Service Manual
Microlab® STAR
P/N 610 754 / 00
Important Notice
• Reproduction of any part of this manual in any form whatsoever without the
express written consent of Hamilton Bonaduz AG is forbidden.
• The contents of this manual are subject to change without notice.
• All 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.
• The 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.
• Windows NT™, Windows 2000™ and Windows XP™ are registered trademarks
of Microsoft Corporation
• Microlab™ is a registered trademark of Hamilton Bonaduz AG
Microlab® STAR Service Manual
Table of Contents
1 Introduction ............................................................................................ 1-1
1.1 GENERAL INFORMATION ................................................................................1-1
1.1.1 ML STAR.....................................................................................................1-2
1.1.2 ML STAR IVD..............................................................................................1-2
1.1.3 ML STAR Extensions ..................................................................................1-2
1.1.4 Description of text icons for special notes ...................................................1-2
1.2 STRUCTURE OF THIS MANUAL ......................................................................1-3
1.3 SERVICE MANUAL UPDATES ..........................................................................1-4
1.4 SERVICE NEWS ................................................................................................1-4
1.4.1 Upgrades.....................................................................................................1-4
1.4.1.1 Firmware upgrade .............................................................................................. 1-4
1.4.1.2 Service Software upgrade .................................................................................. 1-4
1.4.1.3 User Software upgrade....................................................................................... 1-4
1.5 MANUALS OVERVIEW......................................................................................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 P/N 610888 ................................................................1-5
1.5.4 Service Manual P/N 610754........................................................................1-5
1.5.5 Firmware Reference Guides........................................................................1-5
1.5.6 Verification Reference Guide.......................................................................1-5
1.6 SOFTWARE OVERVIEW...................................................................................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
1.6.4 Firmware .....................................................................................................1-6
1.6.5 Adjustment Macro Programs.......................................................................1-6
1.6.6 Updates.......................................................................................................1-7
1.7 SERVICE PLAN .................................................................................................1-7
1.8 PART RETURN TAG..........................................................................................1-7
1.8.1 Return Goods Authorization ........................................................................1-7
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Microlab® STAR Service Manual
1.9 FEEDBACK ........................................................................................................1-8
1.10 CONTACTING HAMILTON ................................................................................1-8
2 Microlab® STAR Instrument ................................................................... 2-1
2.1 OVERVIEW ........................................................................................................2-1
2.1.1 Key Features ...............................................................................................2-2
2.1.2 ML STAR IVD..............................................................................................2-4
2.1.2.1 Total Aspiration and Dispense Monitoring (TADM) ............................................ 2-4
2.1.3 Product variants of Microlab STAR Instruments........................................2-5
2.1.4 Pipetting Head and Tip / Needle Combinations...........................................2-5
2.2 TECHNICAL SPECIFICATIONS ........................................................................2-6
2.2.1 Technical Status of ML STAR Instrument..................................................2-10
2.2.2 Computer Requirements ...........................................................................2-11
2.2.3 Software Requirements .............................................................................2-11
2.3 SERVICE PART CLASSIFICATIONS ..............................................................2-12
2.3.1 Service Assemblies ...................................................................................2-12
2.3.2 Exchange for Parts and Assemblies..........................................................2-12
2.4 ML STAR SERVICE KIT P/N 173970...............................................................2-13
2.4.1 Service Tool Maintenance.........................................................................2-14
2.5 DISPOSAL OF ML STAR INSTRUMENTS ......................................................2-14
3 Service Software.................................................................................... 3-1
3.1 OVERVIEW ........................................................................................................3-1
3.1.1 How to Install the Service Software.............................................................3-1
3.1.2 Service Software Root Directory structure...................................................3-2
3.2 STARTING THE SERVICE SOFTWARE ...........................................................3-3
3.3 HELP MENU.......................................................................................................3-6
3.4 DEINSTALLATION OF SERVICE SOFTWARE .................................................3-7
4 Installation of the instrument.................................................................. 4-1
4.1 OVERVIEW ........................................................................................................4-1
4.1.1 Installation Qualification ..............................................................................4-1
4.1.1.1 Microlab STAR Installation Qualification ............................................................ 4-2
4.1.1.2 Microlab STAR IVD Installation Qualification ..................................................... 4-3
4.2 INSTALLATION ..................................................................................................4-4
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4.2.1 Workplace environment...............................................................................4-4
4.2.2 Unpacking the instrument............................................................................4-5
4.2.2.1 Accessory boxes ................................................................................................ 4-6
4.2.2.2 Accessories ........................................................................................................ 4-7
4.2.2.3 Packing List ........................................................................................................ 4-7
4.2.3 Hooking up the instrument.........................................................................4-10
4.2.3.1 Putting the Instrument in place ......................................................................... 4-10
4.2.3.2 Power / Voltage ................................................................................................ 4-11
4.2.3.3 Communication................................................................................................. 4-12
4.2.3.4 Tip Waste station.............................................................................................. 4-13
4.2.4 Software Installation ..................................................................................4-14
4.2.4.1 User Software Installation................................................................................. 4-14
4.2.4.2 Check Access rights for C:\Barcodes ............................................................... 4-15
4.2.4.3 Accessories Installation (ML STAR IVD) .......................................................... 4-17
4.2.4.4 Service Software Installation ............................................................................ 4-17
4.2.5 Software Presettings .................................................................................4-17
4.2.5.1 Overview........................................................................................................... 4-17
