual 2 3 Service Part Classifications Spare Part Class SPC Description Instrument Service Technician always has these parts with him Dealer has parts in stock Hamilton has parts in stock Service Tools Consumables N lt J l O J 0l gt Accessories Not a Spare Part
104. clean surfaces of deck underneath and electronic chamber cover e Clean Flat Band Cables Groove and ensure collision free movement of Flat Band Cables All belts drives and cables for any damage loose screws e Distance of X measurement Reader Pipetting Arm to magnetic Band Remove Autoload ribbon and check N A For signs of liquid spillage underneath e f necessary decontaminate and clean surfaces of Autoload ribbon underneath e Clean Flat Band Cables Groove and ensure collision free movement of Flat Band Cables All belts drives and cables for any damage or loose screws Microlab STAR Instrument with Autoload Option only dito Microlab STAR Service Manual Half yearly Maintenance continued For signs of damage e f necessary decontaminate and clean Needles e Replace damaged Needles Action Available Program 8 N A e Autoload ribbon e Deck Panels e Pipetting Arm 9 and Adjust Adjustment is done dem in accordance with Pipetting Arm section 6 Adjustment e Pipetting Channels and Calibration on e Autoload pages Verify instrument with verification kit Verification Program Perform a test run N A 10 Check all available Carriers N A For signs of liquid spillage and damage e f necessary decontaminate and clean Carriers e Ensure smooth gliding on Deck Panels and Loading Trays e Replace damaged carriers 41
105. cros Measurement Macro Programs do not change any Calibration values The Software Program provides values which may not exceed the given tolerance e Calibration Macro Programs define new calibration values current values are first deleted by the execute program Note Adjustment Macro Programs must finish completely without errors to confirm that the Instrument is adjusted Adjustment state 1 initialized and ready to operate General notes In case of a program interruption if the program cannot be completed successfully e g due to power failure or user interaction switch the instrument off and then on again to reset the macro program action automatically This action is necessary to avoid the complete loss of calibration values If itis not then possible to start or complete any program ensure that the CO RE O Rings do not remain squeezed as this may reduce their life time significantly A Attention Ensure all Macro Programs once started are correctly completed Only this will leave the Microlab S TAR Instrument within a defined status Note files from the Adjustment Disk CD must be installed The following files are necessary however must not be started independently e g by the Service Technician ABORT MCR e NIX MCR e START MCR A Attention Pipetting Channels complete with Pipetting Heads must be mounted and adjusted properly before running any Adjustment Macro Program 6 11 Microlab
106. ction Step selection Instrument extensions Barcode settings Error settings Barcode settings Communication settings Instrument configuration Communication settings Communication settings Instrument configuration C RS232 Number of channels 8 Default waste Channel type 300 Channel type 1000ul Autoload Teaching Mode Teaching box Keyboard C Both Teach with channel no s Hamilton Microlab STAR Configuration Editor Instrument Simulator Step selection Instrument extensions Barcode settings Error settings Communication settings Instrument configuration Communication settings Com COM1 4 18 Microlab STAR Service Manual 4 2 5 4 User Software settings ML STAR IVD e Select ML STAR Menu Tools gt ML STAR Configuration Editor Advanced Hamilton Microlab STAR Configuration Editor Hamilton Microlab STAR Configuration Editor Select mode for instrument Microlab STAR 4 Select mode for instrument Microlab STAR About About Instrument Instrument Hel Simulator Hep Simulator Hep Save k Exit Save amp Exit lt lt Advanced Exit lt lt Advanced Select Instrument Exit Step selection Instrument extensions Barcode settings Error settings Communication settings
107. d 39 Refer to section 1 10 Contacting Hamilton on page 1 8 12 17 12 4 Appendix D Microlab STAR Service Manual 12 4 1 Microlab STAR Firmware Addresses e Master Module e drive Pipetting Arm Module Pipetting Channel e Auto Load Module e Temperatured Controlled Carrier e Wash station iSwap 12 4 2 Microlab STAR CO XO P I0 T W RO Firmware Files where 0 is the number zero where 0 is the number zero where is 1 to 9 and A to G where 0 is the number zero where is 1 or 2 where is 1 or 2 where 0 is the number zero Firmware file Description e GRUCOS ACH Firmware for Master Module Pipetting Arm X drive Module included e GRUPXS ACH Firmware for Pipetting Channels e GRUALS ACH Firmware for autoload drive e GRUTXS ACH Firmware for Temperatured Controlled Carrier e GRUWXS ACH Firmware for Wash station e GRUROSE ACH Firmware for iSwap Where is the current Version of firmware 12 18 Microlab STAR Service Manual 12 4 3 Firmware Reference Guides 12 4 3 1 Master Module Command Specification File the corresponding Firmware reference guide after this page 12 19 Microlab STAR Service Manual 12 20 Microlab STAR Service Manual 12 4 3 2 X0 Module Command Specification File the corresponding Firmware reference guide after this page 12 21 Microlab STAR Service Manual 1
108. dditionally to the Microlab STAR instrument e g a locked front window a panel in the back a different waste station either 8 or 12 Pipetting Channels and special carriers It runs only with the IVD User Software ML STAR software user software which controls the Microlab STAR instrument ML STAR IVD software user software which controls the Microlab STAR IVD instrument MTP Microtiter plate The terms Microplate and Microtiter plate MTP mean the same and are also referred to simply as plate In general we assume a plate with 96 wells 8 x 12 Pause Interruption of processing The current processing steps are completed The processing can be continued PC Personal Computer Pipetting Transfer of liquids from one container to another Pipetting arm Assembly consisting of pipetting channels as well as the common X drive and arm housing Pipetting channel Hardware part which moves onto pipetting arm in Y and Z direction and carries pipetting head Pipetting head Pipetting device on pipetting channel P N Part Number Programmer The user programming the methods for the Microlab STAR IVD instrument Precision repeatability and reproducibility of e g Pipetting Rack A rack is a template describing a discrete number of positions for the containment of containers or tips Examples of racks include a tube rack a microtiterplate a microtiter strip a deep well plate and tip racks 12 4 Microlab STAR Ser
109. density tolerances The minimum code densities depend on the bar code type and bar code length Minimum module width including a print tolerance of 0 0005 0 0065 inches 0 1651 mm Print Quality The bar code print must be of high quality according to USS Uniform Symbol Specifications defined by AIM U S A Offset typographic intaglio and flexographic printing are suitable Mechanical dot matrix and thermomatrix printing are not suitable The label surface may be treated sealed or plastic covered Print Contrast Signal PCS Minimum contrast between bars and spaces PCS 80 PCS at 632 8 nm Wavelength Positioning of Barcode labels measured from Deck Range on Tubes 30 110 mm Centerline on Plates 118 mm 2 9 Microlab STAR Service Manual Technical Specifications continued General Note on Drive Specifications The User Interface is the Master where all units are 0 1 mm in length and volumes are 0 1 Hl The master transfers the User s software commands to its slaves and therefore you do not have to know drive resolutions when calculating positions volumes etc 2 2 1 Technical Status of ML STAR Instrument Technical Status contains all technical data specific to each instrument It must be updated by the Service Technician whenever any modifications are made Technical Status information is stored on the EEPROM of components of ML STAR Instrument and may viewed
110. dure Place the Carrier onto the deck an left one onto the Instrument d mount only one loading tray say the Pull the carrier out to the loading tray and check for height and parallelity between carrier and tray A parallel gap indicates an ideal adjusted loading tray 6 44 Microlab STAR Service Manual Loading tray adjustment continued mm _ this least on the angle to deck underneath outer edges of the loading tray to Height Adjustment remove loading OEE POPE loading and unloading of carriers tray and raise or lower black table adapter Angle Adjustment with the loading tray mounted and the Carrier placed as shown in picture turn screw underneath loading tray in or out and fix it then with the hex nut Replace the loading tray by the other one and follow the instructions above Finally with both Loading trays mounted ensure both are adjusted onto the same height Especially check for Track 28 in the Middle of the Instrument and perform an automatic loading and unloading step using the Software 6 45 Microlab STAR Service Manual 6 8 4 Automatic Autoload Adjustment Procedure Positioning of Cog wheels in X Y and Z Direction and Sensors Adjustment Start Macro Program AUTOLOAD AUTOADJUSTMENT MCR from Service Software and carefully follow the instructions given in the program Follow ex
111. e 1 squeeze CO RE O Ring menu movements sensors pipetting channels squeezer drive 2 perform a cLLD measurement menu gt control single commands send PXALalllc0 then connect stop disk of Pipetting Channel X with ground for a short moment e g use a conductive cable between stop disk and deck Then send command PXRN the response should then be PXRNid rn1 gt LLD detected 3 If itis PXRNid rn0 then the Squeezer does not squeeze enough or the O ring may be worn out or else the pipetting head or Channel is defective Switch Pipetting Heads and repeat procedure If this eliminates the problem on that specific position replace the Pipetting Head If no Improvement it may indicate that the Channel is defective and must be replaced Pipetting Head pLLD problems Ensure disposables Tips are not being reused Run a method with a Tip pickup an aspirating step and Tip eject Check then the LLD Trace files from Service Software Switch Pipetting Heads and repeat procedure If this eliminates the problem on that specific position replace the Pipetting Head If no Improvement it may indicate that the Channel is defective and must be replaced 10 11 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Pipetting outside volume 1 Run Volume Verification specifications Autoload Step loss In General try to run the specific drive with se
112. e Customer s responsibility to prepare the operating PC for remote access Ensure only read access is enabled e Overview Steps Responsibility 1 Provide Infrastructure for Remote LAN manager at Customer site Access e g RAS Server 2 Setup Account for Service engineer LAN manager at Customer site e g HamService 3 Setup Share on ML STAR IVD PC LAN manager at Customer site or PC Administrator 4 Setup Access rights for Service LAN manager at Customer site or PC engineer on ML STAR IVD PC Administrator 5 Means of Connection e g Telephone LAN manager at Customer site number Account name and Password for Service engineer e Steps 1 and 2 are not elsewhere specified because they are dependent on Network infrastructure at Customer site Step 3 is described below Step 4 refer to section 4 2 5 5 Defining Access Rights ML STAR IVD on page 4 20 ff Then Select Lab Remote Service from Local Users and Groups Step 5 must be determined together with the LAN manager 4 24 Microlab STAR Service Manual Defining Remote Access continued Step 3 Setup Share 3 1 Select Hamilton e g C Program files Hamilton and right click on Sharing OOOO File Edit View Favorites Tools Help lt Back gt search Ca Folders 6 GE X Ed Address a Hamilton gt e Go Folders x
113. e front and side shields ML STAR IVD Instruments have an additional shield toput in place at the back of the instrument N Attention Side Panels must be flush with the outer edges of Instrument After mounting check to ensure there is collision free Pipetting Arm movement Carefully move the Pipetting Arm by Hand Microlab STAR Instrument with Autoload Option only Microlab STAR Service Manual 4 2 3 2 Power Voltage Using an Uninterruptible Power Supply UPS is highly recommended The mains plug is on the left hand side of the instrument towards the rear fuses for the instrument are situated under the mains power switch Plug in the mains cables for the computer and the instrument into the same electrical outlet A Attention Connect only to an earth grounded outlet Voltage selector Attention For safety reasons ensure that the appropriate Fuse is placed into the mains power switch before switching on the instrument Fuses P N 363012 Delayed action FUSE 3 15 A for 230 V P N 363013 Delayed action FUSE 6 3 A for 115 V See section 2 2 Technical Specifications on page 2 6 Microlab STAR Service Manual 4 2 3 3 Communication Two different types of serial Interfaces RS 232 and USB have been defined since the Microlab STAR has been on the market Note ML STAR IVD Instruments run only with the USB serial Interface Connect the serial cable to the plug on the left
114. e t es eee ed eee eed 2 12 2 3 2 Exchange for Parts and Assemblies sese 2 12 2 4 ML STAR SERVICE KIT P N 173970 2 13 2 4 1 Service Tool Maintenance nnne 2 14 2 5 DISPOSAL OF ML STAR INSTRUMENTS 2 14 SOWA Ormana AIL eoe 3 1 3 1 OVERVIEW CO Mer RT PO HH HH HH ij 3 1 3 1 1 How to Install the Service Softlware 3 1 3 1 2 Service Software Root Directory structure 3 2 3 2 STARTING THE SERVICE SOFTWARE 3 3 HELP MENU asta ar ED ue eb c ec a ay n dune OP bebo eod 3 6 3 4 DEINSTALLATION OF SERVICE SOFTWARE 3 7 4 Installation of the instrument 4 1 4 1 OVERVIEW s sr ro pn Ap Qn a Qn aS e en d iet T 4 1 4 1 1 Installation Qualificato u su suu uuu inu iyi y ai uy ayy 4 1 4 1 1 1 Microlab STAR Installation Qualification 4 2 4 1 1 2 Microlab STAR IVD Installation Qualification
