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MP1100/MP1101 Plasma Freezers

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3. InstaCoolant IV Drum 53 Gallons 200 6 Liters 70025 Keypad Membrane 1 61 008 Manual Operator Service 37 00 053 Pocket Repair Kit 7 01 002 Primary Power Panel 7 51 003 Pump Assembly without Motor 7 03 006 Pump Coupler 2 00 008 Pump Motor Box Assembly 7 65 046 Pump Motor Assembly 7 26 01 1 Pump Shaft 6 13 011 Strain Relief Fitting 1 46 023 MP 1100 20 Part Number Pocket 7 47 141 Pocket Spring 6 16 109 Secondary Power Panel 7 51 004 MP 1100 21 Pocket 7 47 157 Pocket Spring 6 16 130 Secondary Power Panel 7 51 004 Continued on next page MP1100 Freezer Operator and Service Manual 37 00 053 B 8 Parts List Please Note Parts that are ordered but not listed here are considered a Special Order and are subject to availability and variable pricing Although we will do everything in our power to expedite delivery there could be a lead time of up to 6 weeks to receive these parts In the event that you frequently order parts not on this list we highly encourage you to maintain a small stock at your facility thermogenesis MP 1100 23 Pocket 7 47 140 Pocket Spring 6 16 115 Secondary Power Panel 7 51 004 MP 1100 27 Pocket 7 47 137 Secondary Power Panel 7 51 020 The Primary Components Kit include fan 230VAC 50 60 Hz adjustable hose clamp clear urethane coolant hose temperature sensor prima
4. 5 8 Draining Water from the System 5 9 Restoring Freezer to Operating Temperature 5 10 Maintaining the Refrigeration System 5 10 Chapter 6 TROUBLESHOOTI NG Introduction Ee pedet 6 1 No Power to 6 2 Freezer Display is Lit but Pumps Do Not Work 6 2 Coolant Chamber Fills Initially but During the Cycle the Coolant Level Drops Off 6 2 Product 15 not Completely Frozen 6 2 Coolant Temperature is too High 6 3 MP1100 Plasma Freezer Operator and Service Manual 37 00 053 B TOC 3 P Table of Contents thermogenesis Condensing Unit Refrigerant System Shuts Down ccc 6 3 Pockets Tearing or Ripping 6 3 Vacuum Light is Not Activating 6 3 Chapter 7 REPLACING PARTS FOR THE MP1100 FREEZER Safety Precautions 7 1 HINGE eee ein ee ed eee 7 2 BE 7 4 Eid Gasket oe deep oer nate teed aera ER 7 4 Lid Gasket 7 5 DOCK 7 8 Motorbox 7 8 Control Panel un Leto ett teh etus 7 11 Power 7 12 Probe BOX 7 12 Motorbox Removal a
5. 1 1 How to Use this 1 1 Text 5 1 2 Electrical 1 2 Safety 1 3 Copyright 1 4 Trademarks 1 4 Disclaimer cere rer x Rp Bed 1 5 Contact Information 1 5 Limited 1 6 Warranty 1 6 Procedure e ee eese attends 1 7 LIMITATIONS 0c cece cece cece 1 7 thermogenesis 1 Introduction Intended Use NOTE There are two types of MicroCascade freezers the MP1100 and MP1101 The only difference between the two models is the certification The MP1101 is the model CE certified for sale in Europe Since operation and service requirements are the same for both freezers they will be referred to collectively as MP1100 Freezer throughout the manual The ThermoGenesis Corp MP1100 freezer with MicroCascade Refrigeration is intended for the fast efficient freezing of blood and blood components This Operator and Service manual is organized to provide easy access to setup and maintain the MP1100 Freezer Please read this manual in its entirety How to Use This Manual Key I nd
6. 3 3 Electrical Installation and Specifications 3 5 Installing the Control Arm and Control Panel Housing 3 5 Connecting all the Wires 3 7 Adding the InstaCoolant IV to the Freezer 3 8 Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 x ova trot t o me ies 3 8 Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 3 9 Adjusting the Safety Thermostat 3 10 Starting the MP1100 Freezer 3 10 Temperature 3 11 Verifying Operating Temperature 3 13 P 3 Installation thermogenesis Unpacking and I nspection Check for any shipping damage upon receiving the freezer If there is any apparent damage notify the shipping company immediately Contact Helmer Technical Service if there are any problems The following items are included with the freezer 75 Gallons 284 liters InstaCoolant IV Spare Pockets Control Panel Housing and Control Panel Control Arm Accessories Kit NOTE Each MP1100 requires 75 gallons of coolant Coolant is shipped in five boxes 22 gallons total and one 55 gallon drum containing 53 gallons Please record the following information from the back of the freezer in the spaces marked below Part Numbe