4.2.5.2 Instrument Configuration .................................................................................. 4-17
4.2.5.3 User Software settings ..................................................................................... 4-18
4.2.5.4 User Software settings (ML STAR IVD) ........................................................... 4-19
4.2.5.5 Defining Access Rights (ML STAR IVD)........................................................... 4-20
4.2.5.6 Remote Access ................................................................................................ 4-24
4.2.6 Adjustment and Calibration .......................................................................4-26
4.2.6.1 Instrument Check Procedure............................................................................ 4-27
4.2.6.2 Automatic Adjustment....................................................................................... 4-28
4.2.7 Weekly Maintenance (ML STAR IVD) .......................................................4-28
4.2.8 Verification.................................................................................................4-28
4.2.9 Performing a test run.................................................................................4-28
4.2.10 Service Software Removal ........................................................................4-28
5 Disassembly .......................................................................................... 5-1
5.1 OVERVIEW ........................................................................................................5-1
5.2 CHECKLIST FOR DEINSTALLATION ...............................................................5-1
5.2.1 Decontamination .........................................................................................5-2
5.2.2 Removing Tips or Needles ..........................................................................5-2
5.2.3 Disconnect ML STAR Instrument ................................................................5-2
5.2.4 Remove all items on ML STAR Instrument..................................................5-2
5.2.5 Remove Panels ...........................................................................................5-2
5.2.6 Packing the ML STAR Instrument ...............................................................5-3
5.2.7 User Software Deinstallation .....................................................................5-13
6 Adjustment and Calibration.................................................................... 6-1
6.1 OVERVIEW ........................................................................................................6-1
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Microlab® STAR Service Manual
6.1.1 The Art / Principle of Adjusting ....................................................................6-2
6.1.2 Interpretation of correction values ...............................................................6-2
6.1.3 Order of adjustment and calibration ............................................................6-3
6.2 ADJUSTMENT TOOLS AND MACRO PROGRAMS..........................................6-5
6.2.1 Tools for Pipetting Arm and Channels.........................................................6-5
6.2.2 Tools for Autoload Adjustment ....................................................................6-8
6.2.3 Tools for Verification of ML STAR IVD ........................................................6-9
6.2.4 Adjustment Macro Programs.....................................................................6-11
6.3 ADJUSTING PIPETTING CHANNEL ...............................................................6-14
6.3.1 Pipetting Channels degrees of freedom........................................................6-15
6.3.2 Pipetting Channel Adjustment Tool ...........................................................6-16
6.3.3 Pipetting Channel Alignment .....................................................................6-17
6.4 ADJUSTING PIPETTING ARM ........................................................................6-19
6.4.1 Pipetting Arm degrees of freedom ................................................................6-21
6.4.2 Pipetting Arm Z Alignment.........................................................................6-22
6.4.3 Pipetting Arm X-Alignment ........................................................................6-24
6.5 ADJUSTING PIPETTING ARM WITH CHANNELS..........................................6-30
6.6 CALIBRATING PIPETTING 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
6.8 ADJUSTING AUTOLOAD DRIVE.....................................................................6-40
6.8.1 Autoload drive degrees of freedom ...........................................................6-41
6.8.2 Cog wheel synchronization........................................................................6-42
6.8.3 Loading tray adjustment ............................................................................6-44
6.8.4 Automatic Autoload Adjustment Procedure...............................................6-46
6.9 VERIFICATION ................................................................................................6-47
6.9.1 Volume Verification ...................................................................................6-47
6.9.2 Verification Kit’s.........................................................................................6-47
6.9.3 Verification after replacement, or remounting............................................6-48
7 Components .......................................................................................... 7-1
7.1 OVERVIEW ........................................................................................................7-1
7.2 REPLACEMENT OF COMPONENTS ................................................................7-1
7.3 COMPONENTS OVERVIEW..............................................................................7-2
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Microlab® STAR Service Manual
7.3.1 ML STAR ........................................................................................................7-2
7.3.2 ML STAR IVD .................................................................................................7-3
7.4 COVERS OF THE MICROLAB STAR ..............................................................7-4
7.4.1 Front Window and Panels left & right side...................................................7-4
7.4.1.1 Part List .............................................................................................................. 7-4
7.4.1.2 Function.............................................................................................................. 7-5
7.4.1.3 Replacement ...................................................................................................... 7-5
7.4.2 Deck Panels ................................................................................................7-7
7.4.2.1 Part List .............................................................................................................. 7-7
7.4.2.2 Function.............................................................................................................. 7-8
7.4.2.3 Replacement ...................................................................................................... 7-8
7.4.3 Pipetting Arm housing ...............................................................................7-14
7.4.3.1 Part List ............................................................................................................ 7-15
7.4.3.2 Function............................................................................................................ 7-15
7.4.3.3 Replacement .................................................................................................... 7-16
7.5 PIPETTING ARM..............................................................................................7-17
7.5.1 Part List .....................................................................................................7-18
7.5.2 Main Components .....................................................................................7-19
7.5.3 Replacement .............................................................................................7-19
7.5.4 Pipetting Arm Replacement Frame P/N 182108........................................7-21
7.5.4.1 Part List ............................................................................................................ 7-22
7.6 PIPETTING ARM X-DRIVE ..............................................................................7-23
7.6.1 Part List .....................................................................................................7-24
7.6.2 Function.....................................................................................................7-24
7.6.3 Replacement .............................................................................................7-25