115. ecommended that you Back up Methods User defined Labware Liquid classes etc before removing current software N C Program Files HAMILTON loj xl Edit View Favorites Tools Help e x Back Forward Up Search Folders History Move To Copy To Delete Undo Views Address a C Program FilesiHAMILTON Folders Size Type Modified Attributes 1 24 HAMILTON File Folder 07 02 2002 17 06 Bin k config File Folder 07 02 2002 17 06 CJ Config HAMILTON C Graphic File Folder 07 02 2002 17 06 C Graphic Cl Labware File Folder 07 02 2002 11 42 CJ Labware Select an item to view its Language File Folder 07 02 2002 11 42 C Language description Library File Folder 07 02 2002 17 06 u Library Sun abo CLodfiles File Folder 08 02 2002 10 38 Logfiles C Methods File Folder 08 02 2002 17 55 C Methods My Documents j My Network Places STARService File Folder 08 02 2002 14 54 CJ STARService C swaPpservice File Folder 15 01 2002 16 57 C SWAPService My Computer EC InstallShield Installa C 461069C6D C8 C 4843A18C3 96F 4pnrn2cFn 491 7 4 10 object s Disk free space 5 61 GB 0 bytes 5 My Computer 2 Microlab STAR Service Manual User Software Deinstallation continued Select START 3 SETTINGS 3 SYSTEM 2 ADD REMOVE SOFTWARE and search for ML STAR as well as for PHOENIX C
116. el Arm Plate Handler Is a mechanical device that can pick up hold and release microtiterplates and that can transfer them between different locations on the deck of the Microlab STAR Labware Refers to movable items to be placed on the Microlab STAR IVD deck such as carriers containers or racks LED Light Emitting Diode LIMS Higher level data processing system generally known as Laboratory Information Management System also LMS Liquid Includes all kinds of liquids among which are included reagents controls standards LLD Liquid Level Detection Detection of liquid surface which may be achieved either by pressure or capacitive signal detection Loading unloading The process by which carriers are brought on to the work surface of the Microlab STAR This happens automatically by means of the Autoload unit Method The method contains all instructions as to how the content of the source vessels is to be processed The assignment of the vessels to positions happens virtually however in the deck layout definition MAD Monitored Air displacement means Aspiration is monitored Microlab STAR The Microlab STAR instrument with pipetting arm deck Autoload and optional extensions such as iSwap Washing Station and temperature controlled Carrier The Number of Pipetting Channels may vary from 4 up to 16 12 3 Microlab STAR Service Manual Glossary continued Microlab STAR IVD The Microlab STAR IVD has a
117. ence mcr until passed Y 606826 Arm X Difference mcr until passed Y 606828 PIP XY Manual Adjustment mcr Y Perform mechanical positioning adjustment according to result values 606828 PIP XY Manual Adjustment mcr if values are far out of tolerance then mechanical 2 improved ng adjustment with adjustment tools must performed yes Y 606825 Arm Z Difference mcr VC untl passed yes Y 606826 Arm X Difference mcr Y until passed 606827 PIP Autoadjustment mcr v 606828 PIP XY Manual Adjustment mcr Y 606867 Instrument Check mcr Y no passed yes adjustment sucessful 6 4 Microlab STAR Service Manual 6 2 Adjustment Tools and Macro Programs 6 2 1 Tools for Pipetting Arm and Channels Tool Description Channel Adjustment Tool P N 173952 For mechanical Channel Adjustment on Pipetting Arm Must be used for preadjustment whenever a Channel is replaced in Order to mount the new channel on the Pipetting Arm Predefines e Parallelity alignment Z Direction in functional dependence on X and Y Axis e Linearity alignment of all Channels in Y Axis Channel Calibration Tool P N 173960 Z Tool P N 173968 Reference for Pipetting Arm Alignment Adjustment and Pipetting Channel Calibration Together with the Adjustment
118. eplace only those Parts which are labeled as Spare Parts The Pipetting Arm Replacement Assembly is an adjusted assembly which is not intended to be serviced in the field so do not loosen any screws or parts which are not labeled on the drawing 7 22 Microlab STAR Service Manual 7 6 Pipetting Arm X Drive P N 250007 P N 413008 P N 258129 P N 182111 P N 258130 P N 405082 P N 250045 Fixing screws P N 400640 y belt tension screw P N 400077 Optical Switch for initialization _ Position Primary Drive Secondary drive belt tension unit Belt tension Tighten Belts however do not over tighten them do not use excessive force Optical Switch for initialization Position Sheet metal P N 173380 with Screws P N 400025 OS PIPETTING ARM X INIT P N 173864 with Screws P N 400262 7 23 Microlab STAR Service Manual Pipetting Arm X Drive continued 0 3 0 2 mm 7 6 1 Part List Reader shoulder E 4 M magnetic band system Gap between Reader P N 173895 and magnetic band P N 396011 must be at least 0 3 0 2 mm Magnetic band is self adhesive and is positioned on the shoulder in the chassis Description 173380 OS HOLDER 173864 PIPETTING ARM X INIT 182111 REPLACEMENT X MOTOR 250007 BEARING ID 8 AD 16 18 B 6 A 250045 BEARING ID 15 AD 35 11 A 257056 SPACER PI
119. eplaced Order of Adjustment Follow strictly the order of adjustment 1 Cog wheel synchronization 2 Loading tray adjustment 3 Automatic Autoload Adjustment Procedure 6 8 1 Autoload drive degrees of freedom 6 41 Microlab STAR Service Manual 6 8 2 Cog wheel synchronization To enable loading and unloading cog wheels must be synchronized Remove Ribbon from Autoload Drive to gain access to Flag wheel Move Autoload drive to a arbitrary Track Position Then place Autoload Calibration Tool cog bar onto the same Track and turn Flag wheel by hand to raise cogwheels up Note If both cogwheels fit perfectly in Autoload Calibration Tool cog bar no corrective action need take place 6 42 Microlab STAR Service Manual Cog wheel synchronization continued With the Autoload Calibration Tool in place loosen both Set screws from front cogwheel and make cogwheels properly fit into Autoload Calibration Tool cog bar by raising cogwheels up until the Autoload Calibration Tool is 3 just raised Then Tighten both Set screws from front cogwheel before removing Autoload Calibration Tool Cogwheels are now synchronized 6 43 Microlab STAR Service Manual 6 8 3 Loading tray adjustment For a proper loading and unloading of Carriers Adjustment By using a Sample Carrier or any other carrier check for height and parallelity to deck Proce
120. er side as shown here on the left covering cap The cap when mounted will then fit snugly on the Autoload drive The covering cap shown here on the right is before modification The ribbon on the right side of Tighten and align the ribbon by turning Autoload drive is to be mounted as in set crews P N 400262 shown above Carefully move the Autoload drive by Note the aluminum thread bar is hand from side to side and adjust wrapped by the ribbon ribbon for a proper movement Service Software for Autoload drive movement may also be used A Attention Do not overtighten the ribbon as this may lead to autoload x movement steps lost Adjustment After replacement run the necessary Adjustment procedures as described in section 6 Adjustment and Calibration on page 6 1 7 45 Microlab STAR Service Manual 7 9 3 Part Numbers for original and replacement Parts Note Original equipped Microlab STAR instruments Autoload drive comes with the following Part Number Label on Autoload drive P N 173309 Ordering The replacement Autoload drive must ordered by Part Number P N 182107 The Label on replacement Autoload drive will show Part Number 173309 7 10 Auto Load P N 250045 P N 413005 P N 173855 N 258053 AZZ lt 258134 Fixing screws P N 400640 P N 173856 P N 400653 19 Microlab STAR Instrument with Autoload Opt
121. erification reports Functional Test Run Inspect instrument and accessories for ship Run demo method 3 Operator s Manual ping damage or missing parts Service Software Use packing list to verify contents If any nent items are missing contact Customer Service ve edem mp Hooking up the Instrument Set up the instrument Connect communication and power cables If included inspect install extensions No iSWAP Yes AVS Yes Un install service software Documentation tion reports to this IO form Customer Summary Q Explain how to request technical and service No assistance Install tip waste chute and container Address any other concerns Recommended Uninterruptible Power Supply Comments UPS installed Yes Software Installation ML STAR IVD software Service software U Set up user groups Remote access Yes Instrument Check Procedure Perform instrument check procedure P N 610886_85 2002 10 31 Labware definitions of carriers No Attach instrument configuration and verifica No Customer Acceptance Date Installed by Date HAMILTON Bonaduz AG 12 9 Microlab STAR Service Manual 12 10 Microlab STAR Service Manual 12 2 2 Maintenance Checklist Decontamination and cleaning OK REMARKS of all exposed surfaces Deck n Docking Station n Loading trays n Instrument Covers r
122. erve them from any damage Plug in and fold Cable remount cable cap and brush strip or docking station as the case may be A Attention Do not push cable into whole of deck panel due to avoid damage through X Arm drive 7 13 7 4 3 Pipetting Arm housing 173568 173557 Microlab STAR Service Manual lt j 173609 _ 173607 Y YN 473559 173615 420560 7 14 Microlab STAR Service Manual 7 4 3 1 Part List 173555 PANEL 173557 SIDE PANEL LEFT 173559 SIDE PANEL RIGHT 173568 COVER 173607 H PROFILE 173609 PANEL 173615 FRONT PANEL 420560 SCREW M4X10 A2 ISO7380 7 4 3 2 Function The function of the Pipetting Arm Pipettes Liquids e Accommodates the Channels with the Pipetting Heads from 4 up to 12 Channels Enables Y Movement for the Channels e Carries a Cover which e Protects the Channels guide shafts and spindles from dust e Security for the user prevents physical contact with the channels e Moves in X Direction driven by the Pipetting Arm X Drive 7 15 Microlab STAR Service Manual 7 4 3 3 Replacement Lift Top Cover P N 173568 off Side panels P N 173557 amp 173559 Top Cover Side panels and H bars P N 173607 fit snugly into place together H bars may remain on Side panels or on Top Cover Remove Front panel P N 173615 by unscrewing 4 Screws P N 420560 Hint Front panel may be used as screw holding place for further
123. esponding pipetting Channel is now frozen by the Channel positioning tool the position of the channel may now be corrected The 2 locking and the 2 fixing screws of the Pipetting Channel must loosened first 6 34 Microlab STAR Service Manual Corrective Actions continued For tilting the Pipetting Channel around Y Axis Release lever of channel positioning tool by unscrewing knurled screw then tilt channel After the Pipetting Channel is corrected tighten the lever of channel positioning tool first and then retighten the 2 fixing and the 2 locking screws of the Pipetting Channel Remove channel positioning tool and continue running the PIP XY MANUAL ADJUSTMENT MCR to verify improvement of alignment For shifting the Pipetting Channel in X Direction Choose the appropriate shift stop to shift the pipetting channel then loosen the opposite shift stop completely By turning the adjustment screw clockwise the channel positiong tool will move together with the pipetting channel towards adjustment screw After the Pipetting Channel is corrected retighten the 2 fixing and the 2 locking screws of the Pipetting Channel Remove channel positioning tool and continue running the PIP XY MANUAL ADJUSTMENT MCR to verify improvement of alignment 6 35 Microlab STAR Service Manual Corrective Actions continued The macro PIP XY MANUAL ADJUSTMENT MCR continues as follows All Pipetting Ch
124. etting Arm in positive X Direction counterclockwise X Axis 6 28 Microlab STAR Service Manual Corrective Actions continued e Just untighten the 8 fixing screws and push or pull the arm by the back to its appropriate position and tighten the 8 fixing screws Note Do not push or pull the Pipetting Arm from the Front to align in X Direction so as to avoid a shift which could prevent proper adjustment Hysteresis e Verify the current position by running the Adjustment Program again and iterate if necessary After completion of Alignment check distance between Pipetting Arm Positioning Reader and the Magnetic Tape underneath the deck Refer to section 7 6 Pipetting Arm X Drive on page 7 23 A Attention Ensure Reader is not touching Magnetic Tape On the other hand the gap should not be too great 6 29 Microlab STAR Service Manual 6 5 Adjusting Pipetting Arm with Channels Overview After readjustment with the Channel Adjustment Tool and Macro programs only a slight tilting around Y Axis should be necessary By using the upper Fixing screw as a pivot point open it up just a very little bit untighten the lower Fixing screw and push or pull the Channel by its Pipetting head around the upper Fixing screw axis Now the Pipetting Arm with its channels can be adjusted using the Channel Adjustment Tool and the Macro Program Service Software Adjustment has to be done by hand as described above the
125. eviation on second Level A Attention Do not loosen fixing screws to much as this would lead to an uncontrolled shift or move restart with the Channel Adjustment procedure is then inevitably 6 32 Microlab STAR Service Manual Corrective Actions continued Using the Channel positioning Tool P N 182960 Note Y Spindle may remain in place Place the Channel positioning Tool onto Pipetting Arm and move it in Y Direction towards the channel to be corrected The goal is to take over the current position of the channel in question and freeze its position with the Channel positioning Tool After the Channel positioning Tool is attached to the channel start tightening it The clamps of the Channel positioning Tool should hold the channel tight then fix the Channel positioning Tool with the two knurled fixing screws onto the rail Clamps and Knurled fixing screws of positioning Tool 6 33 Microlab STAR Service Manual Corrective Actions continued Stabilize Channel positioning Tool by attaching the bracket onto the opposite side of the pipetting arm Fix Bracket with the knurled screw Finally tighten the two shift stops on the rod and use the corresponding adjustment screws to ensure a play free system ready to tilt and shift the pipetting channel The two stops on the rod can be fixed by tightening the knurled screws Since the current position of corr
126. ews again see Picture on previous page e Verify the current position by running the Adjustment Program again and iterate if necessary 6 23 Microlab STAR Service Manual 6 4 3 Pipetting Arm X Alignment Overview The Pipetting Arm and Channels can be adjusted using Channel Adjustment Tool as Reference and Adjustment Macro Program Service Software Adjustment has to be done by hand the Adjustment Macro Program only provides measurement values and helps you to align the Pipetting arm Note The Adjustment may be performed once the Pipetting Channels are preadjusted and the Pipetting Arm Z Alignment is performed Preliminary actions Hint Run the Adjustment Program before uncovering the Pipetting Arm After the first run decide if any corrective Action must take place e Uncover the Pipetting Arm completely see section 7 4 3 Pipetting Arm on page 7 14 to access the 8 fixing screws P N 400047 in the back e First remove side Panels then both buffers from the ML STAR Instrument Chassis Run the following macro program together with Channel Calibration Tool P N 173960 e ARM X DIFFERENCE MCR 8 Fixing screws Uncovered Pipetting Arm view from Uncovered Pipetting Arm view from behind the front left Note the above mentioned Fixing screws may occur as setscrews with hex nuts and washers 6 24 Microlab STAR Service Manual Pipetting Arm X Alignment continued Slide on two Pipett
