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VWR Mega Star 600R Service Manual

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

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Summary of Contents for VWR Mega Star 600R

  • Page 1 Service Manual Mega Star 600R PN: 12001894-01 The original version of this manual is valid. VWR cannot guarantee the accuracy or completeness of subsequent copies...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Introduction Revision Control Chapter 1 Technical Data Chapter 2 Service Servicing Schedule Trouble Shooting Error Codes 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...
  • Page 3 INTRODUCTION Chapter 6 Calibration (Reference Measurement) Introduction Requirements Calibration (Reference Measurement) Procedure Documentation Chapter 7 Spare Parts Preventive Maintenance Checklist Calibration Certification Form Technical Bulletins...

  • Page 4: Introduction

    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.

  • Page 5: Revision Control

    REVISION CONTROL REVISION CONTROL Date Revision Change 01.05.2015 Initial release...

  • Page 6: Chapter 1 Technical Data

    TECHNICAL 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 –...

  • Page 7: Service

    SERVICE SERVICE Servicing Schedule Maintenance Routine without dismantling the centrifuge Maintenance Routine after dismantling the centrifuge casing Trouble Shooting Malfunctions without Error Messages Error Codes Overview Detailed Error Description an Action Plan Test Points 2-13 User Menu and Service Menu 2-15 How to enter the User Menu 2-15...

  • Page 8: Servicing Schedule

    SERVICE 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).

  • Page 9: Maintenance Routine After Dismantling The Centrifuge Casing

    SERVICE 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.

  • Page 10: Trouble Shooting

    SERVICE Trouble shooting Malfunctions without error code Possible Error Error Error Cause Corrective Procedure Source power switch with integrated thermal over current cut out Check supply voltage at XN1. If no voltage no mains is present, check power switch, instrument mains fuse or circuit voltage supply socket and voltage supply.
  • Page 11 SERVICE Possible Error Error Error Cause Corrective Procedure Source Check anti vibration mounts and replace if worn anti vibration worn or older than 3 years. mounts (see page 5-6) Trunnions of Inform users that trunnions must be swinging bucket cleaned and greased on a regular basis. rotor not greased See user manual for more information.

  • Page 12: Error Codes

    SERVICE Error-Codes Should multiple errors occur at the same time, the centrifuge will display up to 3 errors at once, by alternating them on the display. Overview (details on following pages) Error Description E-001 System clock unstable E-002 Main state machine corrupted (software) E-005 System reset by watchdog E-008...
  • Page 13 SERVICE Error Description E-074 Latch motor control fault E-077 System health check error E-078 Set speed above max speed E-079 Speed above rotor maximum: >25rpm E-080 Rotor detection failed E-081 Second top speed check failed E-083 Brake resistor over temperature E-098 Imbalance detected E-099...

  • Page 14: Detailed Error Description An Action Plan

    SERVICE Detailed error description and action plan Possible Error Possible Error Corrective Procedure Source spare part The rotor is coasting freely. System clock on Wait for rotor to stop and turn the power switch off. Wait 5 E-001 Main board main board failed seconds before turning it back on.
  • Page 15 SERVICE Possible Error Possible Error Corrective Procedure Source spare part Wrong rotor The rotor is decelerated with maximum braking. installed, Rotor E-019 Install correct rotor. old version of NV- NV-RAM Install latest NV-RAM version. The rotor is decelerated with maximum braking. Wrong rotor Check rotor in other centrifuge.
  • Page 16 SERVICE 2-10 Possible Error Possible Error Corrective Procedure Source spare part Refrigerated units only: The rotor is decelerated with maximum braking. No ventilation, Check ventilation slots for cleanliness and check fans for Pipes blocked, operation. E-033 Faulty over Disconnect over pressure switch from main board (XO1) OP switch pressure switch and check it for continuity.
  • Page 17 SERVICE 2-11 Possible Error Possible Error Corrective Procedure Source spare part The rotor is coasting freely. Internal software Wait for rotor to stop and turn the power switch off. Wait 5 E-072 Main board problem seconds before turning it back on. If the error persists, replace main board.
  • Page 18 SERVICE 2-12 Possible Error Possible Error Corrective Procedure Source spare part The rotor is decelerated with maximum braking. Wait for rotor to stop and turn the power switch off. Wait 5 E-106 Main board failed Main board seconds before turning it back on. If the error persists, replace main board.