7. esses 7 23 thermogenesis 7 Parts Replacement Safety Precautions NOTE During disassembly keep parts in order to facilitate re assembly CAUTION Prior to starting any electrical work disconnect all power to the freezer NOTE Check all hose and wiring connectors to make sure they are secure and correct NOTE Special tools and service material may be required depending on the repair Be sure to use these tools and materials and follow the proper work procedure NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment CAUTION Make sure the InstaCoolant IV is above freezing before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger MP1100 Freezer Operator and Service Manual 37 00 053 B 7 1 P 7 Parts Replacement thermogenesis Hinge Tools Required T Handle Allen wrench 5 32 Removal 1 Lift up upper and lower plastic hinge covers to expose mounting screws Figures 7 1 7 2 Figures 7 1 7 2 Hinges MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement 2 Figure 7 3 Hinge Assembly 3 4 5 Using the Allen wrench remove the four screws and washers that secure the upper hinge body to the lid Figure 7 3 Remove the two upper
8. 5 5 Checking the Coolant 5 6 Checking the Lid Gasket Seals 5 6 Checking the 5 6 Checking the Deck Screws 5 7 Verifying Operating Temperature Calibration 5 7 The Defrost Cycle 5 7 Before Starting the Defrost Cycle 5 7 Initiating the Defrost 5 8 Draining Water from the System 5 9 Restoring Freezer to Operating Temperature 5 10 Maintaining the Refrigeration System 5 10 thermogenesis 5 Maintenance The following are the minimum recommended maintenance periods Maintenance may be performed more frequently if required Forms are included in Appendix A of this Manual The table below outlines the maintenance schedules to be performed by the blood center The sections following the table provide detail for the routine maintenance schedules listed Maintenance Schedule SCHEDULE MAINTENANCE DESCRIPTION e Clean the deck e Check and clean or repair the pockets repair or replace if necessary Daily Weekly Monthly e Clean the unit e Check desiccant filters e Check motor box cooling fans Check vacuum gauge P N s 8 1100 27 and 8 1101 27 Check coolant level Check lid gasket seals Check hinges Check deck screws
9. 4 3 Verifying Operating Temperature Calibration 4 4 Recalibrating the Operating Temperature 4 4 Setting the Freeze Cycle 4 5 Running the Freeze 4 6 Running the Night 4 7 TOC 2 MP1100 Plasma Freezer Operator and Service Manual 37 00 053 B thermogenesis Table of Contents Chapter 5 MAINTENANCE Maintenance Schedule 5 1 Checking and Cleaning the Pockets 5 1 Cleaning the 5 2 Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 5 2 Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 5 3 Repairing a Pocket 5 4 Cleaning the Freezer 5 5 Checking the Desiccant Filters 5 5 Checking the Pump Motor Cooling Fans 5 5 Checking the Coolant Level 5 6 Checking the Lid Gasket Seals 5 6 Checking the 5 6 Checking the Deck Screws 5 7 Verifying Operating Temperature Calibration 5 7 The Defrost Cycle 5 7 Before Starting the Defrost Cycle 5 7 Initiating the Defrost
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12. temperature has exceeded the safety limit 26 C 80 F and the Safety Thermostat has shut off power to the freezer If this is the case the red light on the right side of the freezer will be on Turn off the main power switch and contact Helmer Technical Service Freezer display is lit but pumps do not work Blown Fuse s Remove primary power panel and replace fuse s Pump s is are iced up Defrost the freezer See Section Running the Defrost Cycle Chapter 5 Coolant Chamber fills initially but during the cycle the coolant level drops off Freezer has accumulated ice that is clogging the pump inlet s Defrost the freezer See Section Running the Defrost Cycle Chapter 5 Product is not completely frozen 6 2 Freezing chamber is not completely filling with coolant Freezer has accumulated ice that is clogging the pump inlet Defrost the freezer See Section Running the Defrost Cycle Chapter 5 Coolant pump is not running See Freezer display is lit but pumps do not work Check fuses in primary power panel MP1100 Freezer Operator and Service Manual 37 00 053 B 4 thermogenesis 6 Troubleshooting Problem Product is not completely frozen continued from previous page Probable Cause Pump coolant transfer hoses are loose on the connections or have broken Solution Reconnect coolant hose to the fitting and tighten c