127. fore starting the replacement of assemblies the instrument has to be uncovered Disconnect the instrument first from the main power Then follow the instructions below This section has the character of a top down structure and starts with uncovering of panels A Attention Never switch on an ML STAR Instrument while any electrical cables are not plugged in e g a pipetting head not mounted onto its channel as this may destroy an electronic component such as a complete Channel 7 2 Replacement of Components Update Data with service Software when one or more of the following Assemblies Components are being replaced 300 and 1000 ul Pipetting Head Channel e Autoload Drive e Extensions such as iSwap washing station temperature controlled carrier For Data input refer to section 3 Service Software on page 3 1 ff After replacement update or upgrade run an installation qualification according to section 4 Installation of the instrument on page 4 1to verify the functionality of the ML STAR Instrument Note file store technical data with Service Software before replacing any part When sending a defective part for repair to Hamilton Bonaduz AG attach a copy of its technical data for investigation 7 1 Microlab STAR Service Manual 7 3 Components overview monitored Front window Pipetting Arm Waste Station 7 3 1 ML STAR Deck panels Docking station or Brush strip 552 2
128. hand side of the instrument and to the corresponding serial interface on your personal computer Cables e USB P N 355130 RS 232 P N 173898 Connecting scheme of RS 232 cable Male Plug to Instrument Female Plug to computer Note older ML STAR Instruments have RS 232 interface only if both serial interfaces are available the USB serial interface should be selected A Attention Do not connect RS 232 and USB together if both serial interfaces are available select either one or the other 4 12 Microlab STAR Service Manual 4 2 3 4 Tip Waste station There are two different types of tip waste station Regardless which one is being used Tip waste station is always located on the right side of Instrument and uses the hole cutout in the deck panel Microlab Star Microlab Star IVD The Microlab Star Tip waste is a container which is placed onto the deck It is positioned on the deck by placing it through the hole in the deck panel Plastic Bags which come with the disposable tips may be folded around upper rim and fixed with the tip waste lid LA A e add t UM b gt f Y 3 4 The Microlab Star IVD waste must be mounted with its clamps onto the deck It must lie flush with the outermost row of slide blocks on the right and with the carrier stops in the rear Plastic chute may folded around the metal frame and guided vertically
129. ice software 1 1 Microlab STAR Service Manual 1 1 1 ML STAR Descriptions in this Manual often refer to Microlab STAR instrument with Autoload Option Disregard such references if the instrument to be serviced is a Manual Load Microlab STAR 1 1 2 ML STAR IVD Additional Information for the Microlab STAR IVD instrument will be found in each chapter where components procedures are different from or additional to the basic Microlab STAR instrument However since the ML STAR IVD is not yet on the market at the time of writing further changes must be expected Once the ML STAR IVD is available there will be a Service Manual update as well 1 1 3 ML STAR Extensions By Extensions we mean assemblies such as the Temperatured Controlled Carrier Wash Station and iSwap These components may ordered as an option or later on as update kits when there is a need to upgrade an existing ML STAR Instrument in the field 1 1 4 Description of text icons for special notes Attention notes are included in this manual to emphasize important and critical instructions They are accompanied by an exclamation mark symbol above the notes and are printed in italics Here is an example Attention All special problems warnings or important text will be accompanied by this symbol at the appropriate point in the manual Items marked Note or Hint provide useful additional information Carefully read these text items as you will find them i
130. iel dbombis hamilton ch hamilton ch H amilton Bonaduz amp ccounting amp Fin Boomsma Wanda wboomsma amp hamilton ch hamilton ch Medical Users Logistics Borner Roland rborner hamilton ch hamilton ch H amilton Bonaduz Marketing Instrum El Brehm Francois fbrehm hamilton ch 7 When the Lab Operator List is complete with all Users then click OK otherwise click Add Lab Operator Properties 2 x General lt Lab Operator Description Jany method They must not modify any method definition Members HAMILTON fbrehm fbrehm hamilton ch HAMILTON Subrodbeck ubrodbeck hamilton ch labor Remove OK Cancel Apply 4 22 Microlab STAR Service Manual Defining Access Rights continued Repeat Steps 4 to 7 for the Users of the following Groups Group User Lab Method Programmer Method programmer Laboratory Manager Lab Service Service Engineer Check the successful installation by logging the specified Users on A Attention Users who have not been registered in this way cannot operate the ML STAR IVD Software not even LAN Administrators The following error message is displayed in the case of unauthorized access attempts Hamilton Method Editor 63 Access is denied Check your user group and privileges with your administrator 4 23 Microlab STAR Service Manual 4 2 5 6 Remote Access It is th
131. ignment the condition of being in satisfactory adjustment and having the parts in proper relative position Aspirate Aspirate is the activity of sucking up liquid by a pipetting device Autoload Autoload is an assembly enabling automatic loading and identification of carriers onto the Microlab STAR Autoload tray Hardware unit On it the carriers can be placed and held outside the Microlab STAR IVD The loading tray is attached to the Microlab STAR IVD to support the automatic loading and unloading process AVS Automated Vacuum System Barcode Mask The barcode mask defines the basic structure of a barcode It is a pattern to which a barcode must conform The assignment of a specific labware item can be done this way The barcode mask can require a barcode to contain specific strings at fixed positions It can contain wildcards too Barcode Reader Part of the Autoload unit Calibration all operations for the purpose of determining the values of a deviation from a theoretical axis 12 1 Microlab STAR Service Manual Glossary continued Carrier A carrier is a template describing a discrete number of positions for locating labware items such as racks or containers A carrier is the only labware item that can be placed directly on the deck Container A container is a vessel for holding fluid including tubes microwells reagent containers etc Container identification Barcode for identification of containers Ser
132. ing Arm Alignment Tools P N 173956 to both sides of Pipetting Arm and gently attach with the adjustment screws The Pipetting Arm may be slightly tilted around Z Axis to align in X Axis Fixing screws of Pipetting Arm should be slightly loosened beforehand Uncovered Pipetting Arm view from the front left with Pipetting Arm Alignment Tools P N 173956 attached The Stop Bars on both sides of ML STAR Instrument are turned out of their original Positions to enable the Pipetting Arm Alignment Tools P N 173956 to be slid on the X Guide Uncovered Pipetting Arm view from the front right A Pipetting Arm Alignment Tool P N 173956 attached to the right side of Pipetting Arm 6 25 Microlab STAR Service Manual Pipetting Arm X Alignment continued Adjustment Before starting the Adjustment Program relieve any stress on the Pipetting Arm by moving it several times in X Direction Use Service Software and let it perform approximately 10 full length strokes in X direction to ensure a neutral positioning of Pipetting Arm Firmware version f 56 2001 11 08 i Initialize pipetter Status 0 Parallelity level 0 0 Download FLASH EPROM error B Parallelity level 1 0 FLASH EPROM checksum error 0 Parallelity level 2 0 RAM test error Download mode 0 EEPROM checksum error Stop 0 EEPROM com error p Single step mode 0 Test mode Cover sensor J Voltage 24V 24 1 V Voltage 40V 41 V mv
133. ion only 7 46 Microlab STAR Service Manual Auto Load X Drive continued Viewpoint is here from inside ML STAR Instrument to the back of the belt tension 1 Screw Secondary drive with belt tension screw P N 420580 Belt tension Tighten Belts however do not over tighten them do not use excessive force 7 10 1 Part List 173855 SM Auto Load X Drive 173856 250016 250045 258053 258134 400640 400653 CYL SCR M3X6 DIN912 A2 TUFLOK 405445 SET SCR M3x8 DIN916 SET SCR M3x8 DIN916 413005 LOCK DISC 4 DIN6799 420580 CYL SCR 4 50 DIN912 TUFLOK 7 10 2 Function e Carriers the Autoload and moves it in X Direction 7 47 7 10 3 Replacement Microlab STAR Service Manual Description DC Motor Loosen Belt of secondary drive disconnect DC Motor P N 173855 cable from Autoload PCB and then remove Primary Drive Assembly 3 screws M4 x 10 P N 400640 Loosen Belt of primary drive 2 screws M3 x 6 P N 400653 and remove DC Motor from sheet metal Primary drive belt Cog belt MXL Z 83 x 3 16 P N 258053 See DC Motor Additionally loosen 2 set screws P N 405445 from big cock wheel remove lock disc P N 413005 then remove axle and large cog wheel Secondary drive belt Cog belt SYN FLEX 10 T2 5 3065 P N 258134 Loosen Belt secondary and remove belt from Autoload drive claw 7
134. ips picked up Measurement Macro Program AUTOLOAD AUTOADJUSTMENT MCR With Autoload Calibration Tool 173975 and Autoload Sensors Adjustment Tool 173980 Calibrates positioning in X Y and Z Direction automatically after mechanical Cog wheel synchronization Checks Barcode reading Cup Presence sensor adjustment and the quality of Carrier loading and unloading Calibration Macro Program Additionally for ML STAR IVD Tightness check procedure With waste block 185281 and user Software ML STAR IVD Especially after replacement of CORE O Rings the tightness of seal on each Pipetting Head may be checked PIP PRESSURE SIGNALS CHECK M CR and PIP PRESSURE SIGNALS AUTOADJ USTMENT MCR With waste block 185281 and pressure Transmitter the values for TADM may be checked and adjusted 6 13 Microlab STAR Service Manual 6 3 Adjusting Pipetting Channel This is to ensure all Channels are aligned towards Y Axis and are parallel to each other towards Z Axis Using the Channel Adjustment Tool you can adjust all Channels after replacement of any parts belonging to Channels pipetting heads etc The Adjustment is of a mechanical nature When a Pipetting Channel is replaced or due to bad adjustment values Adjustment is required The Pipetting Channel with its Pipetting Head has a number of degrees of freedom Degree of freedom Action Reference 1 Tilting around X Axi
135. mage the Y slide of Pipetting Arm When the channels are stored temporarily e g into the Microlab STAR Service Kit Unsecured storage may bend the Z guide irreparably out of shape The same could happen during crashes where movements of the Pipetting Arm in X and or Movements of the Channels in Y collide with an obstacle eg due to imprudent use of Service Software 7 28 Microlab STAR Service Manual 7 7 3 Replacement Before a Pipetting Channel is replaced all data from the channel should be printed out or saved to a file Use the Service Software for this printout see section 3 Service Software on page 3 1 e Uncover Pipetting Arm see section 7 4 3 Pipetting Arm on page 7 14 Remove Y Spindle P N 173446 Remove M4 Hex nut Turn Y Spindle out by Hand If it is too tight use an adjustable wrench to get it loose Cross flats will be found on the front of the Spindle Carefully remove Y Spindle from Pipetting Arm Take care not to scratch coated thread Remove Cable holders on desired Channel since these will be used again e Disconnect and remove 2 Cables Y motor and communication cable on desired Channel e Loosen the 4 screws which connect channel with Y Slide e Carefully remove Channel from Pipetting Arm A Attention Whenever it is necessary to move Channels on Pipetting Arm move them gently by pushing close to their Y Slide Never force them as this may lead to damage
136. ment Channel A 182104 Replacement Channel o gt D 3 gt 12 6 9 Pipetting Head List SPC 12 41 Microlab STAR Service Manual 12 6 10 Autoload Part List O O D P N 173297 173845 Description PINION MXL Z 32 LOAD X CONNECTOR 173849 173874 173875 CABLE X MOVEMENTS DM ROTATOR DRIVE HS H V POSITION gt gt gt 173878 05 TUBE DETECT 173879 SCANNER B 182274 COVER RIGHT C 250016 258140 281401 400262 403452 403453 403499 409200 BALL BEARING ID 6 OD 13 15 COG BELT MXL Z 90X3 16 COVERING CAP SCREW M3X6 SUNK SCREW M3X6 DIN7991 SUNK SCREW M3X8 SUNK SCREW M4x30 DISC M3 12 6 11 Autoload s X Drive Part List gt gt 420580 CYL SCR M4X50 DIN912 TUFLOK 12 42 Microlab STAR Service Manual 12 6 12 Insertion Guide Part List PIN 173292 INSERTION GUIDE 173293 173299 173300 173729 INSERTION GUIDE END 173747 173843 400617 CYL SCR M2 5X5 DIN912 403452 5 SCREW M3X6 DIN7991 z OU eo i 12 6 13 Loading tray Part List PIN 173600 173602 173700 HOLDER W OVAL BORE 173701 182112 182113 400026 403453 403453 408006 HEX NUT 4 DIN934 o gt 12 6 14 Tip Waste Part List SPC 173736 WASTE CONTAINER IP WASTE LID 173738 WASTE HANDLE 420561 TORX SCREW M5x12 gt 12 43 Microlab STAR Service Manual 12 6 15 Spillage Trays Part List P N
137. mportant for understanding the topic or command in question 1 2 Microlab STAR Service Manual 1 2 Structure of this Manual This Service Manual contains all that the Service Technician requires in order to carry out regular servicing of the Microlab STAR instrument and repairs as and when required It consists of 12 chapters Chapter 1 Introduction Chapter 2 Microlab STAR Instrument Chapter 3 Service Software Chapter 4 Installation of the instrument Chapter 5 Disassembly Chapter 6 Adjustment and Calibration Chapter 7 Components Chapter8 Electronics Chapter 9 Maintenance Chapter 10 Troubleshooting and Error Handling Chapter 11 ML STAR Extensions Chapter 12 Appendices e Chapter 1 serves as an introduction to the manual as a whole Chapter 2 serves as an introduction to the Microlab STAR instrument e Chapters 3 10 contain the servicing instructions e Chapter 11 contains the servicing instructions for the Temperature Controlled Carrier Wash Station and iSwap e Chapter 12 contains all appendices 1 3 Microlab STAR Service Manual 1 3 Service Manual Updates As the instrument or parts of the instrument are constantly being improved this Service Manual will be updated regularly Each Service Technician will be sent update sets and is responsible for keeping his Service Manual up to date Necessary instructions on how to do this will be included in the update set On receipt of an update follow the