  • Page 19: Test Points

    SERVICE 2-13 Test Points Test Point Unit Value Conditions Mains input CAUTION! Mains potential! 230V / 120V Mains cable connected, power switch ON Ambient at 20°C, plugs disconnected from XM1-XM2 4.1 Ω main board. Motor XM1-XM3 4.1 Ω XM1, XM2, XM3 Any phase to ground must have an infinite XM2-XM3 4.1 Ω...
  • Page 20 SERVICE 2-14 Test Point Unit Value Conditions CAUTION! Mains potential! Cables connected, power ON Failure Refrigeration unit over 230V / 120V / 100V Good pressure cut out Cables disconnected, power OFF open Failure short Good CAUTION! Mains potential! Compressor 230V / 120V / 100V All cables connected, power switch ON, ~1.4A compressor ON signal by controller...

  • Page 21: User Menu And Service Menu

    SERVICE 2-15 User menu & Service menu How to enter the user menu The user menu allows the user to make advanced settings and read units values as additional information for service calls. To enter the user menu 1. Switch off the centrifuge 2.

  • Page 22: User Menu Structure

    SERVICE 2-16 User menu structure Use TIME UP and Language: English DOWN to select the user MENU desired language. End of run beep? user MENU End of run flash? Yes Use TIME UP and DOWN to select user MENU YES or NO Keypad beep? user MENU Beeper volume...

  • Page 23: Service Menu Structure

    SERVICE 2-17 Service menu structure Number of Total number runs with this Last 4 digits of runs type of rotor of rotor code Cycle count total XXXXXX Cycles rotor XXXX: XXXXX SERVICE MENU SERVICE MENU Last 4 digits Set speed of rotor code Use SPEED UP Use TIME UP...
  • Page 24 SERVICE 2-18 See previous page Use SPEED UP and DOWN to 1. Compressor active toggle between for 60 seconds screens Compressor active Service menu Start compressor test? SERVICE MENU compressor cooldown service menu 2. Compressor cools down for 300 seconds...

  • Page 25: Imbalance Behavior

    SERVICE 2-19 Imbalance Behavior  Install a rotor from the table below in unloaded condition (without adapter or other inserts) Run through Cut off weight Rotor Rotor name weight (grams) (grams) 75005701 TX-150 Rotor 75005702 TX-150 Round Bucket 75005703 TX-150 Oval Bucket 75005704 TX-100S 75005635...

  • Page 26: Electrical Safety Check

    SERVICE 2-20 Electrical Safety Check ATTENTION! A final electrical safety check must be performed after each maintenance and/or repair!  Resistance check of protective conductor The measuring value of the resistance between the mains plug's grounding pin and the grounding conductors of the motor, electronic chassis and the casing must not exceed 200m Caution! ...

  • Page 27: Functional Description

    FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION Block Functions Main Board Functions Power Pack Intermediate Circuit Brake Path Frequency Converter Micro Controller Display Speed Detection, Rotor Recognition, Imbalance Detection Lid Lock System Refrigeration System...

  • Page 28: Block Functions

    FUNCTIONAL DESCRIPTION Block functions The Mega Star 600R is a refrigerated laboratory tabletop centrifuge with microprocessor control, noise reduced induction drive motor and automatic rotor, speed and imbalance detection. The unit is equipped with following boards and components:  Instrument socket with inlet filter for mains cable ...

  • Page 29: Main Board Functions

    FUNCTIONAL DESCRIPTION Main Board Functions The Main board is mounted on an aluminum swivel chassis in the front of the centrifuge behind the front panel. The components on the main board are arranged in following function blocks:  Noise filter and power pack for DC intermediate circuit and compressor with line voltage configuration (1) ...

  • Page 30: Power Pack

    FUNCTIONAL DESCRIPTION Power Pack The power pack consists of 1 bridge rectifier, 1 transformer and 2 voltage regulators. It generates the following low voltage levels: 5V VCC: By step-down voltage regulator LM2674 Supplies all processors and its electronic components on main board, keypad and display.

  • Page 31: Display

    FUNCTIONAL DESCRIPTION Display The LCD is attached to the front panel. The connection to the main board is done by a RJ45 cable. Data transfer as well the low voltage supply of 5VDC is verified. The LED backlight is supplied with 24VDC.

  • Page 32: Refrigeration System

    If you do not have the necessary certification, return faulty units to the next VWR authorized repair workshop. Condenser...

  • Page 33: Chapter 4 Electrical Diagrams

    ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS Overview Power Supply Controller Protection Circuit Frequency Inverter Imbalance RPM Key Control Discharge your body before touching electronic components! Motor Sensor over temp. cover Compressor Over pressure cut out Condenser Latch Motor PT 1000 Motor Switch Power switch Mains inlet Compressor...

