Mopec Maestro Encore Installation, Service And User Instructions Manual
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Mopec Maestro Encore Installation, Service And User Instructions Manual

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Installation, Service, and User Instructions
Grossing Station / MB1000 / MG1000 series
DISCLAIMER
Copyright © 2024 by MOPEC
All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any
means, including photocopying, recording, or other electronic or mechanical methods, without the prior written
permission of the publisher. For permission requests, write to the publisher, addressed "Attention: Permissions
Coordinator," at the address below.
Mopec
800 Tech Row, Madison Heights, MI 48071
Phone: 1-800-362-8491
email:
customerservice@mopec.com
1 |
P a g e

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  • Page 1 Grossing Station / MB1000 / MG1000 series DISCLAIMER Copyright © 2024 by MOPEC All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher.
  • Page 2 TRADEMARKS Is a registered trademark of Mopec Ensemble Pegboard™ Is a registered trademark of Mopec Is a registered trademark of Mopec Owner’s Record Model No.: __________________________________ Serial No.: __________________________________ Voltage: __________________________________ Dealers Name: __________________________________ Dealers Address: _________________________________ Date of Purchase: ________________________________...

  • Page 3: Table Of Contents

    Table of Contents PREFACE ............................7 Description of the User ........................7 Notations Used in This Manual ......................7 Models covered in this Manual M(xxxxxxx) ..................7 Explanation of Safety Warnings ....................... 8 Obtaining Instructions ........................8 1.5.1 Internet................................8 1.5.2 Ordering Documentation ..........................
  • Page 4 3.3.2 Storage on a skid ............................18 Disposal and Recycling ........................18 3.4.1 Stainless Steel .............................. 18 3.4.2 Ferrous Steel ............................... 19 3.4.3 Aluminum ..............................19 3.4.4 Plastic ................................19 3.4.5 Electronics ..............................19 Quick Start Guide ..........................20 Startup ............................20 4.1.1 Powering On ..............................
  • Page 5 6.1.4 Air Flow Button............................32 6.1.5 Ventilation Button ............................34 6.1.6 Date and Time Adjustment ......................... 37 6.1.7 Water Timer Options ........................... 37 6.1.8 Adding Formalin ............................38 6.1.9 Notification Settings ............................ 39 6.1.10 Alarms ..............................40 6.1.11 User Manual Button..........................41 How to Use Maestro Standard Features &...
  • Page 6 7.2.6 Fingerprints and solvent cleaning ....................... 57 Mopec Service ..........................57 TROUBLESHOOTING AND REPAIR ....................58 How to Identify and Solve Problems ....................58 How to Repair Product Components....................63 8.2.1 Electrical Panel Service ..........................63 8.2.2 Lighting/Power Supply Panel Service ......................64 8.2.3 Garbage Disposal Jams ..........................

  • Page 7: Preface

    1 PREFACE 1.1 Description of the User The Mopec Maestro is a Pathology Workstation and is available in several different sizes, elevating and non-elevating, with over 30 modification options, and a growing inventory of workstation accessories, the Mopec Maestro is built to be customizable to your laboratory needs and individual preferences.

  • Page 8: Explanation Of Safety Warnings

    1.5.1. 1.5.1 Internet The latest version of the documentation is available at the following address: http://www.mopec.com 1.5.2 Ordering Documentation Documentation, user instructions, and technical information can be ordered by calling Mopec at 800-362-8491. P a g e...

  • Page 9: Documentation Feedback

    1.5.3 Documentation Feedback If you are reading Mopec product documentation on the internet, any comments can be submitted on the support website. Comments can also be sent to customerservice@mopec.com We appreciate your comments. P a g e...

  • Page 10: Description Of The Product

    2.1 Purpose of the Product The Mopec Maestro™ Encore is the most advanced pathology workstation on the market today and is designed with the special needs of the user in mind. Careful consideration is given to the functional requirements and workflow patterns, as well as the need for maximum space utilization and sanitation.

  • Page 11: Product Elements

    2.6 Product elements The Maestro Encore is constructed as one assembled workstation with 3 main elements in its construction. The station comes in three physical formations. There is an elevating grossing station, a stationary leg frame unit, and a countertop version.