138. n 4 27 Microlab STAR Service Manual 4 2 6 2 Automatic Adjustment Only if results from instrument check procedure are out of range perform an automatic Calibration by using the Channel Calibration Tool and Adjustment Program PIP AUTOADJUSTMENT MCR All Calibration values will be newly defined according to the current state of the Instrument If any corrective action must take place refer to section 6 Adjustment and Calibration on page 6 1 4 2 7 Weekly Maintenance ML STAR IVD Run the Weekly Maintenance procedure from User Software 4 2 8 Verification Run the Volume verification Verification Kit 4 2 9 Performing a test run For general information on how to create a Method refer to the User Manual Create a Method for Tip Pickup Aspirating Dispensing and Tip Eject Observe the precision of movements especially during Tip Pickup Decide if the Instrument is ready to run or if any corrective action must take place For example if Tips are not picked up or only after several tries Firmware error handling adjust and calibrate the Pipetting Arm and Channels For Instruments with Autoload Option extend your Method with a loading and unloading Step involving the Tip Rack Carrier If during loading or unloading the instrument reports any Steps lost calibration must take place 4 2 10 Service Software Removal After successful installation remove Service Software from Customers PC Generally see section
139. n X Axis Is the movement Axis of Pipetting Arm Channel Calibration Tool with Macro Program 3 Tilting around Y Axis 4 Moving on Y Axis Adjustment is generally not possible 5 Tilting around Z Axis Movement on the two X slides in the back is Channel Calibration Tool and Pipetting Arm accomplished by turning adjustment screws from Alignment Tool with Macro Program Pipetting Arm Alignment Tool 6 Moving on Z Axis is accomplished by moving the Front Guide Bar of Channel Calibration Tool with Macro Program Microlab STAR Instrument along Z Axis 6 19 Microlab STAR Service Manual Adjusting Pipetting Arm continued A Attention Guides in X and Y Direction must not be bent and must ensure a parallel movement to the corresponding axis The two box section frames of Pipetting Arm which are the reference to the guides in Y Direction must also be straight and parallel together Ensure a proper mounting onto its X slides 6 20 Microlab STAR Service Manual 6 4 1 Pipetting Arm degrees of freedom Pipetting Arm Fixing Screws When both Pipetting Arm Alignment Tools are in place loosen 8 fixing screws in the rear for tilting around Z Axis Note The Z Axis to tilt around will then be in rear This aligns the Pipetting Arm parallel to Y Axis the X Coordinate will then be the same for the front and the rear of Pipetting Arm Front Guide Bar Not displayed here B
140. n on tubes and plates etc Check Barcode Reader settings in User Software Perform an Autoload Adjustment answer Would you like to setup the barcode scanner parameters with yes and check the laser beam positions with the autoload sensors adjustment tool Ensure no external light source is affecting the Barcode Reader while it is reading barcodes If no improvement replace Barcode reader No Carrier Presence detected _ Carriers do not move completely to carrier Stop Perform an autoload adjustment Carrier s Magnet is defective broken wrongly mounted or lost Replace Carrier The Carrier Sensor Board is defective Check for loose Plugs in any of the 7 segments and replace 10 4 Firmware Error Codes See section 12 4 3 Firmware Reference Guides on page 12 19 ff for the firmware error codes 10 13 Microlab STAR Service Manual 11 ML STAR Extensions Here the ML STAR Extensions Manual may be filed 11 1 Microlab STAR Service Manual Microlab STAR Service Manual 12 Appendices Generally Copy checklist lists and forms for multiple use 12 1 Appendix A 12 1 1 Glossary Access Right the specific permission needed by a user to carry out a certain function with the ML STAR software Accuracy a quality which characterises the closeness of an indicated value of a measuring instrument to the corresponding true value Adjustment Detailed positional setting for the hardware Al
141. nd on Check for correct node settings dip switches Start Download again if need be Check all cables are plugged in properly Perform Auto Adjustment then switch off ML STAR Instrument shut down Service Software and wait at least 10 sec Then switch on ML STAR Instrument and start up Service Software Start Download again if need be Switch off ML STAR Instrument shut down Service Software and wait at least 10 sec Then switch on ML STAR Instrument and start up Service Software The EPROM is defective Assembly e g PCB or Channel where Flash Eprom is built in must be replaced errors Ensure all Parameters are defined such as cycles adjustment status technical status etc Flash EPROM errors typically after download of new firmware Pipetting Channels Run Macro SET EEPROM PX DATA MCR 10 5 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Flash EPROM errors typically after download of new firmware Autoload Drive Run Macro SET EEPROM 10 DATA MCR Flash EPROM E EPROM errors Note After running of the above mentioned Macros switch ML STAR Instrument OFF and then ON Method on PC runs without any action on instrument Check Configuration Settings in user Software and switch from simulation to instrument mode Configuration misma
142. nels and iSwap if available with care Remove left deck panel see section 7 4 2 Deck Panels on page 7 7 For the following removals Refer to section 7 6 Pipetting Arm X Drive on page 7 23 e X Drive Flag P N 173608 e Pipetting Arm belt claw P N 173606 Pipetting Arm measurement carrier P N 173605 Disconnect Cable first A Attention Do not bend or kink X Movement Cable e Unscrew 8 fixing screws P N 400047 from carriage main guide in the back and then carefully remove Pipetting Arm from instrument Note the 8 fixing screws may occur as setscrews with hex nuts and washers Setscrew P N 405092 hex nut P N 173459 washer P N 173458 17 Extension 7 19 Microlab STAR Service Manual Remounting Instructions are the reverse of those for disassembly lead caster onto front guide bar and mount Pipetting Arm with 8 fixing screws to rail slides remount Pipetting Channels iSwap if available Adjust Pipetting Arm according to section 6 4 Adjusting Pipetting Arm on page 6 19 Adjust Pipetting Channels according to section 6 3 Adjusting Pipetting Channel on page 6 14 Cover Pipetting Arm 1 20 Microlab STAR Service Manual 7 5 4 Pipetting Arm Replacement Frame PIN 182108 11381 7 21 Microlab STAR Service Manual 7 5 4 1 PartList 1702 29 CABLE CUIDE DMI Tha 173491 GUIDE 173536 REINFORCING ANGLE BRACKET e PROTECTIVE RING C 281281 TRACKROLLERD 16 1 1 B A Attention Remove or r
143. ning liquids other than on Spindles to remove old grease Avoid any contact with the CO RE O Ring as this may shorten its life span 2 Uncover Pipetting Arm Check Cable connections onto Pipetting Channels e Check and clean Y Spindle on Pipetting Arm Spindle must not be greased at all If needed e g when step losses in Y occurs Silicon oil may used to apply a thin layer onto the Y Spindle N A 3 On Pipetting Heads Replace CO RE O Rings Check Stop Disk s check for any scratches blocked bore or visible damage and replace if such is the case Check Tip ejection Tube s check against contamination and damage Ensure it glides smoothly For replacement Procedures refer to section 7 8 Pipetting Heads on page 7 32 Microlab STAR Instrument with Autoload Option only dito 9 5 Microlab STAR Service Manual Half yearly Maintenance continued Action Available Program On Pipetting Heads clean and only slightly grease e Squeezer Spindle only with brass nuts e Dispensing Spindle Service Software Single Commands or Movements Sensors Clean and slightly grease guide shafts X Guide Pipetting Arm front and rear Service Software Single Commands e X Guide Autoload Movements Sensors Remove Deck Panels and check N A e Forsigns of liquid spillage underneath deck and inside electronic chamber If necessary decontaminate and
144. nnel Pipetting Head Autoload drive or the Master PCB is removed or replaced run the appropriate Adjustment Macro Program from the Service Software and decide if any corrective action needs to be undertaken After delivery of the instrument run the check program and only perform an adjustment if values are out of range Adjustment and calibration is also needed when problems occur e g in running an application Channel positioning Tip pick up and ejection or when Steps are Lost and corrective action is indicated After any adjustment and calibration the functioning of the component concerned must be verified to ensure a properly working Microlab STAR Instrument A Attention before starting any Adjustment and Calibration Work empty decontaminate deck panels e g remove all Carriers and Labware from deck Conditions All Guides in X Y and Z Direction must be straight i e may not be bent and must ensure a parallel movement to the corresponding axis If pipetting heads are replaced ensure a proper mounting onto channels The first three degrees of freedom of the Pipetting Channel must be perfectly adjusted before running any Adjustment Program Typically when a Pipetting Channel is replaced or when bad adjustment values indicate the requirement of any corrective actions 10 Microlab STAR Instrument with Autoload Option only 6 1 Microlab STAR Service Manual 6 1 1 The Art Principle of Adjusting To
145. nstructions are basically the reverse of those for disassembly using Service Software Data may restored if copied from replaced Master PCB Check Master settings e Check for correct Firmware 8 3 5 Adjustment e tis highly recommended that you run the autoadjustment PIP AUTOADJUSTMENT MCR to generate new calibration values for X Drive Pipetting Arm 8 14 Microlab STAR Service Manual 8 4 Pipetting Channel 8 4 1 Pipetting Channel Block Diagram jel Digitel Input je M Driver Af I 1 F Analog Input SEXSSGRTER Microlab STAR Service Manual 8 4 2 Pipetting Channel Wiring Diagram
146. ntenance procedure Verification Q Volume Q Print out verification reports Functional Test Run Run demo method 3 Operator s Manual Service Software Print out instrument configuration Q Un install service software Documentation Q Attach instrument configuration and verifica tion reports to this IO form Customer Summary Explain how to request technical and service assistance Address any other concerns Comments Customer Acceptance Date Installed by Date HAMILTON Bonaduz AG Microlab STAR Service Manual 4 2 Installation 4 2 1 Workplace environment The Microlab STAR is a product which pipettes liquids and dilutions of liquids Some of these latter may well be temperature dependent Therefore it is important to choose a location in the laboratory where the Microlab STAR will not be exposed to unusual temperature variations such as near a window heating duct or air conditioning duct Depending on the Microlab STAR configuration used your Microlab STAR may weigh up to 155 The Microlab STAR must be placed on a table or workbench capable of supporting the weight of the Microlab STAR and providing the minimum space needed The table or workbench has to be strong enough to support the weight of the instrument and stable enough to absorb the vibrations caused by the acceleration of the pipetting arm movement Note ML STAR IVD uses a tip waste chute Therefore ensure an app
147. nutzerhandbuch Acrobat Reader 5 0 HAMILTON AR Service gt Microlab STAR Se jd internet Explorer Uninstall Microlab STAR Service 000 Professional A eg yz r3 Windows Startup for Service Software Start gt Programs HAMILTON Microlab STAR Service gt Microlab STAR Service 3 3 Starting the Service Software continued From Desktop Shortcut File Edit View Favorites Tools Help Microlab STAR Service Manual _ m eu DIO Up Search Folders History am Move To Copy To Delete x Undo Views Address ja C Program Files HAMILTON STARService 4 0 Wi lt 47 c9 Folders 2 17 Name Size Type attributes Desktop T M Li CJFirmware File Folder 15 01 2002 16 57 H A My Documents Cnr File Folder 30 01 2002 11 40 My Computer STARService info File Folder 08 02 2002 07 35 8 28 3 Floppy Language File Folder 30 01 2002 11 40 5 99 Local Disk C STARService exe macros File Folder 07 02 2002 14 28 a D3DTEMP Application File Folder 15 01 2002 16 57 C Documents and Settings Modified 03 12 2001 10 13 test File Folder 15 01 2002 16 57 dataz cab 3885 KB Winzip File 26 04 2001 15 52 RA hamilton Size 888 KB HxThreadAndSyn 48KB Application Extension 16 03 2001 15 11
148. o left Pipetting Arm s left upper Y Guide shaft Fix the channel adjustment tool in between the Pipetting Arm s upper Y Guide shafts with the knurled screw and ensure play free positioning Do not forget to check adjustment tool alignment onto Pipetting Arm s upper Y Guide shaft Preliminary actions A Attention Exercise care when moving the Pipetting Arm and or the Pipetting Channels Move them gently to the desired position To gain access to the Pipetting Channels uncover the Pipetting Arm see section 7 4 3 Pipetting Arm on page 7 14 The 2 Panels in the back may remain on the Pipetting Arm e Carefully unscrew and remove Y Spindles P N 173446 complete with Washer P N 173499 and Nut 408006 from Pipetting Arm Refer to section 7 4 3 Pipetting Arm on page 7 14 Note The Y Spindles must be removed due to the fact that too much friction from the Y drive mechanism hinders a proper alignment between the Channel s Z Guide and the Channel Adjustment Tool reference grooves 6 17 Microlab STAR Service Manual Pipetting Channel Alignment continued Mechanical Adjustment procedure 1 2 3 Carefully move the Pipetting Arm to a desired position the deck Uncover Pipetting Arm and remove both Y Spindles Place Pipetting Channel Adjustment Tool P N 173952 as shown onto Pipetting Arm s upper Y Guide shafts approximately in the middle of Pipetting Arm Gently move Pipetting Channel Z Guide shaft into Adjustmen