  • Page 34: Overview

    ELECTRICAL DIAGRAMS Overview...

  • Page 35: Power Supply

    ELECTRICAL DIAGRAMS Power Supply...

  • Page 36: Controller

    ELECTRICAL DIAGRAMS Controller...

  • Page 37: Protection Circuit

    ELECTRICAL DIAGRAMS Protection Circuit...

  • Page 38: Frequency Inverter

    ELECTRICAL DIAGRAMS Frequency Inverter...

  • Page 39: Imbalance Rpm

    ELECTRICAL DIAGRAMS Imbalance RPM...

  • Page 40: Key Control

    ELECTRICAL DIAGRAMS Key Control...

  • Page 41: Disassembly Of Instrument Parts

    DISASSEMBLY OF INSTRUMENT PARTS DISASSMBLY OF INSTRUMENT PARTS Disassembly of Mechanical Parts Front Panel Back Panel Gas Lid Stay Gasket Casing Replacement of Electrical Components NV-RAM on the Main Board Main Board Lid Latch Keypad Sensor Cover with Speed, Imbalance and Rotor Detection Temperature sensor Replacement of Drive Components Drive Motor...

  • Page 42: Disassembly Of Mechanical Parts

    DISASSEMBLY OF INSTRUMENT PARTS Disassembly of mechanical parts Front Panel Open the lid, switch off the unit and pull out the mains plug Remove the 2 screws on top of the front panel Pull the front panel up and lift it off. Disconnect wiring from display and overlay adaptor board Back panel Switch off the unit and pull out the mains plug.

  • Page 43: Gasket

    DISASSEMBLY OF INSTRUMENT PARTS Gasket The gasket can be removed and installed without removing any other parts. Simply pull it off. Casing Remove the front panel. Remove the back panel. Remove the main board. Remove the lid latch. Remove the condenser cover (4 screws on the right) and the filter.

  • Page 44: Replacement Of Electrical Components

    DISASSEMBLY OF INSTRUMENT PARTS Replacement of electrical components NV-RAM on the main board Before replacing the NV-RAM enter the user menu and note the version and revision number. Remove the front panel. Remove the 3 screws at the swivel cassis and flip down the main board.

  • Page 45: Lcd

    DISASSEMBLY OF INSTRUMENT PARTS Remove the front panel. Remove the 4 screws attaching the LCD to the front panel Keypad Remove the front panel. Disconnect the overlay from the overlay adaptor board. Use a screwdriver, knife or similar to remove a corner of the overlay from the front panel.

  • Page 46: Replacement Of Drive Components

    DISASSEMBLY OF INSTRUMENT PARTS Replacement of drive components Drive motor Open the lid. Remove the front panel and flip down the main board. Disconnect the motor and its over temp. cut out from the main board (XM). Remove the AutoLock, the rubber boot and the sensor cover. It is not necessary to pull out the ribbon cable of the sensor cover und the cable of the temp.

  • Page 47: Removal Of Autolock

    DISASSEMBLY OF INSTRUMENT PARTS Removal of AutoLock This work requires AutoLock tool kit 70904593 or similar tools. Removal of AutoLock Loosen the screw in the center of AutoLock head 4 turns using a 3mm Allen key and the AutoLock key supplied with the tool kit.

  • Page 48: Checking The Autolock

    DISASSEMBLY OF INSTRUMENT PARTS Removing stuck rotors Remove stuck rotors by hitting the green AutoLock button with a hammer. Depending on the type of rotor the AutoLock may be removed first (fixed angle rotors only) and the AutoLock pin supplied with tool kit can be used instead. Checking the AutoLock The inner and outer tapered surfaces of the Autolock must not show signs of damage such as scratches or dents.

  • Page 49: Replacement Of Refrigeration Components

    If you do not have the necessary certification, return faulty units to the next VWR authorized repair workshop. Before performing work on the refrigeration system, verify that mechanical and electrical errors (dirty condenser, faulty fan etc.) can be eliminated.

  • Page 50: Introduction

    CALIBRATION (REFERENCE MEASUREMENT) CALIBRATION (REFERENCE MEASUREMENT) Introduction General Requirements Equipment Documentation Preventive Maintenance Calibration (Reference Measurement) Procedure Speed Time Temperature Imbalance Safety test Documentation...