7.7 PIPETTING CHANNELS ..................................................................................7-26
7.7.1 Part List .....................................................................................................7-27
7.7.2 Function.....................................................................................................7-28
7.7.3 Replacement .............................................................................................7-29
7.7.4 Part Numbers for original and replacement Parts......................................7-31
7.8 PIPETTING HEADS .........................................................................................7-32
7.8.1 Part List .....................................................................................................7-33
7.8.2 Function.....................................................................................................7-33
7.8.3 Replacement .............................................................................................7-34
7.8.4 Part Numbers for original and replacement Parts......................................7-36
7.9 AUTO LOAD DRIVE.........................................................................................7-37
7.9.1 Part List .....................................................................................................7-39
7.9.2 Function.....................................................................................................7-39
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Microlab® STAR Service Manual
7.9.3 Part Numbers for original and replacement Parts......................................7-46
7.10 AUTO LOAD X-DRIVE .....................................................................................7-46
7.10.1 Part List .....................................................................................................7-47
7.10.2 Function.....................................................................................................7-47
7.10.3 Replacement .............................................................................................7-48
7.11 INSERTION GUIDES .......................................................................................7-49
7.11.1 Part List .....................................................................................................7-50
7.11.2 Function.....................................................................................................7-50
7.11.3 Replacement .............................................................................................7-50
7.12 LOADING TRAY...............................................................................................7-51
7.12.1 Part List .....................................................................................................7-52
7.12.2 Function.....................................................................................................7-52
7.12.3 Replacement .............................................................................................7-52
7.13 ADDITIONAL INSTRUMENT COMPONENTS.................................................7-53
7.13.1 Tip Waste ..................................................................................................7-53
7.13.2 Spillage Trays............................................................................................7-53
7.13.3 Instrument Parts ........................................................................................7-53
7.13.4 Teaching Box ............................................................................................7-53
7.13.5 Teaching Station .......................................................................................7-54
7.14 ACCESSORIES................................................................................................7-54
8 Electronics ............................................................................................. 8-1
8.1 OVERVIEW ........................................................................................................8-1
8.1.1 Functional Overview....................................................................................8-2
8.1.2 Functional Description.................................................................................8-3
8.1.2.1 Interfaces:........................................................................................................... 8-3
8.1.2.2 ML STAR Instrument communication architecture: ............................................ 8-3
8.1.2.3 Firmware and Data ............................................................................................. 8-3
8.1.3 Boards Overview .........................................................................................8-4
8.1.4 Location of electronically components.........................................................8-5
8.1.4.1 Part List .............................................................................................................. 8-6
8.1.5 Covers over electronics...............................................................................8-6
8.1.6 Node settings / Dip Switches.......................................................................8-8
8.2 POWER..............................................................................................................8-9
8.2.1 Function.......................................................................................................8-9
8.2.2 Power Components.....................................................................................8-9
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Microlab® STAR Service Manual
8.2.3 Replacement .............................................................................................8-10
8.2.4 Reassembly...............................................................................................8-10
8.2.5 Wiring Diagram Power / Master.................................................................8-11
8.3 MASTER...........................................................................................................8-12
8.3.1 Function.....................................................................................................8-12
8.3.2 Master Block Diagram ...............................................................................8-13
8.3.3 Replacement .............................................................................................8-14
8.3.4 Remounting:..............................................................................................8-14
8.3.5 Adjustment ................................................................................................8-14
8.4 PIPETTING CHANNEL ....................................................................................8-15
8.4.1 Pipetting Channel Block Diagram..............................................................8-15
8.4.2 Pipetting Channel Wiring Diagram ............................................................8-16
8.4.3 Replacement .............................................................................................8-17
8.4.4 Remounting:..............................................................................................8-17
8.4.5 Adjustment ................................................................................................8-17
8.5 AUTOLOAD......................................................................................................8-18
8.5.1 Function.....................................................................................................8-18
8.5.2 Autoload Block Diagram............................................................................8-19
8.5.3 Autoload Wiring Diagram...........................................................................8-20
8.5.4 Replacement .............................................................................................8-21
8.5.5 Remounting:..............................................................................................8-21
8.5.6 Adjustment ................................................................................................8-21
8.6 CABLES ...........................................................................................................8-22
8.6.1 Location of cables .....................................................................................8-22
8.6.2 Cables Part list ..........................................................................................8-22
9 Maintenance .......................................................................................... 9-1
9.1 OVERVIEW ........................................................................................................9-1
9.2 ITEMS NEEDED.................................................................................................9-2
9.2.1 Duration.......................................................................................................9-2