149. om Hamilton P N 612554 See Appendix on page 12 16 HAMILTON Bonaduz AG reserves the right to refuse any returned parts or instruments which may pose a health hazard due to contamination and to charge the customer for any expenses incurred Please ensure that the tag is filled in correctly Describe the problem as precisely as possible Attach all information available such as trace files and technical data for investigation Either a printout hardcopy or files on floppy disc are suitable 1 7 Microlab STAR Service Manual 1 9 Feedback Information from the field is a determining factor for improving Hamilton products Communicate your observations to Hamilton Bonaduz AG so that we may continue to provide a quality product and service Our Hotline will support you on any problems you may encounter 1 10 Contacting Hamilton Europe Africa and Asia Hamilton Bonaduz AG Technical Support P O Box 26 CH 7402 Bonaduz Switzerland Phone 41 81 660 60 60 Fax 41 81 660 60 70 Hotline 41 81 660 60 50 E mail itechsupport hamilton ch Americas Far East and Pacific Rim Hamilton Company P O Box 10030 Reno NV 89520 0012 USA Toll Free 1 800 648 5950 Phone 1 775 858 3000 Fax 1 775 856 7259 E mail tech hamiltoncompany com 1 8 Microlab STAR Service Manual 2 Microlab STAR Instrument 2 1 Overview Microlab STAR X mm The Microlab STAR is a Sequential Transfer and Aliquoting Robo
150. omponents and remove them if still present Pra 2222222 La e Currently installed programs Sort by Change or 23 Adobe Acrobat 5 0 Size 12 4MB Remove Programs Corel Uninstaller Fiery Downloader Size 628KB Bl McAfee VirusScan Size 19 1MB Add New Microlab STAR Size 3 22MB Programs Used occasionally Last Used On 07 02 2002 N To char ge this program or remove it from your computer Change Remove click Change Remove Add Remove Windows Microlab STAR Service Size 1 84MB Components Close After deinstallation of User Software ensure that no more components are left on the PC If PHOENIX and Microlab STAR Components are not able to be removed then select run from start menu and type in regedit to enter the registry section of the PC s operating system Select HKEY LOCAL MACHINE 3 SOFTWARE and delete remaining Phoenix and or Microlab STAR Folder 5 14 Microlab STAR Service Manual 6 Adjustment and Calibration 6 1 Overview Adjustment and calibration are an important part of the installation procedure and may also be required following maintenance and repair work The purpose of adjustment and calibration is to ensure that all pipetting channels are using the same set of coordinates and moving in the same space It guarantees the best performance for tip pick up and pipetting in very small wells Whenever a Pipetting Arm Pipetting Cha
151. on Guides on the left side and disconnect cable screws P N 403499 View from above Removed Insertion Guides and disconnected cable to gain access to Autoload drive 1 42 Microlab STAR Service Manual Removal continued View from above The Autoload drive is connected with a total of 6 screws P N 400632 onto 2 sliding carriages 4 screws onto the right and 2 screws onto the left sliding carriage The belt clamp is mounted with 2 screws P N 400010 onto the autoload drive and must be disconnected as well 3 screws are involved however the middle screw is to remain in place Through the hole unscrew two screws P N 400653 holding sheet metal and removing it then unscrew four slide screws P N 400632 underneath sheet metal Sheet metal away from aluminum block 2 of the 4 slide screws 7 43 Removal continued Microlab STAR Service Manual Finally unplug cable P N 173874 from Autoload drive and carefully lift assembly out of instrument View from right to left underneath Autoload drive Hint carefully lift Autoload drive assembly a little bit in the rear to gain better access to the cable plug 7 44 Microlab STAR Service Manual Reassembly Instructions are basically the reverse of those for disassembly Hint for easier removal of covering caps modify them Cut away two spring catches 1 p
152. on each side then the 2 remaining screws Replacement continued e Cover Switch HS Cover Control P N 173860 i r hand on left vertical post to access HS Screw P N 400619 Cover Control To replace Cover Control it is necessary to remove left Deck Panel and Autoload ribbon See section 7 4 2 Deck Panels on page 7 7 and section 7 9 Auto Load drive on page 7 37 Side Panels Simply loosen 6 screws P N 420560 per Panel and gently move them out of their sockets It is not necessary to remove any screw at all A Attention To avoid any damage to Panels do not use extensive force during removing or mounting them Handle with care Covering Instructions are the reverse of uncovering Take care to avoid scratches 14 Microlab STAR Instrument with Autoload Option only 7 6 7 4 2 Deck Panels Deck Panels left and right h rz ES x K lt 7 4 2 1 Part List Description 173378 173288 CONTACT PLATE 420010 CYL SCR M2 5X8 DIN912 A4 420074 CYL SCR M4X16 DIN912 A2 7 7 7 4 2 2 Function The Deck Panels provide the reference grid for Carriers as well as Pipetting Channels Using Slide Blocks and Carrier Stops the Working area is divided into 55 Tracks These components are responsible for correct and precise positioning and smooth transport of all Carriers The Carrier Sto
153. ormation 10 2 Microlab STAR Service Manual Investigtation of Errors with Trace files continued Focusing on the higlighted section of the above window we can see the following As seen from the editor Commands lt 16 36 28 976 8AF 8000 00 C0DIid0046xp13400 amp yp4050 3925 3800 3675 3550 3425 3300 3175 3050 2925 2800 2675 2550 2425 2300 2175tp1970tz1870te2450tm1 amp lt 16 36 35 395 8AF 8000 00 COHDid0047 gt 16 36 35 405 8AF 8000 00 COHDid0047er00 00 gt 16 36 44 638 8AF 8000 00 CODlid0046er99 00 X003 00 Command from PC to Instrument CODI a typical Initialize command Command from PC to Instrument COHD Return Message from Instrument to PC COHDid0047er00 00 Return Message from Instrument to PC CODlid0046er99 00 X003 00 Note Always check for the complete command which may include several lines in the Trace File Editor to gather all information In this case the Master CO has sent a general Initialize Command DI for his Slaves refer to Firmware reference Guide Command Specifications Master Module Disregard any Identification Number e g id0081 While initializing a Halt command has been sent which command interrupted the initialize The Slave is Pipetting Arm X Drive XO with Error 03 which is Command completed refer to Firmware reference Guide Command Specifications XO Module In this case the method could have been aborted by the user
154. ovement of Pipetting Arm Arm e Check Collision free movement of Channels Pipetting Arm x Pipetting E Drive EC Pipetting Arm x E x X Position P Arm Flag x x x Channel x x _ _ x Pipetting Head x x x x Stop Disk _ x x CO RE O Ring x x x x 6 49 Microlab STAR Service Manual Verification after replacement or remounting continued Autoload Adjustment Volume Functional check PINT DOTTED Instrument Auto Autoload adjustment ESI TEL Check adjustment Autoload drive E Incl all of its components Autoload X drive _ 2 S x Insertion Guides _ 2 Loading E Le 6 50 Microlab STAR Service Manual Verification after replacement or remounting continued Electronically Adjustment Volume Functional check Instrument Auto Autoload adjustment MES TEL Check adjustment Master PCB x x a Autoload PCB E x x Main Switch 2 E B x Power distribution Extension Board Power supply B Cables 6 51 Microlab STAR Service Manual 7 Components 7 1 Overview All mainly mechanical Components of the Microlab STAR are listed below In this section will be found a description of functions how to replace Assemblies or single parts and a list of part numbers Be
155. petting Channel Alignment issu tete te nete dede tte ute du d daten 6 17 6 4 ADJUSTING PIPETTING ARM tee t e eto ERN e hn t kk k Eee er KK KK KRA 6 19 641 Pipetting Arm degrees of freedom 6 21 6 4 2 Pipetting Arm Z Alignment LLLL LL eene heben eene 6 22 6 4 3 Pipetting Arm X Alignment 6 24 6 5 ADJUSTING PIPETTING ARM WITH CHANNELS 6 30 6 6 CALIBRATING ARM WITH CHANNELS 6 37 6 6 1 Pipetting Channel Positioning Check LLD Check 6 38 6 7 PRESSURE ADJUSTMENT VALUES OF TADM ML STAR IVD 6 39 68 ADJUSTING AUTOLOAD DRIVE ER Een HH ka HE TR e ka k Eia SHE 6 40 6 8 1 Autoload drive degrees of freedom 6 41 6 8 2 Cog wheel synchronization eese eene 6 42 6 9 3 Loading tray adjustn nt aoreet tob b ka aka b KEVA 6 44 6 8 4 Automatic Autoload Adjustment Procedure 6 46 6 9 VERIFICA TION ue ted ted ua is MuR usu E 6 47 6 9 1 Volume Vetmcalloli elephant aptis 6 47 6 9 2 Verification IUS Soccooeoo eoe Da Don D end eU 6 47 6 9 3 Verification after re
156. placement or remounting 6 48 COMPONENIS a 66 ehla 7 1 SOVERWIBMW uuu ee ie mou pube esos ome deed eiie epe gar r r 7 1 7 2 REPLACEMENT OF COMPONENTS 1 seen 7 1 73 COMPONENTS OVERVIEWN e e ES aie m KK KK KK KAKA 7 2 Microlab STAR Service Manual mod MESTAR sz avane enya NUS bd VERe k n he PP a bake ne NN 7 2 722 MESTAR suyu anasu mu ua 7 3 74 COVERS OF THE MICROLAB 5 2 7 4 7 4 1 Front Window and Panels left amp right 7 4 TAAT D rr ea b T e mm 7 4 452 EUDClOD 7 5 7 4 1 3 Replacement cei t td LAYA aA le S iet LA k S a n ba Res 7 5 Deck UU ete Akar AA A Ana ANA SAN 7 7 722 14 iS IG n u sutin Susa a p De T 7 7 14 22 FUNCION n eet entere hr eie ke Feb cete aane Lea Pd Ee eka 7 8 7 4 2 3 ted ae e RT 7 8 fob JuUpelng Arm houSIng ide Cove binl W kal de eee htl donde ben du e 7 14 74539217 SPAM e Uber ni recte 7 15 1 4 3 272 FUNCION Oo ttt ttti A n xe bk Ee ur busua dek 7 15 1433 Replacemient ricette rete ree DE toO EHI E GARAN G HA D
157. ps in the rear detect presence of carriers and that they have snapped into place The stops also ground Carrier to Instrument The Docking Station in place of the Brush Strip enables customers to extend the ML STAR Instrument with options such as Wash Station temperature controlled Carriers Automated Vacuum System etc A Brush Strip located between the Carrier Stops and the X Guide Shaft covers over the trough and prevents dust and e g disposable Tips from falling into ML STAR Instrument 7 4 2 3 Replacement Described in this section is the replacement of Docking Station or Brush Strip Carrier Stops Deck Panels Slide Blocks A Attention All Carrier Stops and Docking Station Brush Strip must removed before Deck Panels can be removed e Docking Station Brush Strip Remove either Docking Sation P N 182283 or Brush Strip P N 173194 with its sheet metal whatever the configuration of the ML STAR Instrument is by removing 4 screws P N 400302 from Deck Panels 7 8 Replacement continued Carrier Stops Unscrew and remove Plug Cap P N 173354 Screw P N 420074 on the left hand side of Carrier Stops disconnect Cable P N 173858 from Carrier Sensor Board and push Cable with Plug through the hole in the deck e Then completely unscrew and carefully remove all Carrier Stops in the rear Screws P N 420074 N Attention Do not break any plugs from Carrier Sensor Board located on Ca
158. r ordered Check the packing list The items from these boxes must mounted on the Microlab STAR Instrument as a part of the installation N Attention Items for ML STAR and ML STAR IVD may vary therefore ensure correct parts are being used when setting up the Instrument Back Panels only for ML STAR IVD Instruments available 4 6 Microlab STAR Service Manual 4 2 2 2 Accessories Accessories i e carriers needles and Consumables i e tips must be ordered by the user For ordering information refer to the User Manual N Attention Accessories for ML STAR and ML STAR IVD may vary therefore refer to the according User Manual ML STAR or ML STAR IVD 4 2 2 3 Packing List The Packing List will be found inside one of the Accessory boxes Check the contents carefully against it 4 7 Microlab STAR Service Manual Unpacking the instrument continued 3 Square Foams 2 Accessories Boxes 2 U shaped holding bars 2 Z shaped blocks 4 8 ETC E Microlab STAR Service Manual Unpacking the instrument continued Initial situation the ML STAR Instrument is still sitting on the wooden pallet Next action is to remove the Pipetting Arm s supporting and protective Foam blocks Therefore untie cords around Pipetting arm housing then remove Pipetting Arm s Top and front housing Channel protection foam blocks between Channels Pipetting Arm supporting Block iSwap p
159. reach an optimum with adjustment the concept Degrees of freedom must be understood e Tilting around axis means rotating or turning around a specific axis e Moving an axis means parallel shift on that specific axis It is absolutely necessary to follow the order of adjustment and iterate an adjustment procedure until the criteria are met If iteration is not successful start adjustment again from the very beginning 6 1 2 Interpretation of correction values A correction Value of 7 means a necessary shift of 7 Units away from the direction of the coordinates And a correction Value of 16 means a necessary shift of 16 Units in the direction of the coordinates For coordinates refer to section 2 1 Overview on page 2 1 Microlab STAR Service Manual 6 1 3 Order of adjustment and calibration 1 Adjustment of Pipetting Channels and Heads e Befor running any adjustment program Pipetting Channels with their heads must be properly mounted and adjusted with Channel Adjustment Tool P N 173952 onto Pipetting Arm 2 Adjustment of Pipetting Arm e Adjust Z alignment parallel to deck X and Y Axes by moving the front guide bar on the left and right side up or down as appropriate e Adjust X alignment to deck perpendicular to Y Axis by tilting Pipetting Arm around Z Axis on its slides in the back 3 Calibration of Pipetting Arm with Channels After adjustment of Pipetting Channels and Pipetting Arm all Pipetting
160. removed before Slide Blocks can be replaced First it must be ensured that no broken parts have fallen inside instrument and second proper remounting is only possible when Deck Panels are placed onto appropriate supports Remove damaged or broken Slide blocks and replace with new ones Connect two Slide Blocks together push them into square hole in deck and finally push a Slide Blocks Wedge to wedge the replaced parts into position A rubber Hammer may be used to gently tap the Slide blocks into place 7 Slide Blocks P N 173600 j L N Slide Block wedge P N 173602 173602 Preassembled Slide blocks with wedge Z 113600 Attention Deck Panels may damaged warped if they are not placed onto appropriate supports when remounting slide blocks Avoid bending during mounting slide blocks e g by using a rubber hammer 7 12 Microlab STAR Service Manual Covering of deck panels Instructions are the reverse of those for uncovering Remember to guide Carrier Sensor Board Cable through left deck panel first Guide deck panels as well as Carrier Stops into their positioning pins or holes as required A Attention Do not bend sheet metal tongues of the Carrier Stops in the rear otherwise Carriers won t snap in correctly See section 7 4 2 3 Replacement on page 7 8 Note Start put Carrier Stops in place on Deck Panels working from right to left Carefully connect them together so as to pres
