VWR VWR Mega Star 600R User manual

Service Manual
VWR Mega Star 600R
PN: 12001894-01
The original version of this manual is valid. VWR
cannot guarantee the accuracy or completeness of
subsequent copies

iTABLE OF CONTENTS
TABLE OF CONTENTS
Introduction iii
Revision Control iv
Chapter 1 Technical Data 1-1
Chapter 2 Service 2-1
Servicing Schedule 2-2
Trouble Shooting 2-4
Error Codes 2-6
Test Points 2-13
User Menu and Service Menu 2-15
Imbalance Behavior 2-19
Cleaning of Instrument Parts 2-19
Electrical Safety Check 2-20
Chapter 3 Functional Description 3-1
Block Functions 3-2
Main Board Functions 3-3
Display 3-5
Speed, Imbalance and Rotor Detection 3-5
Lid Lock System 3-5
Refrigeration System 3-6
Chapter 4 Electrical Diagrams 4-1
Overview 4-2
Power Supply 4-3
Controller 4-4
Protection Circuit 4-5
Frequency inverter 4-6
Imbalance RPM 4-7
Key Control 4-8
Chapter 5 Disassembly of Instrument Parts 5-1
Disassembly of Mechanical Parts 5-2
Replacement of Electrical Components 5-4
Replacement of Drive Components 5-6
Removal of AutoLock 5-7
Replacement of Refrigeration Components 5-9

INTRODUCTION ii
Chapter 6 Calibration (Reference Measurement) 6-1
Introduction 6-2
Requirements 6-2
Calibration (Reference Measurement) Procedure 6-3
Documentation 6-5
Chapter 7 Spare Parts 7-1
Preventive Maintenance Checklist A-1
Calibration Certification Form B-1
Technical Bulletins C-1

INTRODUCTION iii
INTRODUCTION
CAREFULLY READ THIS MANUAL BEFORE SERVICING YOUR
INSTRUMENT.
INFORMATION CONTAINED IN THIS DOCUMENT IS THE PROPERTY OF
VWR.
IT MAY NOT BE DUPLICATED OR DISTRIBUTED WITHOUT THE
OWNER’S AUTHORIZATION!
PURPOSE
This manual contains maintenance instructions intended for use by a qualified
maintenance or service technician.
It is organized to provide information on the theory of operation to assist in
troubleshooting for personnel of VWR and authorized service organizations.
Moreover, it outlines parts replacement and calibration procedures for putting
the centrifuges back into service.
Should a specific maintenance problem arise which is not covered in this
manual, please contact our after sales or product support department. Make
sure you have all necessary information on hand before contacting. This
information includes serial number, software ID and revision, NV-RAM ID
and revision, options and accessories installed and set parameters.

REVISION CONTROL iv
REVISION CONTROL
Revision Change
Date
01 Initial release 01.05.2015

1-1TECHNICAL DATA
VWR
Mega Star 600R
VWR
Mega Star 600R Micro
Environmental conditions
-Indoor use only
-Max. height above sea level 2000m
-Max. relative humidity 80% at 31°C
-
Linear decrease until 50% relative humidity at 40°C
Permissible ambient temperature
+2°C to +35°C
Timer range
10sec – 99h 59min and hold mode deviation: +/- 10 sec.
Max. speed
17850 rpm accuracy: +/- 10rpm
Min. speed
300 rpm accuracy: +/- 10rpm
Temperature set range
-10°C to +40°C
Max. kin. energy
10.1 kNm
Max. sound level at top speed
< 55 dB (A)
Volt Version
230V
Heat output BTU/h
1170
Power consumption
750 W
Rated current
4.0 A
Height (lid closed)
32 cm / 12.6 in
Height (lid open)
70 cm / 27.5 in
Width
46 cm / 18.1 in
Depth
67 cm / 26.4 in
Weight (without
rotor) 74 kg / 156 lbs
Rotor /
bucket Rotor name
Allowable
imbalance
[g]
max. speed
[rpm] max. rcf [xg] max radius [cm]
75005701 TX-150 Rotor 10 4350 3046 14.4
75005702 TX-150 Round Bucket 10 4350 3046 14.4
75005703 TX-150 Oval bucket 10 4350 3046 14.4
75005704 TX-100S 10 4350 3004 14.2
75005705 TX-100 10 4350 3046 14.4
75005706 M-10 Rotor 8 4400 2576 11.9
75005723 M-10 Unsealed Bucket 8 4400 2576 11.9
75005721 M-10 Sealed Bucket 8 4400 2359 10.9
75005600 MT-12 Rotor 4 13000 16438 8.7
75005709 HIGHConic III Rotor 10 9500 12108 12.0
75003623 CLINIConic Rotor 7 4400 3030 14.0
75005719 MicroClick 30x2 Rotor 4 14000 21693 9.9
75005715 MicroClick 24x2 Rotor 4 17850 30279 8.5
75003473 Hematocrit Rotor 1 capillary 13300 16810 8.5
75005643 PCR Strip Rotor 8x8 4 15000 17860 7.1
75007585 MicroClick 18x5 Rotor 4 14000 22351 10,2
75003694 8x50 Sealed Vessel 10 5600 5014 14,3