9.2.2 Tasks...........................................................................................................9-2
9.3 DECONTAMINATION ........................................................................................9-3
9.4 LUBRICATION ...................................................................................................9-4
9.5 HALF-YEARLY MAINTENANCE ........................................................................9-5
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Microlab® STAR Service Manual
10 Troubleshooting and Error Handling................................................. 10-1
10.1 OVERVIEW ......................................................................................................10-1
10.1.1 Version Information ...................................................................................10-1
10.2 TRACE FILES ..................................................................................................10-1
10.2.1 Communication Trace files ........................................................................10-1
10.2.2 System Trace files.....................................................................................10-2
10.2.3 Investigation of Errors with Trace files.......................................................10-2
10.3 ERROR HANDLING .........................................................................................10-4
10.4 FIRMWARE ERROR CODES ........................................................................10-13
11 ML STAR Extensions........................................................................ 11-1
12 Appendices ....................................................................................... 12-1
12.1 APPENDIX A ....................................................................................................12-1
12.1.1 Glossary ....................................................................................................12-1
12.2 APPENDIX B ....................................................................................................12-7
12.2.1 Installation Qualification ............................................................................12-7
12.2.1.1 IQ Microlab STAR............................................................................................. 12-7
12.2.1.2 IQ Microlab STAR IVD...................................................................................... 12-9
12.2.2 Maintenance Checklist ............................................................................12-11
12.3 APPENDIX C..................................................................................................12-15
12.3.1 Service news ...........................................................................................12-15
12.3.2 Parts return tag........................................................................................12-16
12.3.3 Problem report form ................................................................................12-17
12.4 APPENDIX D..................................................................................................12-18
12.4.1 Microlab STAR Firmware Addresses:....................................................12-18
12.4.2 Microlab STAR Firmware Files:.............................................................12-18
12.4.3 Firmware Reference Guides....................................................................12-19
12.4.3.1 Master Module Command Specification......................................................... 12-19
12.4.3.2 X0 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 .......................................................... 12-31
12.5 APPENDIX E ..................................................................................................12-33
12.5.1 Microlab® STAR Service Kit ....................................................................12-33
12.5.1.1 Parts ............................................................................................................... 12-33
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Microlab® STAR Service Manual
12.5.1.2 Tools............................................................................................................... 12-36
12.5.2 ML STAR Verification Kit .........................................................................12-37
12.6 APPENDIX F PART LIST SUMMERY............................................................12-38
12.6.1 Instrument Cover Part List.......................................................................12-38
12.6.2 Covers over electronics ...........................................................................12-38
12.6.3 Deck Panel Part List................................................................................12-38
12.6.4 Pipetting Arm Cover Part List ..................................................................12-39
12.6.5 Pipetting Arm Part List.............................................................................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..............................................................12-41
12.6.8 Pipetting Channels Part List ....................................................................12-41
12.6.9 Pipetting Head Part List...........................................................................12-41
12.6.10 Autoload Part List....................................................................................12-42
12.6.11 Autoload's X Drive Part List.....................................................................12-42
12.6.12 Insertion Guide Part List..........................................................................12-43
12.6.13 Loading tray Part List ..............................................................................12-43
12.6.14 Tip Waste Part List..................................................................................12-43
12.6.15 Spillage Trays Part List ...........................................................................12-44
12.6.16 Instrument Parts......................................................................................12-44
12.6.17 Teaching Station .....................................................................................12-44
12.6.18 Teaching Box ..........................................................................................12-44
12.6.19 Boards Part List and accessories............................................................12-45
12.6.20 Cables Part list ........................................................................................12-45
12.7 INDEX ............................................................................................................12-46
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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.
Attention: You should read User Manual Chapter 1 "General Information" before
repairing or servicing the system.
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.
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.
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 service software.
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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 important for understanding the topic or
command in question.
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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
Chapter 8 Electronics
Chapter 9 Maintenance
Chapter 10 Troubleshooting and Error Handling
Chapter 11 ML STAR Extensions
Chapter 12 Appendices
• Chapter 1 serves as an introduction to the manual as a whole.
• Chapter 2 serves as an introduction to the Microlab® STAR instrument.
• Chapters 3-10 contain the servicing instructions.
• Chapter 11 contains the servicing instructions for the Temperature-Controlled
Carrier, Wash Station and iSwap.
• Chapter 12 contains all appendices.
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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 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.
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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 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.
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Microlab® STAR Service Manual
1.6 Software Overview
1.6.1 User Software P/N 911004
This is the software operated 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
• GRUALS16.ACH
• GRUC0S18.ACH
• GRUPXS17.ACH
• GRUR0S10.ACH
• GRUTXS10.ACH
• GRUWXS13.ACH
• Autoload
• Master
• Pipetting Channel
• iSwap
• Temperature-
controlled Carrier
• Wash Station
• AL
• C0
• PX
• R0
• TX
• WX
• 1.6S
• 1.8S
• 1.7S
• 1.0S
• 1.0S
• 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
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 Manual. 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).
Microlab® STAR Service Manual
1.8 Part Return Tag
The part return tag has following functions:
• Page 1: part identification, reason for return and description of problem
• Page 2: decontamination declaration (where required).