  • Page 12: Warranty Statement

    (if installation is provided by Mopec), the defective or nonconforming Product or Part thereof will be repaired or (at Mopec's option) replaced free of charge, FCA Mopec's dock. All warranty claims must be in writing and received by Mopec within the warranty period. The warranty is not transferable (other than to customers of Mopec’s authorized Distributors), and will not apply unless the Equipment has been properly installed, maintained, and operated in accordance with all instructions;...

  • Page 13: Installation

    • Check that the top of the crate has not sustained damage or has evidence of being placed upside down. • Take photographs of any damage and contact Mopec or your private freight carrier if applicable. 3.1.2 Uncrating Contents: •...

  • Page 14: Transporting Unit To The Final Location

    3.1.5 Placing unit into position: • Before you unload the equipment check that the utilities have been prepared in accordance with the Mopec rough-in drawing for your model workstation. • Check the floor condition is clean dry and as level as possible. Masonite boards can be used to protect softer styles of flooring.

  • Page 15: Electrical Connection

    3.1.6 Electrical Connection: • The 15amp dedicated circuit electrical system should then be tested per local codes or guidelines at this time and before the unit is plugged in supplying power. o The workstation receives powered by a rear mounted IEC 15amp three prong connector. These plugs are recognized globally and make it simple to use in the global marketplace by simply changing the power supply cord.

  • Page 16: Ventilation Connection (In-House Ventilation)

    • With the plumbing bracket mounted to the factory location on the frame (as shown in the image above) the facility drain line can be connected either via a flexible line with hose clamps or hard plumbed per your local codes and regulations.

  • Page 17: Recirculating Ventilation (If Equipped)

    • At this point, the unit should still be in its lowest elevation position, if not, please lower it to the lowest position to properly size the flexible ducts to the facility connection. Locate the (2) 8” (20.32cm) diameter flexible vent ducts and (4) hose clamps shipped with the unit. These •...

  • Page 18: Decommissioning The Unit

    • Encore models have filters located in the front grill and require no tool to replace the Potassium Permanganate filters. 3.2 Decommissioning the Unit 3.2.1 Decontaminate the unit. • Decontaminate the workstation per your standard processes. • Determine if drainage from the unit is classified as a biohazard. This will depend on your local ordinances. •...

  • Page 19: Ferrous Steel

    3.4.2 Ferrous Steel • The only ferrous steel used on the Maestro is in the lower frame weldment where the linear actuators mount. • If equipped with a magnetic tool bar this will also be made from steel. 3.4.3 Aluminum •...

  • Page 20: Quick Start Guide

    4 Quick Start Guide 4.1 Startup The following section explains how to start the Maestro and some of its standard functions. CAUTION The unit must be installed per factory recommendations in section 3.1 of the user manual. 4.1.1 Powering On •...

  • Page 21: Home Screen Menu Buttons

    • The Maestro Encore will land on its home page after all processes have finished loading. 4.1.2 Home Screen Menu Buttons • Timers – The timers page allows users to set a timer for a future notification. An Alarm will notify the user when the specified time has lapsed.

  • Page 22: Operating Touch Screen

    Home – The home button provides quick access back to the main home screen where the time and • any active alarms are shown. Water Timer Options – The water timers page is for units that have options for foot pedals, and •...

  • Page 23: Elevation

    o An illustrated example of when the user presses the “Lighting” button is shown below. 4.1.4 Elevation • The elevation of the unit is adjustable from the Elevation (</>) button located on the front corner of the sink The unit has 12” (30.48cm) of elevation, select the best position for sitting or standing. Stand clear and check for obstructions surrounding (and under) the Maestro when raising and lowering the unit.

  • Page 24: Power Outlets

    4.1.7 Power outlets • The unit is equipped with 15amp power outlets intended for small appliances on the back shelf. These outlets cycle on/off with the unit power switch and are protected by the main GFCI circuit located in the top inside panel of the hood.