2-1SERVICE
SERVICE
Servicing Schedule 2-2
Maintenance Routine without dismantling the centrifuge 2-2
Maintenance Routine after dismantling the centrifuge casing 2-3
Trouble Shooting 2-4
Malfunctions without Error Messages 2-4
Error Codes 2-6
Overview 2-6
Detailed Error Description an Action Plan 2-8
Test Points 2-13
User Menu and Service Menu 2-15
How to enter the User Menu 2-15
How to enter the Service Menu 2-15
User Menu Structure 2-16
Service Menu Structure 2-17
Imbalance Behavior 2-19
Cleaning of Instrument Parts 2-19
Electrical Safety Check 2-20

2-2SERVICE
Servicing schedule
This chapter describes the maintenance work to be performed on a yearly basis.
A checklist can be found in the attachment A-1.
Maintenance routine without dismantling the centrifuge
Electrical installation and safety
Switch OFF the centrifuge and disconnect the unit from power, check voltage supply and mains
fusing (16 (15) Amps, slow blow characteristic).
Check condition of plug and wall socket - (let) replace defective parts.
Check cord condition and fixing / connection - replace or refit it.
Check condition of instrument socket and replace it in case of bad contacts.
Location and mechanical installation
Check the base (ground, table, trolley with lockable wheels etc.) for resonance-free and stable
conditions.
Check for a well ventilated place and sufficient distances to walls or adjacent equipment, without
exposition to direct sunlight.
Check the leveling of the centrifuge drive with help of a spirit level.
Lid latch mechanism and safety circuit
Connect the centrifuge to power and switch ON.
Check for correct lid closing and opening - if in disorder, readjust lid, hinges and/or lid latch.
Check the rubber gasket for correct sealing and replace, if damaged.
Check gas lid stay for correct function.
Check the electronic safety circuit: start the centrifuge. Let it shortly run and press stop. The lid
must not be unlocked by the microprocessor as long as the speed is more than 60 rpm - if safety
circuit is out of function, replace main board.
Cleanliness of rotor chamber and motor cover
Open the lid and remove the rotor by pressing the green AutoLock button in the center of the
rotor.
Clean the spin chamber with a dry and absorbent cloth (remove all dust and moisture - see also
page 2-18 for cleaning).
Check the cleanliness of the motor cover and take special care of the slot between the bowl and
the motor cover: penetrating fluids can damage the motor and/or electronics and foreign objects
may block the air flow.
Condition and sealing of rotors and accessories
Check the condition of rotors and accessory parts (especially all supporting or stressed
partitions): the rotor and/or accessory parts must not be used any longer, if there are visible
traces of mechanical damage or corrosion.
Check the condition of rotor and/or accessory sealing and replace them in case of malfunction.

2-3SERVICE
AutoLock and motor shaft
Check the perfect condition of the AutoLock system. In case of malfunction use tool Kit
# 70904693 to change the AutoLock. (see page 5-7)
Check the condition of the drive motor shaft: the centrifuge must not be used any longer, if the
drive shaft is damaged (e.g. bend or it’s bearings are worn out).
Temperature level
Check the air inlet slots for free ventilation. Insufficient air flow will lead to an inadmissible
temperature rise of the motor and electronic parts.
Refrigeration unit
Install a rotor, set the temperature to -10°C and the speed to 300rpm. Start the centrifuge. After
10 minutes stop it and check that the chamber is cold all over.
Imbalance behavior
Install available and empty rotors and check the imbalance behavior with rotor dependant cut off
and run through weights (see page 2-19) and replace worn anti vibration mounts, faulty main
board or sensor cover.
Maintenance routine after dismantling the centrifuge casing
Motor supporting elements
Check the anti vibration mounts of the drive motor and replace them in case of increased rubber
abrasion or abnormal occurrence of imbalance but at least after 3 years of usage.
Braking circuit
Check the function of the braking circuit (warming up of brake resistor, even and noiseless brake
effect) and replace defective parts in case of malfunction.
Clamp and plug connections of wires
Check the clamp and plug connections of all leads on the main board and all electrical Protection
earth core and grounding connections.
Check the grounding connection for continuity and all grounding plug connectors. (see also page
2-20 Electrical Safety Check)
Check insulation resistance and accessible current. (see page 2-20)

2-4SERVICE
Trouble shooting
Malfunctions without error code
Error Error Cause Possible Error
Source Corrective Procedure
Display
remains off
no mains
voltage supply
power switch with
integrated thermal
over current cut out Check supply voltage at XN1. If no voltage
is present, check power switch, instrument
socket and voltage supply.
Replace defective parts
mains fuse or circuit
breaker failed
faulty mains cord or
instrument socket
no low
voltage
supply for
display
faulty connection
from main board to
display Check presence of 5VDC, 15VDC and
24VDC control voltages on main board. If
a voltage is missing replace main board.
Check the display cable (SSTP patch
cable). Replace the display.
faulty display or
main board
Display
backlight is
lit, but
nothing
displayed
or
display
shows
cryptically
(wrong)
characters
data
connection
disturbed
faulty connection
from main board to
display
Check for interferences such as radios,
micro wave ovens, etc. Check for good
grounding connection. Check the display
cable (SSTP – shielded cable). If no other
error
source can be identified, replace main
board.
No display
backlight
LCD
powersafe
mode
Press any button. To switch off the LCD
powersafe mode enter the system menu.
faulty
backlight faulty backlight Replace display.
Display
shows
BOOTING…
CPU program
reset may be
caused by
EMI
supply voltage drop
(>10%)
(Let) improve the power supply. If the
voltage drops often, use a voltage
stabilizer.
bad or missing
grounding
connection check all grounding connections