1.8.1 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 from
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
Fax
Hotline
E-mail
Americas, Far East and Pacific Rim:
Hamilton Company
P.O. Box 10030
Reno, NV 89520-0012 USA
Toll Free
Phone
Fax
+41 81 660 60 60
+41 81 660 60 70
+41 81 660 60 50
itechsupport@hamilton.ch
+1 (800) 648-5950
+1 (775) 858-3000
+1 (775) 856-7259
E-mail
tech@hamiltoncompany.com
1-8
Microlab® STAR Service Manual
2 Microlab® STAR Instrument
2.1 Overview
Z
Y
X
The Microlab® STAR is a Sequential Transfer and Aliquoting Robot 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 Xdirection, 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
xpansion) technology
E
• Independent Y, Z, volume, and LLD for
each pipetting head
CO-RE Technology
• Tips and needles on the same
pipetting head
• Flexible use of tips and needles during
the same run
• 300 µl channel:
low- and standard-volume tips or
needles
when volumes < 5 µl must pipetted.
• 1000 µl channel:
standard- and high-volume tips or
needles
when volumes > 5 µl 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
• 2 types of pipetting heads are
available:
• 300 µl (0.5-300 µl)
and
• 1000 µl (5-1000 µl)
Tips and Needles
The types of tips and needles currently available are:
10, 300 and 1000 µl disposable tips with or without filter
and
50, 300 and 1000 µl 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 aborts 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:
• Sample preparation for ELISA, LIA, RIA, FIA, agglutination and CLIA tests
• Preparation for amplification techniques for DNA detection
• 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
Auto load
4 to 16 channels
300 µl, or 1000 µl
iSwap
Wash station
Temperature-controlled
carrier
Automated vacuum
system
2.1.4 Pipetting Head and Tip / Needle Combinations
All pipetting heads mounted on channels are either of 300 or 1000 µl type. A mixture
of these two types is not allowable - the user software will not support a
configuration with both types of pipetting heads.
300 µl Pipetting Head 1000 µl Pipetting Head
Low Volume Standard Volume High Volume
Tip Needle Tip or Needle Tip or Needle
0.5 – 10 µl
0.5 – 50 µl
1 - 300 µl
10 - 1000 µl
2-5
Microlab® STAR Service Manual
2.2 Technical Specifications
Item Value
maximum weight of instrument
with the Autoload option and trays installed
8 Channel Version:
16 Channel Version:
ML STAR Instrument packed for
transportation – total weight including
shipping crate:
electrical requirements
maximum power consumption:
Voltage:
Frequency:
Delayed action fuse:
115 V∼:
145 kg
155 kg
< 200 kg
600W
115 / 230 V∼ -15 % + 10 %
50 / 60 Hz ± 5 %
6.3 A
230 V∼:
Operating temperature range:
Storage temperature range:
3.15 A
15-35 °C
relative humidity 30 – 85 % with
no condensation
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:
Instrument: incl. attached Autoload tray
ML STAR Instrument packed for
transportation – shipping crate dimensions
Width: 1670 mm
Height: 868 mm
Depth: 780 mm
Depth: 780 +220 mm = 1000 mm
Width: 1820 mm
Height: 1000 mm
Depth: 900 mm
2-7
Microlab® STAR Service Manual
Technical Specifications (continued)
Item Value
Work area
Movement
Increments for x, y, z
drives
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
Refer to Firmware Reference Guides
2-8
Microlab® STAR Service Manual
Technical Specifications (continued)
Criteria Value
Barcode Types Specification:
The following types of bar code symbol can
be recognized by the system:
See also user software Menu:
Tools ML STAR Configuration Editor
Advanced Barcode settings
Bar Code Density and Resolution:
Code density, tolerances:
The minimum code densities depend on the
bar code type and bar code length
ISBT standard
Code 128 (subset B and C)
Code 39
Codabar
Code 2 of 5 Interleaved
UPC A/E
JAN/EAN 8
Up to 32 characters (excluding
start, stop and check characters)
can be read and decoded.
Minimum module width (including
a print tolerance of 0.0005“) *
0.0065 inches (= 0.1651 mm).
Print Quality:
Print Contrast Signal (PCS):
Positioning of Barcode labels:
measured from Deck
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.
Minimum contrast between bars
and spaces: PCS 80 %
(PCS at 632.8 nm Wavelength)
Range on Tubes: 30 – 110 mm
Centerline on Plates: 118 mm
2-9
Microlab® STAR Service Manual
Technical Specifications (continued)
General Note on Drive Specifications1:
The User Interface is the Master where all units are 0.1 mm in length and volumes
are 0.1 µl.
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, 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 2000 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 NT Version 4.0 (or higher) and Service Pack 5 (or higher),
• Windows 2000 or
• Windows XP.
Ongoing updates of User and Service Software may also require Operating System
updates.
The Microlab
instrument.
®
STAR software installed on one PC controls one Microlab® STAR
2-11
Microlab® STAR Service Manual
2.3 Service Part Classifications
Spare Part
Class (SPC)
I Instrument
A Service Technician always has these parts with him.
B Dealer has parts in stock.
C Hamilton has parts in stock.
T Service Tools
V Consumables
Z Accessories
Not a Spare Part
The Spare Part Class (SPC) appears as a column of each part list in this manual.
Description
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).
2-12
Microlab® STAR Service Manual
2.4 ML STAR Service Kit P/N 1739702
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.
2
See also section 12.5 Appendix E on page 12-27 for a complete Part List
2-13
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:
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.
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.