  • Page 51: Introduction

    This chapter describes the calibration work to be performed on a yearly basis. A calibration certification form can be found in the attachment B-1. General Successfully completing the preventive maintenance checklist and calibration procedure as outlined will ensure that the instrument is properly maintained and calibrated to VWR specifications. Requirements Equipment ...
  • Page 52 CALIBRATION (REFERENCE MEASUREMENT) CALIBRATION (REFERENCE MEASUREMENT) Calibration (reference measurement) (reference measurement) procedure Speed Install a rotor and attach a piece of reflecting tape (or black tape and attach a piece of reflecting tape (or black tape on reflecting rotors) near the center of the rotor. Close the on reflecting rotors) near the center of the rotor.
  • Page 53 CALIBRATION (REFERENCE MEASUREMENT) Temperature This centrifuge does not use any correction values to show a calculated sample temperature in its display. Instead the displayed value is the measured air temperature inside the spin chamber. Therefore the deviation between displayed and sample temperature depends on the rotor in use, the load, the speed and the run time.

  • Page 54: Documentation

    CALIBRATION (REFERENCE MEASUREMENT) Safety test Perform an electrical safety test according to the instruction manual of the tester. The test should consist of Grounding resistance check Insulation resistance check Earth leakage current check Record the measured values in the safety test section of the calibration form Determine whether the values recorded meet the specifications on the form.

  • Page 55: Spare Parts

    SPARE PARTS SPARE PARTS Front Panel Front View Back View Refrigeration Drive Spare part numbers and spare parts are subject to change in case of technical upgrades or supplier change. New specifications and part numbers are announced through technical service bulletins.
  • Page 56 SPARE PARTS Front panel 50138753 20059804 20150316 Front panel Keypad Display 20150285 20290706 20480320 20480317 Keypad adaptor O-Ring Screw Washer...
  • Page 57 SPARE PARTS Front view 20053064 Hook 20490287 50141066 70903047 Gas spring Latch 20180747 50136435 Power switch Gasket 20150330 (230V) Main board assembly Incl. fan, brake resistor, choke (230V only) and keypad cable 50142481 Display cable 70904785 NV-RAM...
  • Page 58 SPARE PARTS Back view 50141185 Hinge 20180747 Power switch 20170369 Inlet filter 50141352 50139770 Filter Foot...
  • Page 59 SPARE PARTS Refrigeration 50116522 (230V) 20210450 20240462 (230V) Overpressure cut out Compressor 50139837 20240577 50136432 Expansion valve Filter Dryer Condenser...
  • Page 60 SPARE PARTS 20056732 Lid window 20056625 Lid window nut 50138752 Outer lid 20053064 Hook 50141826 Insulation 20059045 50135798 Mounting bracket 50141185 Hinge 50136700 Decal „AutoLock“ 20310530 Decal „Biohazard“ 50138754 Inner lid 50140941 Insulation...
  • Page 61 SPARE PARTS Drive 50140042 AutoLock 20059152 Rubber boot 20150322 Sensor cover 50142320 Temp. Sensor PT1000 20057879 Motor 50143891 incl. 3x AV-mount 6x sand paper disc...

  • Page 62: Preventive Maintenance Checklist

    Preventive maintenance Mega Star 600R checklist Account name: Account address: Instrument model: Instrument serial number: Report number: Date: Page: 1/2 Maintenance without dismantling the centrifuge Acceptance criteria Pass Fail Electrical installation Supply voltage and main power fusing meets specifications (data plate)
  • Page 63 Preventive maintenance Mega Star 600R checklist Account name: Account address: Instrument model: Instrument serial number: Report number: Date: Page: 2/2 Acceptance criteria Pass Fail Imbalance behavior Cuts off with “cut off weight” Does not cut off with “run through weight”...

  • Page 64: Calibration Certification Form

    (y/n) (initials) +/- 10 Custom test Rotor Used: +/- 10 +/- 10 SAFETY TEST Limit Actual Passed (initials) Grounding resistance < 200 mΩ Insulation resistance > 10 MΩ Accessible current < 500 µA X:\DEOHA\Public\TS\SM\Ueberarb\VWR Geräte\VWR MegaStar 600R\12-Megastar 600R_B1_V160215 calibration form.docx...
  • Page 65 Optical tachometer Safety tester Remarks: Certified by:__________________________ Reviewed by:__________________________ Expiration date ______ Signature Date Customer Signature Date Use ONLY blue permanent ink when filling out. Leave NO blank spaces. June, 1999 Revised 08/08/13 X:\DEOHA\Public\TS\SM\Ueberarb\VWR Geräte\VWR MegaStar 600R\12-Megastar 600R_B1_V160215 calibration form.docx...

  • Page 66: Technical Bulletins

    TECHNICAL BULLETINS TECHNICAL BULLETINS Page Title...

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