161. rive or function is defective replace the Channel 7 27 Microlab STAR Service Manual 7 7 2 Function To reach a grid pattern of 9 mm two different Channels A amp B are used in the Microlab STAR All A Channels use the upper guide shafts and therefore all B Channels use the lower guide shafts on the pipetting arm Note The left and the right side of the Pipetting Arm have each upper and lower Y guides for the Pipetting Channels to travel on The Pipetting Channel carries the pipetting head which performs all Pipetting Steps The following features are implemented in the channel e Independent Z and Y movements The limitations in Y direction are due to the neighbouring Channel e Carries both types of Pipetting heads 300 and 1000 ul e All A and all B Pipetting Channels are universal and may be individually addressed with dip switches see section 8 1 6 Node settings on page 8 5 Each channel has its own u Controller and its own CAN Address which may individually set Note This means every A Pipetting Channel may be placed onto every A and every B Pipetting Channel may be placed onto every B Position A Attention As mentioned before and after Handle with care when servicing touching handling the pipetting Channels Avoid applying any direct or indirect force to any guides Special attention must be given to when the channel fixing screws must be loosened or tightened for adjustment reasons as this may da
162. ropriate work bench so that a waste container may be placed underneath the waste area of the ML STAR IVD when installing the Instrument For proper ventilation leave at least 5 cm space between the Microlab STAR and any wall Ensure that there is collision free movement of the Pipetting arm Access to the mains connector and the mains switch located on the left hand side of the Microlab STAR should not be hindered The Microlab STAR should be located within easy reach of a standard electrical outlet 1 socket for the Microlab STAR 1 for the computer 1 for the monitor and 1 each for any other products daisy chained to the main one e g UPS Other considerations include operator comfort and easy access to needed supplies and equipment Finally the position of the Microlab STAR must not hinder operation or accessibility of other equipment in the work area Space for waste container underneath workplace if waste chute is being used Weight 155 kg Workplace 3 i e without extensions If you are or will be using extensions with your ML STAR instrument we recommend a stronger table or workbench capable of supporting the additional weight 4 4 Microlab STAR Service Manual 4 2 2 Unpacking the instrument The Microlab STAR comes in a box on a wooden pallet Examine the packaging for signs of damage If there is any damage contact the shipper or your Hamilton representative immediately Lift off the top and sur
163. rotection block Channel supporting block Carefully remove all protective foam blocks from between channels Remove pipetting arm supporting block from the front Carefully remove channel supporting block from underneath pipetting arm If iSwap is present untie it from the back of Pipetting arm and carefully remove its protective block 4 9 Microlab STAR Service Manual 4 2 3 Hooking up the instrument 4 2 3 1 Putting the Instrument in place Using the lift points in the Chassis lift the Microlab STAR off the pallet and put it on the desired table or workbench in the laboratory Refer to section 4 2 1 Workplace environment on page 4 4 when deciding where it should go A Attention Given the weight of the instrument it will take at least 4 people to lift it After placing the Instrument in its final position on the workbench or table check and if necessary adjust the feet of the Instrument so that it stands evenly It is recommended that you check the Channels cable connections With the Pipetting Arm uncovered see section 7 4 3 Pipetting Arm on page 7 14 check the cable connections on the Pipetting Arm and Pipetting Channels visually and by hand in case they have become loose during shipment Check the Y Motor and communication Cable connection on each Channel for proper fit Cover the Pipetting Arm mount Side Panels place Spillage Trays Tip Waste station and Loading Trays onto the Instrument Attach protectiv
164. rounding cover Note the Form Unpacking Instructions will be found inside the ML STAR packaging on top of the Instrument The Instructions will mainly guide through the unpacking procedure as described below The Instructions form describes packing the ML STAR Instrument as well For general packing Instructions see section 5 Disassembly on page 5 1 Remove all Panels from top of accessories boxes then remove accessory boxes and examine the Instrument and all parts against damage Leave the protective material in place until the Microlab STAR has been placed in its permanent position A Attention Do not turn Barcode Reader by hand as this may damage the DC Motor If the Barcode Reader must be turned use the Service Software or remove the outer covering to access Gear and turn on cogwheel or belt instead See section 7 9 Auto Load drive on page 7 37 4 5 Microlab STAR Service Manual Unpacking the instrument continued Instrument on pallet without top and surrounding covering Note Instrument Panels such as side and back Panels are placed on top of Accessories boxes To avoid any damage such as scratches remove Instrument Panels from top of accessories boxes and store them until they are to be assembled Remove the two Accessories Boxes and their supporting foam blocks 3 square blocks and 2 z shaped blocks 4 2 2 1 Accessory boxes The contents of these two boxes can vary depending on what the custome
165. rrier Stops while removing Carrier Stops from Deck Panel Start removing Carrier Stops from left to right 7 9 Replacement continued Do not bend any parts of Contact Plate sheet metal Tongues of Contact Plate must be as close as possible to Replace Carrier Stop solid piece Replace Carrier Stop P N 182118 solid piece Contact Plate P N 173288 sheet metal Carrier Sensor board P N 173833 3 Screws P N 420010 holding Carrier Sensor board on Replace Carrier Stop 7 10 Microlab STAR Service Manual Replacement continued Deck Panels Replacement Deck Auto Load IFA PPAR Tiree oppi i R EK AA A b Bt b P N 182115 PIN 182114 FAA A An b Aa AA AA a ab j a al j a i 1 l l l li PERS E P Note only Deck Panels for ML STAR Instruments with Autoload Option may ordered as replacement parts Microlab STAR Service Manual Replacement continued Unscrew Deck Panels 4 screws P N 403491 each panel and remove them A Attention Before removing Left deck Panel note presence of of Carrier Sensor Board Cable Note Store Deck Panels on appropriate surface and prevent from damage i e protect slide blocks e Slide Blocks Note Deck Panels must
166. rts the run when the window is opened 2 3 Microlab STAR Service Manual 2 1 2 ML STAR IVD The Microlab STAR IVD is foreseen to be used in an in vitro diagnostic environment e g for blood analyses and DNA analytics Typical applications are e Sample preparation for ELISA RIA FIA agglutination and tests e Preparation for amplification techniques for DNA detection e Sample archiving and pooling 2 1 2 1 Total Aspiration and Dispense Monitoring TADM The Microlab STAR IVD is equipped with an additional safety feature the pressure based Total Aspiration and Dispense Monitoring TADM allowing the in process control of aspiration and dispense steps The principle works as follows Before tip pickup the environmental absolute pressure is measured and used as zero base line When the liquid level is found the relative pressure of the air volume within the tip is measured every 10 ms during the following aspiration and dispensing The measurement values are checked on line if they are lying within a liquid and volume specific predefined tolerance band If not the step is stopped with an error message The TADM enables the detection of leaky or clogged tips blood clots and foam 2 4 Microlab STAR Service Manual 2 1 3 Product variants of Microlab STAR Instruments Type of Instrument Configurations Extensions Manual load 4 to 16 channels iSwap Auto load 300 ul or 1000 ul Wash station
167. rvice software to determine the degree of malfunction 1 Ensure Deck Carriers and Slide Blocks are not contaminated Clean them if necessary 2 Check for damaged Slide Blocks on Deck and loading trays and replace them if necessary 3 Load and unload Carriers move them by Hand Check that they glide smoothly Clean the guides of Carriers 4 Replace those Carriers which don t move smoothly 5 Check Synchronisation of both Cog Wheels 6 Perform an Autoload Auto adjustment Autoload rattles sticks and Generally see Autoload Step loss slips while loading carriers 1 Lower calibration value of Z Drive Autoload Use Service Software Menu Settings Inst Configuration read Instrument data and change existing Carrier Z value E g current Carrier Z value is 037 change to 057 Keep lowering until improvement 2 Shift the cogwheel angle position forwards or backwards whatever suits better E g current Carrier Y value is 003 8913 change to 006 8913 Keep shifting until improvement 1 Value defines angle position of Cogwheel 219 Value defines the number of steps to load a carrier 10 12 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Barcode reading Problems Ensure all Barcode Specifications are met according to technical Specifications in User Manual E g print contrast signal density of barcode code type quiet zone label positio
168. s Channel to Y Slide Fixing Screws Channel Adjustment Tool 2 Moving in X Axis Channel Fixing Screws Channel Adjustment Tool 3 Tilting around Y Axis Channel Fixing Screws Channel Adjustment Tool 4 Moving in Y Axis Position will defined by calibration value which will be determined by automatic adjustment program Channel Calibration Tool with Macro Program 5 Tilting around Z Axis Adjustment not possible Position is given through Y Slide guide Pipetting Arm with its Y Slide and guide 6 Moving in Z Axis Position will defined by calibration value which will be determined by automatic adjustment program Channel Calibration Tool with Macro Program 6 14 6 3 1 Pipetting Channels degrees of freedom Microlab STAR Service Manual Attention Exercise great care when loosening or tightening the Channel Fixing screws as excessive torque tension has a direct effect on the ball bearings of the slides and in fact may damage them then proper positioning is no longer possible Channel Fixing Screws First loosen both locking set screws which are located just above the upper and underneath the lower fixing screw Then slightly loosen the 2 fixing screws for a moving in X Axis and tilting around Y Axis Torque Tension fixing screws M4 300 cNm or fixing screws M3 110 cNm locking set screws M2 50 cNm Channel to Y Slide Fixing Screws By slightly loosening the
169. s Methods File Fol 08 02 2002 17 55 C3 Methods My Documents My Network Places CISTARService File Fol 08 02 2002 14 54 CJ STARService SWAPService File Fo 15 01 2002 16 57 SWAPService Computer un EC InstallShield Installa C 461069C6D C8 C 4843A18C3 96F 73 491 4 di 10 object s Disk free space 5 61 GB 0 bytes g My Computer Version Information After a successfully installation of user Software a Version Info Program will be found on START gt Programs HAMILTON Version Info This Tool will provide information about the User Software installed r xi Installation Path C Program FilesXHAMILTONXBin Installed Applications Phoenix version ML STAR version File details r 4 14 Microlab STAR Service Manual 4 2 4 2 Check Access rights for C Barcodes Open Explorer Select Directory C Barcodes if necessary create directory Barcode first and right click on Properties o x File Edit Favorites Tools Help Back General Sharing Security gt Address Go Links Name Attributes Modified 2001 08 30 05 33 File Fol Type File Folder A 2002 08 09 10 23 File Fol Ga DELL 4 2001 09 18 07 48 File Fol 4 C3prscoveR A 2001 08 30 05 35 Folde us E ERE EY aa Ga DMI A 2001 08 30 06 04 File Folde Size on disk 84 5 KB
170. s aspiration e Aspiration and dispensing of liquid e Tip ejection with CO RE technology ML STAR IVD additionally features e TADM Total Aspiration and Dispense Monitoring where aspiration and dispensing are monitored 7 33 7 8 3 Replacement Preliminary actions Uncover Pipetting Arm see section 7 4 3 Pipetting Arm on page 7 14 Channels should remain on Pipetting Arm Otherwise refer to section 7 7 Pipetting Channels on page 7 26 Hint Remove Y Spindles for better access to channels and Pipetting Heads A Attention Never switch on ML STAR Instrument while cables such as those between Channel and Pipetting Head are not plugged in when replacing Pipetting Heads as short circuits are possible 7 34 Removal Removal of Pipetting Head see Drawing above Carefully push Pipetting Head on Channel s Z Drive all the way down Then unscrew and remove the 4 screws of Pipetting Head and carefully draw it out of the Channel to access the 2 cables and disconnect them The items listed below may removed with Pipetting Head installed Item Description Stop Disk Loosen and remove Stop Disk P N 173332 Use Stop Disk Mounting Tool P N 173953 If Pliers are used to unscrew Stop Disk ensure no damage e g scratches during removal Check for any scratches or blocked bore hole on Stop Disk replace if any damage is visible CO RE O Ring See above loosen and remove Stop Disk P N 254167 Replace CO RE O Ring
171. s on ML STAR Instrument All Carriers Tip Waste Spillage Trays and loading trays Pack the accessories in the accessory boxes 5 2 5 Remove Panels Remove ML STAR instrument s side panels On ML STAR IVD Instruments back cover must be removed as well 8 Microlab STAR Instrument with Autoload Option only 5 2 5 2 6 Packing the ML STAR Instrument Microlab STAR Service Manual Use ML STAR PACKAGING P N 220308 to ensure adequate packing and shipping Item 1 Pallet 10 amp 11 Surrounding Cover with Top 12 Accessories Boxes 2 pieces 5 3 Packing the ML STAR Instrument continued Microlab STAR Service Manual 3 2 Square Foam 1 piece Channel protection foam blocks between the Channels 25 pieces iSwap protection block 1 piece Channel supporting block 1 piece U shaped holding bars 2 pieces Pipetting Arm supporting Block 1 piece 2 Profiles block 2 pieces Square Foam 2 pieces 5 4 Microlab