2-14
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
• Configures the Microlab STAR Instrument
• Downloads Firmware
• Updates the Technical Status
• Performs calibration and adjustments (Macro Programs)
• Controls all single movements of the instrument
• Checks Sensor status
• Gathers all Trace information
• Features both Single Commands and Macro Programs
(refer to firmware reference guide)
3.1.1 How to Install the Service Software
Attention: 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.
• Put Service Software CD into CD-ROM Drive
• start Setup.exe Program File from the CD-ROM and carefully follow the
installation instructions.
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
3-2
Microlab® STAR Service Manual
3.2 Starting the Service Software
From Start Menu:
Startup for Service Software:
Start Programs HAMILTON Microlab STAR Service Microlab STAR Service.
3-3
Microlab® STAR Service Manual
Starting the Service Software (continued):
From Desktop Shortcut:
Service Software may also started from the desktop, if you create a shortcut to the
“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)
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:
“->” identifies a command from PC to ML STAR Instrument
and
“<-“ identifies a response from ML STAR Instrument to PC after the command has
been executed.
3-5
3.3 Help Menu
In this section, all Menu Choices of the Service Software are explained.
Microlab® STAR Service Manual
3-6
Microlab® STAR Service Manual
3.4 Deinstallation of Service Software
Select Start Programs HAMILTON Microlab STAR Service UnInstall
Microlab STAR Service, then follow the Instructions given in the Program.
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 SETTINGS SYSTEM ADD / REMOVE SOFTWARE and
search for ML STAR Service Components, removing them if still present.
3-8
Microlab® STAR Service Manual
4 Installation of the instrument
4.1 Overview
The initial unpacking, installation and setup of the Microlab® STAR 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.
Attention: Exercise great care if touching the Channels when unpacking the
Instrument!
4.1.1 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.
Attention: Do not skip any Chapter as 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
4-2
Microlab® STAR Service Manual
4.1.1.2 Microlab STAR IVD Installation Qualification
4-3
Microlab® STAR Service Manual
ace
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 airconditioning duct.
Depending on the Microlab® STAR configuration used, your Microlab® STAR may
weigh up to 155 kg3. The Microlab® STAR must be placed on a table or workbench
capable of supporting the weight of the Microlab
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 appropriate 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
any wall. Ensure that there is collision-free movement of the Pipetting arm.
®
STAR and providing the minimum
®
STAR and
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!
Workpl
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 surrounding 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.
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 Panels4) 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 customer ordered.
Check the packing list.
The items from these boxes must mounted on the Microlab
part of the installation.
Attention: Items for ML STAR and ML STAR IVD may vary, therefore ensure correct
parts are being used when setting up the Instrument.
®
STAR Instrument as a
4
Back Panels only for ML STAR IVD Instruments available
4-6
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.
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.
Microlab® STAR Service Manual
.
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
Microlab® STAR Service Manual
k
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 protection bloc
Channel supporting block
1. Carefully remove all protective foam blocks from between channels
2. Remove pipetting arm supporting block from the front
3. Carefully remove channel supporting block from underneath pipetting arm
4. 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.)
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 Trays6 onto the Instrument.
Attach protective front and side shields. ML STAR IVD Instruments have an
additional shield toput in place at the back of the instrument.
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!
6
Microlab®-STAR Instrument with Autoload Option only
4-10
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.
• The 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.
Attention: Connect only to an earth-grounded outlet
Voltage selector
Microlab® STAR Service Manual
Fuses
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.
4-11
4.2.3.3 Communication
23578123578
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-hand side of the instrument and to
the corresponding serial interface on your personal computer.
Cables
• USB P/N 355130
• RS 232 P/N 173898
Connecting scheme of RS 232 cable
Microlab® STAR Service Manual
1
to Instrument
Male Plug
Female Plug
to computer
Ground
Note: older ML STAR Instruments have RS 232 interface only, if both serial
interfaces are available, the USB serial interface should be selected.
Attention: Do not connect RS 232 and USB together - if both serial interfaces are
available, select either one or the other!
4-12
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
Microlab® STAR Service Manual
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.
The Microlab Star IVD Tip 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
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.
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Microlab® STAR Service Manual
4.2.4 Software Installation
4.2.4.1 User Software Installation
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.
• 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:
Version Information
After a successfully installation of user Software a Version Info Program will be
found on START Programs HAMILTON Version Info
This Tool will provide information about the User Software installed.
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.
• select Security Tab
Check if 'Users' have Modify
and Read & Execute rights
as shown here.
If not, see next page…
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Microlab® STAR Service Manual
Check Access rights for C:\Barcodes (continued)
• If ‘Users’ do not have the permissions needed, click 'Add'
• Ensure current PC is selected in 'Look in'
• Select 'Users', click 'Add' and then ‘OK’
Allow 'Modify' for Group 'Users'
The ‘Permissions’ section of the
window should then look like this.
Finally click ‘OK’
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Microlab® STAR Service Manual
4.2.4.3 Accessories Installation (ML STAR IVD)
• Accessories CD comes together with Carrier
• Put CD into CD-ROM-Drive
• start Setup.exe Program File from the CD-ROM and carefully follow the
instructions during installation.
4.2.4.4 Service Software Installation
Generally - see section 3 Service Software on page 3-1.