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15. 8 1100 27 and 8 1101 27 only MP1100 Freezer Operator and Service Manual 37 00 053 B The vacuum system is not working properly 1 Check pockets for leaks If leaking pockets are found repair or replace leaking pockets see Sections Removing and Replacing a Pocket and Repairing a Pocket Chapter 5 Maintenance 2 If no leaking pockets have been found defrost freezer 3 If vacuum system is still not working have a qualified technician check the system If vacuum system needs to be replaced contact Helmer Technical Service 6 3 Chapter 7 Parts Replacements for the MP1100 Freezer TABLE OF CONTENTS Safety 7 1 HIN QC debe ode teed nb 7 2 MC 7 4 Eid GasK6et c 12er ideis ore xr Moe eaa 7 4 Lid Gasket 7 5 prd 7 8 Motorbox 7 8 Control Panel 7 11 Power 7 12 Probe BOX tr DR MER 7 12 Motorbox Removal and Installation 7 14 Motorbox Disassembly and Assembly 7 16 Defrost 7 18 Safety Thermostat 7 19 Sensor Temperature 7 22 Chamber d 7 23 Condensing Unit
16. MP1100 Freezer Operator and Service Manual 37 00 053 B 3 7 P thermogenesis 3 Installation Adding the I nstaCoolant IV to the Freezer The MP1100 uses 75 gallons of InstaCoolant IV silicone based coolant The coolant is added to the freezer in a 53 gallon 200 6 liter drum and small 4 5 gallon 9 5 liter containers using the following method 1 Remove a pocket in the left hand chamber closest to the left side of the chamber 2 Insert the hose from the transfer pump through the pocket opening 3 Add the coolant to the freezer until the level is about 2 5 6 35 cm above the bottom of each chamber NOTE When coolant is added wait two minutes before checking coolant level in each chamber CAUTION InstaCoolant IV should be stored in a room where the temperature does not exceed 85 F 29 4 C Never store InstaCoolant IV in direct sunlight Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 Removing a pocket 1 Remove the pocket spring by reaching in the pocket and grasping the ends and pressing them slightly together as the spring is removed Figure 3 6 Protective 4 e Caps Pocket Spring c 3 2 Figure 3 6 Pocket Springs 3 8 MP1100 Freezer Operator and Service Manual 37 00 053 B P 3 Installation thermogenesis 2 Grab the inside front seam of the
17. a new gasket installer should use gasket plate as a template and transfer holes onto gasket using an awl before proceeding with this step 4 Continue around the lid by lifting gasket aligning mounting holes and installing mounting screws until all screws are secure 5 Re check each mounting screw to ensure tightness 6 Re install lid per Section Lid Lid Gasket Plate Tools and Supplies Required e 2 Phillips screwdriver e Bostik 1100FS P N 5 13 004 e 4 cable tie Removal 1 Remove lid gasket per Section Lid Gasket 2 Separate gasket plate from lid by pulling up and away from lid NOTE Gasket plate is factory bonded to lid with a flexible sealant Some force maybe required in breaking this bond In some rare cases older freezers for instance the old gasket plate may be needed for a mounting hole template to transfer holes to new gasket plate Therefore it is recommended that care be taken to keep the old gasket plate intact during removal 3 Disconnect desiccant tube from barbed elbow located on backside of plate by cutting cable tie that secures tube to elbow Figure 7 5 MP1100 Freezer Operator and Service Manual 37 00 053 B 7 5 p 7 Parts Replacement thermogenesis 4 Remove threaded barbed elbow from plate and retain for installing on new gasket plate Figure 7 5 Installation 1 If new gasket plate does not have pre drilled mounting holes use old gasket as a t
18. at room temperature 75 F to 85 F 24 C to 29 C If the freezer detects a coolant temperature of greater than 80 F the red indicator light would be illuminated and the safety thermostat would need to be temporarily adjusted Call Helmer Technical Service for assistance with adjusting the safety thermostat CAUTION Only a trained service technician should adjust the safety thermostat Starting the MP1100 Freezer 1 Make sure the unit is properly connected to power supply then turn on the power switch 3 10 MP1100 Freezer Operator and Service Manual 37 00 053 B p 3 Installation thermogenesis NOTE There is a built in 2 to 5 minute time delay once the power is turned on before the high stage compressor turns on along with the condenser cooling fans Thirty seconds after the high stage compressor starts the low stage compressor will start 2 After the MicroCascade refrigeration system starts the MP1100 Freezer will begin to chill the InstaCoolant to the set operating temperature Temperature Pull down At the start of the temperature pull down it is recommended to do the following 1 Record the temperature on the display at the beginning of the pull down NOTE Record the temperature approximately every 10 minutes as the unit drops in temperature to verify proper operation NOTE During temperature pull down it is necessary to run all chambers in continuous 90 min