  • Page 25: Factory Options & Accessories

    Factory Options & Accessories 5.1 Standard Features 5.1.1 The Maestro is equipped with the following standard features. • Dimensions: 60" L x 32" W x 75" H & 87” elevated (1.5m L x 0.8m W x 1.9m H elevated 2.2) •...

  • Page 26: Available Factory Options

    5.2.1 Available Factory Options • MB1008 MAESTRO, LEXAN SIDE SHIELDS • MB1039 MAESTRO, RECIRCULATING BOX, 60IN (1.5m) UNITS • MB1039-048 MAESTRO, RECIRCULATING BOX, 48IN (1.2m) UNITS • MB1039-054 MAESTRO, RECIRCULATING BOX, 54IN (1.3m) UNITS • MB1039-066 MAESTRO, RECIRCULATING BOX, 66IN (1.6m) UNITS •...

  • Page 27: Customization (Cust)

    5.2.3 New Options • As New factory-built options become available they will be posted on www.mopec.com 5.3 Accessories Accessories are features and tools that can be added to the Maestro at any time by the user or supporting staff. 5.3.1 Standard Accessories shipped with your Maestro.
  • Page 28 AX110 MAESTRO, RECIRCULATING TO IN-HOUSE KIT • AX111 MAESTRO LITE, EXHAUST DAMPING KIT, 8IN DUCT • AX112 MAESTRO, VIRTUS CAMERA HOOD • AX113 MOPEC CORNER DOLLY, SET OF 4 • AX114 MAESTRO, MILESTONE CAMERA • AX115 MAESTRO, HITCH MOUNT, KEYBOARD 28 |...

  • Page 29: Customization (Cust)

    If your factory “Accessory” has been customized the Model No. will show a “CUST” suffix. 5.3.4 New Accessories • New Maestro Accessories are developed every day! To make a suggestion for a new accessory or to check on our latest go to www.mopec.com for more information. 29 | P a g e...

  • Page 30: Operation/Use

    Understanding the Maestro Operational Interface Mopec designed the Maestro to be highly customizable in its construction to meet all types of process flows and procedural preferences in the pathology lab. The touchscreen display allows for variable user interface controls to support the many configurations available on the Maestro.

  • Page 31: Lighting Buttons

    The home screen is where the users can quickly navigate to any feature installed on the grossing station. The home page is set up in a manner that categorizes the main features into easily accessible buttons. It can also be used as a back button to quickly exit back to the home page and select another subcategory.

  • Page 32: Air Flow Button

    6.1.4 Air Flow Button When the Air Flow button is pressed, the user is taken to the Airflow Monitoring screen. This screen features the current air flow operation, airflow alert, the Last Certified Level and date, and the ability to set the alerting level for airflow for the laboratory.
  • Page 33 Pressing the middle button at the top of the screen will take the user to the Integrated Filtration System Page. This page is for setting the interval time for laboratory personnel to change their filters. Standards particulate air filters and Potassium Permanganate filters require different change intervals, which will be specific for laboratory use.

  • Page 34: Ventilation Button

    When the ventilation button is pressed, the user is taken to the ventilation screen. This screen features the Recirculation fan and Front Air System (FAS) On and Off toggles. The patented FAS system is a key safety feature on Mopec laboratory equipment.
  • Page 35 FAS Fans under front edge FAS ports on the inside edge direct flow across the surface NOTE: Flow sensor is not a calibrated volumetric airflow device. The Recirculation option is intended for facilities that do not have available HVAC exhaust flow available for temporary use or in limited-use environments.
  • Page 36 The Integrated Filtration System page is intended to set a reminder and alert the user(s) when it is time to replace the filters in the system. This functionality can be used for units with standard particulate filters and Potassium Permanganate filters that are utilized with grossing stations having recirculation. To set a determined Filter Change Interval tap on the HOURS box, input the required hours, and select Submit.

  • Page 37: Date And Time Adjustment

    If facility ventilation remains ON while the unit is OFF it is recommended to change the pre-filters every 90 days. Checking and setting a time that works for your laboratory practices is highly recommended. 6.1.6 Date and Time Adjustment To change the Date and Time press the gear icon on the home screen. This will land you on the System Settings page.