172. s reported by the User Software See User Manual It contains all software reported problems that the user himself cannot solve In the User Manual the user is instructed to make a service call whenever one of these problems occurs and there is not an obvious solution he can implement himself The last column recommended action is the action to be taken by the Service Technician when called in by the user 10 1 1 Version Information For User Software a Version Info Program will be found START Programs gt HAMILTON 3 Version Info For Service Software see section 3 3 Help Menu on page 3 6 10 2 Trace Files Trace Files can be of great help to the Service Technician with error investigation Typically when an undetected error occurs on the customer site e g a damaged or contaminated tip ejection tube which hinders a proper functioning of the Tip presence sensor checking these Files first for possible Hardware errors may help to solve the problem very quickly 2 Types of trace files are available 10 2 1 Communication Trace files A record of every single Firmware command sent to and acknowledged by the ML Star Instrument Every Day when any method is started a new Trace File is created and named for the current day it will be found in C Program Files HAMILTON Logfiles E g 20010112 trc which is the date format JJJJJMMDD 12 of January 2001 10 1 Microlab STAR Service Manual 10 2 2 System Trace files
173. settings control panel You may delete the ML STAR USB driver switch then off and on again the ML STAR Instrument The System is then looking automatically for the appropriate driver Choose a Hardware Device SS Which hardware device do you want to troubleshoot A The following hardware is already installed on your computer lf you are having problems with one of these devices select the device and then click Next If you are attempting to add a device and it is not shown below select Add a new device and then click Next Devices 3Com 3C320 Integrated Fast Ethernet Controller 3C905C TX Compatible m Intel r 8280144 LPC Interface Controller 8280144 Bus Master IDE Controller Intel r 8280144 USB Universal Host Controller m Intel r 8280144 SMBus Controller Intell 8280144 PCI Bridge fl Intel 8281 DC 133 Sustem and firanhics Controller lt Cancel 10 4 Microlab STAR Service Manual Error Handling continued Incident Corrective Action No communication Compare physical Configuration with settings first in Service and then in user Software Switch off ML STAR Instrument and shut down Service Software Then restart service software and switch on Instrument Replace Master PCB P N 173881 After replacement remember to check Firmware Versions and perform Auto adjustments Flash Memory errors a A N Switch ML STAR Instrument off a
174. sible then parameter dt1 must be used 6 After sending these comands use P AI which resets the Firmware to its default values this is absolutely necessary 7 If no improvement replace Pipetting Head 10 8 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Pipetting Channels Step loss Squeezer Drive Clean Dispensing Spindle by removing all old grease and slightly grease it with new grease Using Movement Sensors Menu from Service Software perform a whole stroke run in approx 10 times Perform an Auto adjustment If no improvement replace Pipetting Head Z movement Ensure no crash has caused the Pipeting Channel to lose steps e g a crash involving Pipetting Channels and Carriers Labware Check if the Spring is still in place e g after transportation Check if the Belt is still in place Check all the cable connections of the channel focussing on z motor cable Check the z movement manually by gently pushing or pulling the Channel up or down Do not forget to switch off current to z motor beforehand In the absence of visible Hardware collision with other components no corrective action is possible and the Channel must be replaced 10 9 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Y Movement Check visually the elastic sheet metal
175. stment Macro 1 6 1 6 6 Updates unten ee ee 1 7 14 SERVICE PLAN peg een pe vents em ehem Rem aree e 1 7 126 RBARIDREBHJRINTEAG n y WEN usu uu pa IMEEM pede 1 7 1 8 1 Return Goods Authorization 1 7 Microlab STAR Service Manual 19 FEEDBACK 1 8 1 10 CONTACTING 1 8 2 MIcrolab STAR Instrument e Pet 2 1 2 1 e Miri 2 1 2 1 1 lt 2 2 2 1 2 MIS TAR IVD 2 4 2 1 2 1 Total Aspiration and Dispense Monitoring 2 4 2 1 3 Product variants of Microlab STAR Instruments Lucy 2 5 2 14 Pipetting Head and Tip Needle Combinations 2 5 2 2 TECHNICAL SPECIFICATIONS cco noel eae ie aan 2 6 2 2 1 Technical Status of ML STAR 2 10 2 2 2 Computer Requirements roses ocio req ma Imc 2 11 2 2 3 Software Requirements RU Vi REB RE 2 11 2 3 SERVICE PART CLASSIFICATIONS 2 12 2 3 1 Service Assemblies a oo eoe iti Oy SONA DO V tet ees
176. stomer Summary 2 Connect communication and power cables Explain how to request technical and service If included inspect install extensions assistance iSWAP Yes No Address any other concerns AVS Yes No Comments TCC s Yes No WS s Yes No Recommended Uninterruptible Power Supply UPS installed Yes No Software Installation ML STAR software Service software Labware definitions of carriers Customer Acceptance Date Remote access Yes No Installed by Date P N 610911 00 HAMILTON Bonaduz AG 12 7 Microlab STAR Service Manual 12 8 Microlab STAR Service Manual 12 2 1 2 IQ Microlab STAR IVD 06 of Ref Service Manual P N 610754 Ref Operator s Manual P N 610889 Contact Person Microlab STAR IVD Installation Qualification IQ Installation Date Installation Report W Contact Person Extensions Serial ML STAR Software Ver sion Always wear required personal protection equipment Work Place Environment Weekly Maintenance 3 Operator s Manual Inspect workplace environment for accor Perform Weekly Maintenance procedure dance to technical specifications Inspect table or workbench for supporting the weight of the Microlab STAR IVD and provid ing the minimum space needed Unpacking the Instrument Verification Volume Print out v
177. t 1000 W Load Detect Tube Detect Load Display Actuators Sensors Sx SM EC 1x DM 2x OS 5x HS 1x BR 55x LG BD 614 168 WD 604 432 BD 614 184 WD 604 452 Actuators Sensors EM EC Motor BR Barcode Reader DM DC Motor EC Encoder FA Fan Ventilator FS Force S nsor HE Heating Element HS Hall Sensor LB LED blue Ls Liquid Level Sensor LG LED green MS Micro Switch LR LED red os Optical Sensor LY LED yellow PS Pressure Sensor sM Stepper Motor TS Temperature Sensor SN Solenoid VS Volume Sensor Microlab STAR Service Manual 8 1 2 Functional Description 8 1 2 1 Interfaces is User Interface Either a RS 232 or an USB Interface connects PC to the Master PCB of ML STAR Instrument e Optionally a teaching Box connected to the ML STAR Instrument may used as an additional User interface when recognized by the User software PC e Mains is connected to Power supply of ML STAR Instrument 8 1 2 2 ML STAR Instrument communication architecture The Master Slave architecture is designed as follows e The Master PCB controls its slaves which are Pipetting Arm X Movement physically located on the Master PCB Pipetting channels Autoload PCB and ML STAR extensions The Power supply provides power to connected modules such as Master PCB Pipetting Arm Pipetting channels Autoload PCB and ML STAR extensions 8 1 2 3 Firmware and Dat
178. t Tool reference grooves If necessary loosen first Pipetting Channels locking set screws and then slightly loosen fixing screws to make it fit Pipetting Channel Z Guide shaft must slide into reference grooves without sticking Check for absolute parallelity between Z Guide shaft and reference grooves No Gap should be visible Freeze adjustment positioning by tightening all loose fixing screws Verify Adjustment and check again for absolute parallelity between Z Guide shaft and reference grooves Finally thighten Pipetting Channels locking set screws 6 18 Microlab STAR Service Manual 6 4 Adjusting Pipetting Arm This is to ensure the Pipetting Arm is aligned parallel to Deck surface and towards Y Axis The Y Axis is aligned when the rear and the Front of the Pipetting Arm is on the same X Coordinate Using the Channel Calibration Tool the Pipetting Arm Alignment Tool and the appropriate Macro Programs you can adjust the Pipetting Arm The Adjustment is of a mechanical nature The Adjustment Macro Programs provide measurement values When due to bad adjustment values Adjustment is required The Pipetting Arm has a number of degrees of freedom Degree of freedom Action Reference 1 Tilting around X Axis is accomplished by raising and lowering the Front Channel Calibration Tool with Macro Program Guide Bar of Microlab STAR Instrument in Z Axis on the left and the right side 2 Moving o
179. t and performs pipetting operations on liquids in containers on the work surface Movable carriers holding reagent containers e g tubes microtiter plates or any other kind of laboratory material are placed on the deck work surface The work surface is divided into 54 tracks T of equal width for the purpose of loading carriers This means the deck has partitions for a maximum of 54 specialized 1 T carriers for sample tubes or a maximum of 9 6 T carriers for microtiter plates or a mixture of both An additional partition is provided for the tip waste station The Microlab STAR is equipped with a pipetting arm containing typically 4 8 12 or 16 pipetting channels which work independently The pipetting arm moves in X direction whereas each pipetting channel can move relatively independently both in a Y and a Z direction The Microlab STAR supports pipetting with disposable tips or with needles 2 1 2 1 1 Key Features Pipetting Channels Microlab STAR Service Manual Monitored air displacement No tubing no system liquid no pumps Independent pipetting heads with CO RE Compression induced O Ring Expansion technology Independent Y Z volume and LLD for each pipetting head CO RE Technology Outer Release Sleeve Stop 7 i Pressure Sleeve O Ring 22 Coupling Shoulder Tp M CO RE stands for Compression Induced O Ring Expansion Patent Pending PCT EP 00
180. talled by Date HAMILTON Bonaduz AG Microlab STAR Service Manual Ref Service Manual P N 610754 Ref Operator s Manual P N 610889 Installation Qualification IQ Installation Date Contact Person 4 1 1 2 Microlab STAR IVD Installation Qualification Microlab STAR IVD Installation Report ML STAR Software Ver sion Always wear required personal protection equipment Work Place Environment inspect workplace environment for accor dance to technical specifications Inspect table or workbench for supporting the weight of the Microlab STAR IVD and provid ing the minimum space needed Unpacking the Instrument Inspect instrument and accessories for ship ping damage or missing parts Use packing list to verify contents If any items are missing contact Customer Service Hooking up the Instrument Set up the instrument Connect communication and power cables If included inspect install extensions iSWAP Yes No AVS Yes No Install tip waste chute and container Recommended Uninterruptible Power Supply UPS installed Yes No Software Installation ML STAR software Service software Labware definitions of carriers Set up user groups Remote access Yes No Instrument Check Procedure Perform instrument check procedure P N 810886 85 2002 10 31 Weekly Maintenance 3 Operator s Manual Perform Weekly Mai
181. tch on starting any method Check the physical Configuration of Microlab STAR instrument Autoload number of channels channel type etc Compare physical Configuration with settings first in Service and then in user Software 10 6 Microlab STAR Service Manual Error Handling continued Incident Corrective Action Pipetting Arm Step Loss 1 Ensure no crash has caused the Pipetting Arm to lose steps e g a crash involving Pipetting Channels and Carriers 2 Ensure the Pipetting Arm Cover is not touching the Front guide Bar anywhere 3 Uncover Deck Panels see section 7 4 2 Deck Panels on page 7 7 4 Check X Motor and Belt Tensions 5 Especially the Belt from the primary Drive must not be damaged Check for signs of anything worn out broken inlays teeth etc 6 Ensure proper collision free movement by carefully pushing the Pipetting Arm by hand all the way from the left to the right 7 Ensure the X Position Reader is not touching the Magnetic band anywhere see section 7 6 Pipetting Arm X Drive on page 7 23 8 Check the gap between Reader and Magnetic Band 9 Ensure the X Flag black sheet metal cover is not loose tighten the screws if necessary 10 Check tightness of fit between X drive belt and Pipetting Arm check for loose screws 11 Check Cables to pipetting Arm for any signs of damage or disconnection 12 By using Service Software Check Init Sensor
182. ted by the user when running methods on Microlab Star Instrument 1 6 2 User Software for Microlab STAR IVD P N 911039 This is the software operated by the user only when running methods on Microlab Star IVD Instrument 1 6 3 Service Software P N 911003 This is the software operated by the Service Technician when testing components of Microlab Star 1 6 4 Firmware This is the software stored on ML STAR s Master Pipetting Channel Autoload and any Extensions PCB which executes commands sent by the User and Service Software Note For example Firmware Version 1 9 contains File Name Module Firmware Address Version e GRUALS16 ACH 1 65 e 0518 e Master 1 85 e GRUPXS17 ACH e Pipetting Channel PX 1 75 e GRUROS10 ACH iSwap RO 1 05 e GRUTXS10 ACH Temperature 1 05 controlled Carrier e GRUWXS13 ACH Wash Station WX 1 3S 1 6 5 Adjustment Macro Programs These are software programs accompanying the Service Software which help you to adjust the ML STAR Instrument 1 6 Microlab STAR Service Manual 1 6 6 Updates Firmware updates as well as new Adjustment Macro Programs will sent to all Service Technicians registered with HAMILTON See the instructions accompanying the Firmware files 1 7 Service Plan The Microlab STAR instrument is installed by the Service Technician according to the instructions in this Service Man
183. their boxes Both spillage trays Ensure no movement inside accessories boxes Fill up empty space with crumpled paper protection foam etc Then close accessories Box use adhesive tape Place accessories boxes onto the Z shaped blocks Both Z shaped blocks go onto instrument s deck panel left and right beside pipetting arm 10 Square foam block placed above pipetting arm s top cover serves as a buffer between the two accessory boxes 11 Lower the packing surround from above onto instrument on pallet 12 Place additional square foams between accessory boxes and cover of packing surround 13 Place side panels left and right on top of both accessory boxes 14 ML STAR IVD instrument s back cover must also placed on top of the two accessory boxes Avoid scratches on panels and cover 15 Close instrument packing surround with its top cover and tie up the crate securely 5 11 Microlab STAR Service Manual ML STAR packaging continued 2 Square Foams blocks 2 Accessories Boxes 2 U shaped holding bars w w un un VEN CEA Instrument on pallet without top and surrounding covering cos 2 Z profiles 5 12 Microlab STAR Service Manual 5 2 7 User Software Deinstallation When removing the ML STAR User Software you will find that no data such as METHODS LABWARE LOGFILES etc are removed The Software root structure remains the same However it is strongly r