19. is restored If hinge is not loose replace the gasket seal NOTE A tight seal reduces water from entering into the unit reducing ice build up on deck and in coolant Checking the Hinges 1 Open the lids Lids should remain open 2 Visually inspect the hinges for damage Grasp either side of the hinge and gently move hinge side to side and up and down If hinges are loose they will move during this test If hinges are loose re seat lid if necessary and tighten appropriate hinge screws Repeat test until no hinge movement is detected 3 Close lids and inspect them to make sure there is no gap between the lid and gasket 5 6 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 5 Maintenance Checking the Deck Screws 1 Open both lids 2 Inspect the deck to ensure that all screws are tight Tighten the screws if needed Verifying the Operating Temperature Calibration See Section Verifying Operating Temperature Chapter 4 The Defrost Cycle Factors that may influence the need for defrost are e Operation of the freezer in a high humidity environment e Improperly sealed pockets When this happens moisture in the air condenses and turns to ice Ice buildup in the reservoir will eventually clog the pump inlets and cause improper filling resulting in unfrozen product Ice buildup can also cause pump breakage and costly repairs NOTE THERMOGENESIS CoRP recommends as a min
20. of overwrap bags during freeze Use of transport boxes during freeze Attached satellite bags during freezing e Orientation of plasma bag in the pocket that allows part of the bag to be above the coolant level e Lower coolant temperature e Ambient operating temperature NOTE Please take into account the above variables when determining your freeze cycle time Operational Input Codes The following codes are programmed to perform various functions with the freezers Enter the codes using the keypad on the control panel Codes are entered using the following sequence CODE gt RESET DESIRED FUNCTION gt START For example to set the operating temperature to 42 C the operator would enter 100 press RESET enter 42 for 42 C and press START within 10 seconds to save the instructions For example to set the freeze cycle time press RESET The time function display will flash the current freeze cycle time i e 1230 for 12 minutes 30 seconds Enter the desired freeze cycle time and press START to save the new cycle time NOTE Press START within 10 seconds to save instructions otherwise the MP1100 will default to the previous setting 4 2 MP1100 Freezer Operator and Service Manual 37 00 053 B p thermogenesis 4 Operating Instructions CODE FUNCTION 100 Set operating temperature 200 Set calibrated operating temperature 300 Nite cycle o
21. on top of deck and align lid mounting holes with hinge mounting holes 2 Install eight each hinge mounting screws and washers 3 Check lid gasket to deck seal per Maintenance Chapter 5 4 Install upper plastic hinge covers 5 Remove cap from desiccant filter fitting and connect desiccant tube extending from rear of lid to filter assembly Lid Gasket Tools Required e 2 Phillips screwdriver e Awl for new gasket installation Removal 1 Remove lid per Section Lid and place on flat work area with gasket side up 2 Starting on one side lift inner flange of lid gasket toward outside edge of lid to expose mounting screws Figure 7 4 Figure 7 4 Lid Gasket Removal 7 4 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement 3 Using the screwdriver remove the exposed mounting screws 4 Continue around the lid by lifting the gasket and removing exposed screws until all screws are removed 5 Remove gasket by stretching flange over edge of mounting plate Installation 1 Position gasket on gasket plate and stretch over edge all around perimeter until gasket flange is fully seated between gasket plate and lid 2 Starting on one side lift inner flange of lid gasket toward outside edge of lid to expose gasket plate mounting holes 3 Align one gasket plate mounting hole with corresponding gasket and lid mounting holes and install one mounting screw NOTE If installing