  • Page 38: Adding Formalin

    6.1.8 Adding Formalin The Formalin Dispense system on a grossing station utilizes a siphon hose and a transfer pump to fill up a reservoir tank located in the hood of the unit. This enables a very controllable gravity-fed dispense from a simple lever pull on the spigot.

  • Page 39: Notification Settings

    • To start pumping simply hold down the green Dispense Pump button located just inside the knee panel. The system is equipped with level sensors and will turn off the pump when full. The user can visually see if the tank is Low, Partially Full, or Full by viewing the tank Level Screen.

  • Page 40: Alarms

    6.1.10 Alarms Visual Alarms will populate on the Home Screen with a readable notification popup. Recall this feature must be enabled in the Notification Settings Page. If the Mute option is also enabled the user will also be shown a mute icon attached to the notification, indicating that the alarm can be muted by tapping on the speaker icon to mute an alarm.

  • Page 41: User Manual Button

    Alarms are meant to provide notice of an event or precaution. The Alarm will stay present until the cause of the alarm notification is no longer present. To keep your grossing station in the optimal working environment it is recommended that the alarm condition is corrected to prevent further disruption or accidents.

  • Page 42: How To Use Maestro Standard Features & Options

    6.2 How to Use Maestro Standard Features & Options 6.2.1 Lighting (standard) The Maestro has recessed LED lights integrated into the hood, and a few supplemental light options are available. • The overhead LED dimmer is adjustable by touching the Light button on the Home screen. The blue bar on the screen indicates the brightness level and the up/down arrows adjust the setting.

  • Page 43: Elevation (Standard)

    6.2.2 ELEVATION (standard) The Maestro is equipped with an elevation system with approximately 12” (30.4cm) of travel. This system is controlled though the up/down switch located on the front sink side of the workstation. Simply press the up icon on the button to raise the worksurface and the down icon to lower the station to the desired height.

  • Page 44: Faucet Controls (Standard)

    Keep all objects clear of highlighted areas when adjusting elevation. 6.2.3 Faucet Controls (standard) The Maestro utilizes a mixing valve to control flow and hot/cold temperature mix. Operation is much like any residential or commercial faucet; rotate the lever up to start the flow and push or pull the lever to mix the hot and cold. If your Maestro is optioned with a foot pedal or infrared-activated solenoid valve the mixing valve settings still apply, but nothing will flow out of the faucet until one of the other user inputs is activated.

  • Page 45: Infrared Faucet Control "Hands-Free" Option

    Foot Pedal Hot/Cold Mixing Valve • The foot pedal is mounted to a floor plate that can be positioned within reach by the user. • A single tap of the pedal turns the hot/cold mixed water on. • Tap the pedal a second time to turn it off. •...

  • Page 46: End Rinse Option

    The Syphon Hose is intended to be connected to your formalin supply container (cut factory zip tie to uncoil the hose). Mopec cubitainers utilize a quick disconnect. Insert the connector and pull to make sure it is latched. If you are pumping from a formalin barrel remove the supplied quick disconnect fitting and directly insert the end of the siphon hose into the barrel.

  • Page 47: Formalin Collection Option

    • An alarm will alert users when the tank becomes low. • Mopec recommends refilling the dispensing tank after usage to reduce the crystallization buildup on the float level sensor. • To dispense pull the spigot handle. The spigot also has a flow control on the side. Adjust this to your desired flower rate.

  • Page 48: Integrated Camera System

    • Unscrew the carboy cap and remove the carboy for disposal. If you prefer to wheel the collection caddy to the disposal site, you will have to disconnect the fitting and unscrew both the leak and collection sensors shown above. 6.2.10 Integrated Camera System The Maestro is designed to utilize the PathCam camera system but will also accept other popular pathology camera systems.

  • Page 49: Bms (Building Management System) Connection

    6.2.11 BMS (Building Management System) Connection Mopec BMS (Building Management System) connection, option MB1022, is a simple output signal intended to be connected to a hospital remote management system. The function is a dry contact relay output that is triggered by an alert condition on the Maestro.
  • Page 50 • Suspected electrical issue. o Turn off the main power switch. ▪ Any faucets or fixtures that are controlled by solenoids will close automatically. o Turn off the unit’s facility breaker if further electrical issues are detected. • Suspected plumbing issue. o Turn off all water fixtures, typically the mixing valve levers will do this.