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:
• Using the Service Software, you can set the Microlab
Configurations on the Master Board located inside the Instrument.
• Using the User Software, you can set the Microlab
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.
STAR Instrument
STAR Instrument
4-17
4.2.5.3 User Software settings
• Select ML STAR
• Menu: Tools ML STAR Configuration Editor Advanced
Microlab® STAR Service Manual
4-18
Microlab® STAR Service Manual
4.2.5.4 User Software settings (ML STAR IVD)
• Select ML STAR
• Menu: Tools ML STAR Configuration Editor… Advanced
Differences from the ML STAR User
Software are:
• Communication only via USB
(not selectable)
• Channel Type only 1000 µl
(not selectable)
• TADM settings Tab
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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'.
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’.
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’.
Decide if the User is to be defined only locally or also to a domain (in that 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.)
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’
7. When the ‘Lab Operator’ List is complete with all ‘Users’ then click ‘OK’ –
otherwise click ‘Add’.
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
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:
4-23
4.2.5.6 Remote Access
It is the Customer’s responsibility to prepare the operating PC for remote access.
Ensure only read access is enabled.
• Overview
Microlab® STAR Service Manual
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
engineer on ML STAR IVD PC.
5. Means of Connection (e.g. Telephone
LAN manager at Customer site, or PC
Administrator
LAN manager at Customer site
number), Account name and Password
for Service engineer.
• 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.
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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...'
3.2. Activate 'Share this folder', define Share name and optional Comment,
then click ‘OK’
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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 Autoload7.
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 CHECK.MCR”.
setup / installation of ML STAR instrument
606867 Instrument Check.mcr
yes
passed?
no
606827 PIP Autoadjustment.mcr
606867 Instrument Check.mcr
passed?
no
606828 PIP XY Manual Adjustment.mcr
Perform mechanical positioning adjustment
accordi ng to result va lues
606828 PIP XY Manual Adjustment.mcr
improved?
yes
no
Passed?
yes
606827 PIP Autoadjustment.mcr
606867 Instrument Check.mcr
no
Passed?
yes
setup sucessful
yes
no
if values are far out of tolerance then mechanical
adjustment with adjustment tools must performed
606825 Arm Z-Difference .mcr
until passed
606826 Arm X-Difference .mcr
until passed
606828 PIP XY Manual Adjustment.mcr
continue according to installation qualification
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 3.4 Deinstallation of Service Software on page 3-7.
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.
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.
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
• 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
• 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
Attention: Good Laboratory Practices should be observed when disposing of
consumable items such as used 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.
• 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:
• By using the Service Software Menu Control Single command Send
command P#MD (where # is the Pipetting Channel Number). A minimum
initialization is provided by sending Single Commands P#YI and P#ZI prior to the
P#MD Command.
or:
• By using the Service Software Menu Control Movement/Sensors Pipetting
Channel Initializing each squeezer drive.
or:
• After Instrument has been switched off, turning the squeezer spindle by hand to
release the O-Ring coupling.
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 items on ML STAR Instrument
All Carriers, Tip Waste, Spillage Trays and loading trays8. 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
Use ML-STAR PACKAGING P/N 220308 to ensure adequate packing and shipping.
Microlab® STAR Service Manual
Item:
1 Pallet
10 & 11 Surrounding
Cover with Top
12 Accessories Boxes (2
pieces)
5-3
Microlab® STAR Service Manual
Packing the ML STAR Instrument (continued)
Item:
2. Square Foam
(1 piece)
3. Channel protection foam
blocks (between the
Channels)
(25 pieces)
4. iSwap protection block
(1 piece)
5. Channel supporting block
(1 piece)
6. U-shaped holding bars
(2 pieces)
7. Pipetting Arm supporting
Block
(1 piece)
8. Z Profiles block
(2 pieces)
9. Square Foam
(2 pieces)
5-4
Microlab® STAR Service Manual
ML-STAR packaging (continued):
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.
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
Instrument9.
Pipetting arm – U-shaped protective foam bars go on X linear guide.
9
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 the rear, protect it with the
iSWAP protective block and tie it to the back.
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.
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):
8. Place all accessories into the accessories boxes.
Accessories include:
• Wrapped loading trays and waste station.
• Carriers in 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).
9. 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
2 Z profiles
Instrument on pallet without top and
surrounding covering
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 recommended that you Back up Methods, User defined
Labware, Liquid classes etc. before removing current software.
5-13
Microlab® STAR Service Manual
User Software Deinstallation (continued)
Select START SETTINGS SYSTEM ADD / REMOVE SOFTWARE and
search for ML STAR - as well as for PHOENIX Components - and remove them if
still present.
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 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 Channel, Pipetting Head, Autoload drive10 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.
Attention: before starting any Adjustment and Calibration Work empty and
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 reach an optimum with adjustment the concept “Degrees of freedom” must be
understood:
• Tilting around an axis means rotating or turning around a specific axis.
• Moving on 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.
6-2
Microlab® STAR Service Manual
6.1.3 Order of adjustment and calibration
1. Adjustment of Pipetting Channels and Heads
• 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
• 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.
• 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
Channels and Heads on Pipetting Arm must have the same orientation in X-,
Y- and Z-Direction.