184. this Tool twice in Track one both times exactly the same way The first time the center axis of Track one to the center of the cogwheels is determined the second time the cog s uppermost position is defined relative to the cogwheel home sensor The Autoload Drive has a number of degrees of freedom Degree of freedom Action 1 Tilting around X Axis Adjustment is generally not possible 2 Moving in X Axis Is a movement Axis of Autoload drive and is automatically adjusted calibrated with the corresponding reference Tool and Macro Program 3 Tilting around Y Axis Adjustment is generally not possible 4 Moving in Y Axis Is a movement Axis of Autoload drive and is automatically adjusted calibrated with the corresponding reference Tool and Macro Program 5 Tilting around Z Axis Adjustment is generally not possible 6 Moving in Z Axis Is a movement Axis of Autoload drive and is automatically adjusted calibrated with the corresponding reference Tool and Macro Program 13 Microlab STAR Instrument with Autoload Option only 6 40 Microlab STAR Service Manual Conditions Guides in X Direction must be straight i e may not be bent and must ensure a parallel movement to the corresponding axis Bad loading and unloading of carriers Steps lost or faulty Barcode reading indicates a need for corrective action Adjustment may solve the problem If not the Autoload Drive may need to be r
185. through the instrument For a complete installation a tip waste container is provided with the instrument witch must placed underneath the tip waste Guide the Plastic chute into the tip waste container Microlab STAR Service Manual 4 2 4 Software Installation 4 2 4 1 User Software Installation A Attention Do not install new software version over existing software First Back up Methods User defined Labware Liquid classes etc then remove current software After removal of current software the new software version may be installed e Put CD into CD ROM Drive Start SETUP EXE Program File from the CD ROM and carefully follow the instructions during installation The User Software creates a Root Directory as follows C Program Files HAMILTON E 101 File Edit View Favorites Tools Help un a pus pu Back Forward Up Search Folders History Move To Copy Delete Undo Views Address a C Program z 60 Folders LA E E HAMILTON r Li File Fo 07 02 2002 17 06 Bin config File Fo 07 02 2002 17 06 C Config HAMI LTON Graphic File Fo 07 02 2002 17 06 C Graphic Labware File Fol 07 02 2002 11 42 9 Labware Select an item to view its Cl Language File Fol 07 02 2002 11 42 C Language description Library File Fol 07 02 2002 17 06 Library See also Cl Logfiles File Fol 08 02 2002 10 38 Logfile
186. tion Good Laboratory Practices should be observed when disposing of consumable items such as useq plates disposable tips steel needles etc Exercise care if touching the Channels when repacking the Instrument 5 1 Microlab STAR Service Manual 5 2 1 Decontamination Wipe exposed surfaces with desinfectant liquid 5 2 2 Removing Tips or Needles Before Disassembling anything ensure that there are no Tips or Needles remaining on the Pipetting Channels e Assuming the Instrument is working Tips or Needles may be ejected by starting any Method which must have an initialization at the very beginning The Method may be aborted after Tip ejection Or Byusing the Service Software Menu Control 3 Single command 3 Send command P MD where is the Pipetting Channel Number A minimum initialization is provided by sending Single Commands P YI and prior to the PZMD Command Or e using the Service Software Menu Control gt Movement Sensors gt Pipetting Channel Initializing each squeezer drive Or e After Instrument has been switched off turning the squeezer spindle hand to release the O Ring coupling A Attention Tips or Needles must not pulled away from Channels by Hand as this may cause damage to the O Ring and the squeezer mechanism of Pipetting head 5 2 3 Disconnect ML STAR Instrument Switch off and unplug the Microlab STAR Instrument Disconnect it from the PC 5 2 4 Remove all item
187. ual The user is instructed to maintain the instrument on a regular basis this maintenance consists largely of surface cleaning and does not require opening up the instrument i e any unscrewing removing deck covers etc The Microlab STAR user is responsible for changing consumable parts disposable tips needles waste bag etc Spare parts PCBs cables channels etc are generally changed by the Service Technician The Service Technician will need to service the instrument in the field at least twice a year every 6 months In addition the Service Technician may be called on by the user to repair a damaged component of the instrument or to resolve a functional problem which the user cannot resolve himself such as adjusting and calibrating the pipetting channels 1 8 Part Return Tag 1 8 1 The part return tag has following functions 1 part identification reason for return and description of problem 2 decontamination declaration where required Return Goods Authorization Parts of instruments may only be returned to HAMILTON Bonaduz AG with a Return Goods Authorization RGA Ask the Hamilton Order Processing Dept OPD for an RGA number prior to sending any material This number must be entered in the appropriate blank on the part return tag A completed part return tag must be attached to all parts or instruments which are returned to HAMILTON Bonaduz AG Tags may be ordered free of charge fr
188. ument een 5 2 5 2 4 Remove all items on ML STAR Instrument 5 2 03235 REMOVE Panel ERE S V SERI E E GERI GE Z E EEE YE 5 2 5 2 6 Packing the ML STAR 5 5 3 5 2 7 User Software Deinstallation te audeo 5 13 6 Adjustment and 6 1 6 1 OVE TS VIE Q paspa brad oad gt coed brad nek misin upa smua ss D oca na nas Arabe ma ka a EC 6 1 Microlab STAR Service Manual 6 1 1 The An Princible of JAGIUSUDO iavccevs sa saritax sayika kab V REVO HAS HE M IR E EVARA HAVE VEL as 6 2 6 1 2 Interpretation of correction values 1 6 2 6 1 3 Order of adjustment and calibration 6 3 6 2 ADJUSTMENT TOOLS AND MACRO 6 5 6 2 1 Tools for Pipetting Arm and 6 5 6 2 2 Tools for Autoload 6 8 6 2 3 Tools for Verification of ML STAR IVD 6 9 6 2 4 Adjustment Macro 5 6 11 6 3 ADJUSTING PIPETTING CHANNEL sess 6 14 6 31 Pipetting Channels degrees 8 6 15 6 3 2 Pipetting Channel Adjustment 4010 00000000000000006 000044 8 6 16 6 3 3 Pi
189. ustment screw P N 420074 Note make very small movements i e 1 8 turns with the adjustment screw tighten the fixing screws and check by running adjustment program again Fixing screws 6 22 Microlab STAR Service Manual Pipetting Arm Z Alignment continued A Attention Ensure a completely empty deck before starting macro program Therefore remove any carriers beforehand Start Adjustment Macro Program ARM Z DIFFERENCE MCR from Service Software and caretully follow the instructions given in that program STARService y 4 Put the adjustment tool 173960 to slot position 5 ATTENTION THE DECK MUST BE EMPTY e Adjustment must performed if difference criteria are not met x 2 Deviation left center right back 0 2 0 front 7 5 6 correction 1 D 5 in counts 1 count 0 0107277 mm Repeat the measurement Interpretation of Result of Adjustment procedure Adjusting Pipetting Arm in Z Direction which would not be necessary in the result window shown above Corrective Actions The Front guide bar may only be lifted or lowered on the left and right side of the Microlab STAR Instrument In this example the corrective action would be lowering the Front guide bar on the left side e Just loosen 2 fixing screws on each side and lower Front guide bar with adjustment screw according to the values provided by the program then tighten the fixing scr
190. ve block and tie it to the back A Attention Do not use adhesive tape to attach iSWAP to the back as this may damage the paint on the pipetting arm housing 5 6 Microlab STAR Service Manual Packing the ML STAR Instrument continued 3 Tie the remaining protective foam blocks for the channels together and place this package into the empty space of the pipetting arm housing This will help to hold all the channels in place 5 7 Microlab STAR Service Manual Packing the ML STAR Instrument continued 4 Put pipetting arm s top housing in place 5 With the pipetting arm s front housing removed push channel supporting block towards the rear into the pipetting arm housing Then push it very carefully upwards to the channels 5 8 Microlab STAR Service Manual Packing the ML STAR Instrument continued 6 Tie channel supporting block onto pipetting arm with a suitable piece of cord A Attention Do not use adhesive tape as this may damage the paint on the pipetting arm housing 5 9 Microlab STAR Service Manual ML STAR packaging continued 7 Finally place pipetting arm supporting block as shown in picture into the pipetting arm and re assemble front housing to pipetting arm 5 10 Microlab STAR Service Manual ML STAR packaging continued Place all accessories into the accessories boxes Accessories include e Wrapped loading trays and waste station e Carriers in
191. ves for unambiguous identification of the vessel e g a sample test tube CO RE Compression induced O Ring Expansion Cover The cover shelters the whole Microlab STAR leaving user access for loading and unloading of the racks onto their respective carriers All activities must be suspended before the cover is opened The cover should always be closed while the Microlab STAR is in use Deck The deck is the physical work surface used by the Microlab STAR It includes discrete bounded sites for locating carriers Dispense To distribute quantities of liquid from a pipetting device EEPROM also known E2PROM Non volatile ROM for volatile Data Firmware Programs sequences of commands which are carried out on the processors of the Microlab STAR Flash Memory Code Memory FW Firmware Front Side and Rear Windows Covering for the Microlab STAR IVD in such a way that it is shielded from user intervention At the same time it protects the user from the movements of the Microlab STAR It is made of transparent plexiglass GLP Good Laboratory Practice GUID Globally unique identifier 12 2 Microlab STAR Service Manual Glossary continued Hardware error Type of error which depends exclusively on faulty functioning of the hardware HSL HAMILTON Standard Language Instrument Hardware of the Microlab STAR Mechanics Electronics and Firmware IVD In vitro diagnostic iSwap Internal Swiv
192. vice Manual Glossary continued Rack identification Barcode for rack identification Sample Refers to a liquid in an unambiguously identified container which is to be processed Service Technician Trained and authorized service engineer STAR Sequential Transfer and Aliquoting Robot The System Refers to the Microlab STAR instrument together with the PC running the ML STAR software and the serial cable connecting the two together SSW Service Software TADM Total Aspiration and Dispense Monitoring Tip Disposable tip for dispensing Tip rack Frame that holds tips together used to store a set of tips for access by pipetting channel Tip waste station An opening in the Microlab STAR deck to direct used disposable tips via a plastic chute into a laboratory supplied waste container below the working area Trace Note of a status during a processing Tube A tube is a narrow container for liquid usually showing a circular cross section and a cylindrical length section User The user actually operating the Microlab STAR instrument and the ML STAR software USW User Software Verification Kit Aid to check the functions of the Microlab STAR IVD 12 5 Microlab STAR Service Manual Glossary continued Waste Container The Waste Container is a device on the Microlab STAR deck to collect used disposable tips Well The individual hollow in the MTP Well type Geometrical shape of the well such as U
193. w cable to fit 8 6 1 Location of cables Refer to the block diagrams in this chapter 8 6 2 Cables Part list Description SPC 146355 W65 A 173817 CABLE X ARM PCHN BOARD 173849 CABLE X MOVEMENTS 173850 CABLE FILTER POWER SUPPLY 173851 CABLE POWER SUPPLY 40VDC gt gt 173852 CABLE POWER SUPPLY GND 173853 POWER MASTER 173854 CABLE POWER AUTO LOAD 173858 CABLE SSC 173863 CABLE DM X DRIVE PIPETTING ARM 7 173890 CABLE POWER SUPPLY EARTH 173891 CABLE EC AUTO LOAD X POSITION 173898 CABLE RS232 173905 CABLE X ARM CONNECTOR 8C gt gt 173906 CABLE X ARM CONNECTOR 16C 173911 CABLE FILTER EARTH 182820 CABLE MASTER EXTENSIONS 355130 CABLE USB TYPE A B 3M Mains cables for different countries P N Description 235062 355008 355009 355010 POWER CABLE GERMANY FRANCE 8 22 Microlab STAR Service Manual 9 Maintenance 9 1 Overview As well as the routine maintenance by the user described in the User Manual the Service Technician carries out an in depth maintenance at least twice a year This chapter provides a checklist of things to do as part of that in depth maintenance Note The preventive Maintenance for Microlab Star IVD Instruments must carried out every 6 months In order to ensure error free operation of the instrument the content of the maintenance and verification procedures and the intervals at which these
194. y slightly lifting and lowering tilting around X Axis is enabled Note The X Axis to tilt around will then be in the rear Note the above mentioned Fixing screws may occur as setscrews with hex nuts and washers 6 21 Microlab STAR Service Manual 6 4 2 Pipetting Arm Z Alignment Overview The Pipetting Arm with its channels can be adjusted using the Channel Adjustment Tool with its Steel Needle as Pointer and the Macro Program Service Software Adjustment has do be done by hand the Pipetting Arm Adjustment Program only provides measuring values and helps you to align the Pipetting arm Note The Adjustment may be performed where the Pipetting Channels have been preaqjusted Preliminary actions Hint Run the Adjustment macro Program before removing all Panels of the Instrument After the first run check the result window the values are out of range corrective Action must take place To gain better access to Front guide bar remove side Panels from Instrument Refer to section 7 Components on page 7 1 Loosen two middle screws front panels as they are attached to the Front guide bar Run the following macro program together with Channel Calibration Tool P N 173960 e ARM Z DIFFERENCE MCR Slightly loosen all 4 fixing screws Adjustment screw P N 420564 but do not allow play between vertical post and Front guide bar In accordance with Adjustment values move Front guide bar up or down by turning adj

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