  • Page 51: Maintenance

    • Replacement Potassium Permanganate Filters (Ref Section 10). Use latex or nitrile gloves when removing the filters. All replacement filters will use a Mopec Potassium Permanganate Filter inside the filter carrier near the grill. •...

  • Page 52: Health Hazard Information & Disposing Of Filters

    • The potassium permanganate (KMnO4) filters change color from bright purple to dark brown with the amount of exposure. To check this please remove a used filter per section 7.1.1 above. • Pry open the corner of the filter and dump out some pellets for examination. •...

  • Page 53: Resetting/Leveling The Elevation System

    The new filter will side in and rest behind the grill. Once installed close the filter hinge and re-install the two thumb screws on each end. The filter change interval will vary depending on cleanliness of the incoming air. The best practice is to change filters quarterly. Please see section 10.1.2 for replacement filters.

  • Page 54: Resetting The Main Gfci

    • While holding both buttons, the unit will then move to the lowest position and synchronize and level out. • Continue to hold for another 3 seconds and then release both buttons. • Adjust the unit up and down and confirm the unit has remained level. Repeat the reset procedure multiple times if you suspect it has not fully leveled out.

  • Page 55: Resetting The Auxiliary Gfci

    • If the GFCI fails, there may still be a ground fault in the system or the GFCI unit may need to be replaced. See the section on Troubleshooting (8.0) or call Mopec Service (7.3) 7.1.7 Resetting the Auxiliary GFCI The Maestro is equipped with an auxiliary 15amp GFCI power outlet for uninterrupted supply on a computer system or other auxiliary devices plugged into the side panel.

  • Page 56: Stainless Care And Maintenance

    • DO NOT USE a straight bleach solution to clean your unit. Bleach will eventually erode stainless steel if not thoroughly rinsed. o Erosion from chlorine bleach is detectable and will void the warranty. o If your process must use chlorine bleach it must not exceed 10% and must be rinsed immediately after disinfection to avoid damage to the metal.

  • Page 57: Fingerprints And Solvent Cleaning

    It is best to follow with a warm water rinse. 7.3 Mopec Service PLEASE have the following information available BEFORE you call from your station ID tag or original order or quote.

  • Page 58: Troubleshooting And Repair

    8 TROUBLESHOOTING AND REPAIR 8.1 How to Identify and Solve Problems WARNING: The troubleshooting section is for reference only. Repairs are be made by licensed electrician or plumbing professional and shall follow proper facility safety protocols and a Lock out tag out Procedure. Error / Issue / Failure Cause Solution...
  • Page 59 Water Fixture Failures Facility water turned “OFF” Turn “ON” facility water supply Turn mixing valve “ON”. This is the handle nearest Mixing valve (pressure/temp control turned “OFF” the faucet. Check Y Strainers for debris. Water system plugged Check for kinked supply lines. Check backflow prevention devices (REF 8.2.5) My station’s faucets do not 1.
  • Page 60 mechanical switch. Replace if inoperable. Reinstall components in reverse order. 4. (REF 8.2.4.2) Un-kink hand spray hose Hand spray hose kinked Check in lower skirting for interference Mixing valve “OFF” Turn mixing valve “ON” Gate valve for end rinse Turn gate valve “ON” “OFF”...
  • Page 61 LED failure Replace fixture Power switch in light head Turn power switch on back of light head “ON” not turned “ON” Hanging task light not working LED failure Replace LED light head Adjust brightness to user preference in Light menu Brightness set too dim.
  • Page 62 Green Button is bad Replace green button Alarm Screen Say “Formalin Internal Formalin storage Dispense Low” at bottom of Add formalin to internal tank using transfer pump Tank is low screen Formalin Dispensing Leak alarm is There is a formalin leak or Repair leak &...