4. Adjustment of Autoload11:
• Adjustment (synchronization) of Cogwheels
5. Calibration of Autoload12:
• 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.
11
Microlab®-STAR Instrument with Autoload Option only
12
dito
6-3
Microlab® STAR Service Manual
Order of adjustment and calibration
Deadjusted Channel, or replaced Channel
mechanical adjustment with adjustment tools
606825 Arm Z-Difference .mcr
until passed
606826 Arm X-Difference .mcr
until passed
606828 PIP XY Manual Adjustment.mcr
Perform mechanical positioning adjustment
according to result values
606828 PIP XY Manual Adjustment.mcr
improved?
yes
no
606827 PIP Autoadjustment.mcr
passed?
yes
no
if values are far out of tolerance then mechanical
adjustment with adjustment tools must performed
606825 Arm Z-Difference .mcr
until passed
606826 Arm X-Difference .mcr
until passed
606828 PIP XY Manual Adjustment.mcr
606867 Instrument Check.mcr
no
passed?
adjustment sucessful
yes
6-4
Microlab® STAR Service Manual
6.2 Adjustment Tools and Macro Programs
6.2.1 Tools for Pipetting Arm and Channels
Channel Adjustment Tool P/N 173952 For mechanical Channel Adjustment on
Channel Calibration Tool P/N 173960
Z- Tool P/N 173968
Tool Description
Pipetting Arm.
Must be used for preadjustment
whenever a Channel is replaced in
Order to mount the new channel on the
Pipetting Arm.
Predefines:
• Parallelity (alignment) in Z Direction
in functional dependence on X- and
Y-Axis.
• Linearity (alignment) of all Channels
in Y-Axis.
Reference for Pipetting Arm Alignment
/ Adjustment and Pipetting Channel
Calibration
Together with the Adjustment 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)
Channel Positioning Tool P/N 182960
Tool Description
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)
Pipetting Arm Alignment Tool P/N
173956
Front window Magnet P/N 173950
Tool Description
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.
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).
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 Supports mechanical Cock wheel
synchronization and automatically
Groove for automatic positioning in
X, Y and Z Direction of Autoload
positioning in X, Y and Z Direction of
Autoload drive.
drive
Cog rail only for mechanical Cog
wheel synchronization.
Autoload Sensors Adjustment Tool P/N
173980
Checks Barcode reading, Cup
Presence sensor adjustment and the
quality of Carrier-loading and unloading.
Reference Barcode
Tube Set P/N 173986
Reading Height from Deck:
• for Plates 118 mm
• for Tubes 30 – 110 mm
Included with Autoload Sensors
Adjustment Tool are:
Label P/N 173985
• Label P/N 173985 for Barcode
Reader alignment
• Reference Barcode Tube Set P/N
173986
6-8
Microlab® STAR Service Manual
6.2.3 Tools for Verification of ML STAR IVD
Barcode Carrier P/N 185270 Supports verification of Barcode
Waste Block P/N 185281
Tool Description
reading of 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)
Pressure Transmitter P/N 185380
Tool Description
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.)
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.
C:\ program files \ HAMILTON \ ML STAR \ services \ macros \.
There are two types of Adjustment Macro Programs:
Measurement and Calibration Macros.
• Measurement Macro Programs do not change any Calibration values. The
Software Program provides values which may not exceed the given tolerance.
• 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 it is 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.
Attention: Ensure all Macro Programs once started are correctly completed. Only
this will leave the Microlab STAR Instrument within a defined status.
Note: All 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
• NIX.MCR
• START.MCR
Attention: Pipetting Channels (complete with Pipetting Heads) must be mounted and
adjusted properly before running any Adjustment Macro Program.
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Microlab® 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.
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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 Tips picked up.
Measurement Macro Program.
Tightness check procedure With waste block 185281 and user
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
Software ML STAR IVD
PIP_PRESSURE_SIGNALS_CHECK.M
CR
and
PIP_PRESSURE_SIGNALS_AUTOADJ
USTMENT.MCR
Especially after replacement of
CORE O-Rings the tightness of seal
on each Pipetting Head may be
checked.
With waste block 185281 and
pressure Transmitter the values for
TADM may be checked and
adjusted.
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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-Axis 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.
5. Tilting around Z-Axis Adjustment not possible, Position is given through YSlide 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
Pipetting Arm with its Y-Slide and -guide.
Channel Calibration Tool with Macro Program
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A
6.3.1 Pipetting Channels degrees of freedom
Microlab® STAR Service Manual
ttention: 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 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
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Microlab® STAR Service Manual
e
ft
6.3.2 Pipetting Channel Adjustment Tool
Pipetting Arm's left upper Y-Guide shaft
Channel Adjustment
Tool placed approx. In
the middle onto Pipetting
Arm's upper Y-Guides
• Remove Y-Spindles first
• Gently drive Pipetting Head all the
way down, then gently push
Channels Z-Guide Shaft into
Adjustment Tool. If not possible
release locking and fixing screws.
• Check visually, there may be no
Gaps between Z-Guide and referenc
grooves of Adjustment Tool.
• Freeze Adjustment Position by
carefully tightening the fixing screws.
Pipetting Channels Z-Guide sha
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.
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