  • Page 63: How To Repair Product Components

    8.2 How to Repair Product Components 8.2.1 Electrical Panel Service The Maestro has an electrical service panel located on the sink side of the unit. This panel is where all the power is distributed to the Maestro. Use a Phillips screwdriver to remove the 10 fasteners. It is important to leave 10 inches of clearance to access this panel as it houses the PLC, HMI, Electrical DIN rail, and relays that may need service.

  • Page 64: Lighting/Power Supply Panel Service

    8.2.2 Lighting/Power Supply Panel Service The top of the hood houses the DC power supply and LED lighting components. To service components in the hood, use a Phillips screwdriver to remove the top cover. 64 | P a g e...

  • Page 65: Garbage Disposal Jams

    8.2.3 Garbage Disposal Jams The most common disposal failure is a Jam. Turn off the power to the station and check the disposal with a piece of wood, like a broom handle. Attempt to rotate the rotor both clockwise and counterclockwise to confirm the motor is not locked up.
  • Page 66 Reference Moen GX50C specification for more information. • MB1021 Optioned Models use a 1 HP disposal Mopec part PP0944 – (Moen GX100C) o https://manualzz.com/doc/53171928/moen-gx100c-gx-series-1-hp-continuous-feed-garbage-dispos o The MB1021 option includes a water injection feature. Disconnect the water injection line by loosening the hose clamp at the disposal inlet.

  • Page 67: Faucet, Hand Spray & End Rinse Service Panel

    • Check the airline connection to the switch has not become dislodged or completely disconnected due to shipping and handling or service in the area. The airline is located on the back of the unit behind the sink. The foot pedal is also operated via an airline take note of which one you are inspecting. 8.2.5 Faucet, Hand Spray &...

  • Page 68: Backflow Prevention And Service

    8.2.6 Backflow prevention and Service The Maestro utilizes two types of products for backflow prevention. • Atmospheric Vacuum Breaker equipped faucets – Chicago Faucets #GN8BVBJKABCP 8" (20cm) rigid/swing gooseneck spout with atmospheric vacuum breaker | Chicago Faucets • In-line Dual Check valve backflow preventer. Used on hand sprays, end rinses & water injected disposal units. LF7 - Watts Consult the manufacturer’s recommendation for testing and service intervals and your local ordinances.

  • Page 69: Documentation

    9 Documentation 9.1 Sample Rough in Drawing 69 | P a g e...
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  • Page 71: Electrical Diagrams

    9.2 Electrical diagrams 71 | P a g e...
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  • Page 74: Tuv Certification

    9.3 TUV Certification 74 | P a g e...
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  • Page 76: Plumbing Diagrams

    9.4 Plumbing diagrams 76 | P a g e...
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  • Page 79: Hvac / Ventilation Diagram

    9.5 HVAC / Ventilation diagram The following is a graphic representation of airflow on an in-house ventilated Maestro. 79 | P a g e...
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  • Page 81: Appendices

    Various Plumbing Part Description Mopec # OEM # Use(s) Collection Carboy PM0141 US plastics #73003 Formalin collection n/a – custom to Mopec Collection Cap assembly 5850 Formalin collection Collection tubing (¾” Vinyl) PP0045 McMaster 5233K71 Formalin collection Disposal ½ HP...

  • Page 82: Consumables

    Part Description Mopec # Use(s) In-grill ventilation filter for 48 or 96” units built with filters in the Mopec 48” Maestro MERV 8 Filter BF045 front of the unit. Mopec 56” Maestro MERV 8 Filter In-grill ventilation filter for 56” units built with filters in the front of BF048 the unit.
  • Page 83 BE045 Disinfectant foaming spray ClearSteel Stainless Wipes BE039 Stainless steel cleaner and polishing wipes Mopec Prefilled Formalin Cube – BG520/ Formalin Containers are filled with a 10% neutral buffered formalin 2.5/5 Gallons (9.46/18.92L) BG525 used as a general-purpose fixative for tissues.

  • Page 84: Glossary

    11 GLOSSARY Term Meaning Trademarked name of Mopec’s flagship grossing workstation Maestro Acronym for the Patented technology, Front Air System, where an extra burst of air is blown across the front of the worksurface to help protect the user from dangerous...

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