22. opposite side 6 Close lid and turn vacuum disable switch back on CAUTION Wear protective gloves and use safety precautions If repairing pocket during a decontamination procedure follow biohazardous precautions 1 Use the pocket repair kit that comes with the freezer See Section Unpacking and Inspection Chapter 3 a cotton swab and a disposable cup 2 Remove the leaking pocket see previous Section Removing and Replacing a Pocket Use soft cloth to remove coolant from pocket 3 Locate the hole visually or by filling the pocket with water and watching for leaks NOTE The pocket repair kit is designed for repair of small holes not for tears along the seam or around the snap seal ring 4 Make sure the surface of the pocket to be patched is dry Place a small amount of repair kit tape on the inside of the pocket covering the hole 5 Clean 1 cm around the hole by applying a small amount of Cotol 240 with the cotton swab to the outside of the pocket 6 In the disposable cup mix equal amounts of Cotol 240 and Aquaseal using the wooden stir stick The consistency should be like liquid glue 7 Apply a coating of this mixture onto the hole overlapping 1 cm around the hole 8 Let dry for a full 2 hours Test the repaired pocket for leaks by following step 3 If there is no leak then pocket is ready to use If there is a leak repeat the repair procedure steps 4 through 8 Re test for leaks before
23. screws washers and spacer that secure the lower hinge body to the chassis Figure 7 3 Loosen the two lower screws that secure the lower hinge body to the chassis Figure 7 3 Remove the hinge by pulling upward Installation 1 Position lower mounting slots of lower hinge body so they engage between the freezer chassis and flat washers of the two loosened lower mounting screws Align upper mounting slots of lower hinge body with chassis mounting holes and install the two upper hinge mounting screws and washers Align lid mounting holes with upper hinge mounting holes and install the four remaining mounting screws and washers Check lid gasket to deck seal per Maintenance Chapter 5 Lower both upper and lower plastic hinge covers MP1100 Freezer Operator and Service Manual 37 00 053 B 7 3 P 7 Parts Replacement thermogenesis Lid Tools and Supply Required e T Handle Allen wrench 5 32 e 3 8 rubber cap or duct tape Removal 1 Remove pull off upper plastic hinge covers to expose hinge to lid mounting screws 2 Using Allen wrench remove the 16 screws eight per hinge and washers that secure upper hinge body to lid Figures 7 1 7 2 3 Disconnect desiccant tube extending from rear of lid to filter assembly mounted on rear of freezer chassis Figures 7 1 7 2 4 Cap off desiccant filter fitting duct tape works well in place of a rubber cap 5 Remove lid from deck I nstallation 1 Place lid
24. sides of the freezer when passing through passageways and doorways NOTE There must be at least 18 46 cm clearance from the back and left side of the freezer to any wall to allow for adequate ventilation There must be 36 91 cm between the wall and right side of the freezer to service the condensing unit If adjacent equipment is also putting out heat additional space may be required For P N s 8 1100 27 and 8 1101 27 There needs to be enough space to read the vacuum system gauge located on the back of the freezer Contact Helmer Technical Service for assistance with additional space requirements before connecting to the power supply CAUTION Make sure the Power Switch is in the OFF position Once the freezer is in position lower the leveling feet There will only be about 1 2 to level the unit with the feet If more is needed to level the unit the unit may need to be relocated or call Helmer Technical Service for help NOTE Level the freezer both side to side and front to back by placing a level on the top of the freezer and adjusting the leveling feet up or down 3 4 1100 Freezer Operator and Service Manual 37 00 053 B 3 Installation thermogenesis Electrical Installation and Specifications A qualified electrician should wire the power source of the freezer The unit shall be wired directly to a minimum circuit plug of 50 amps or a 60 amp disconne
25. than 10 12 inches vacuum the vacuum system needs adjustment To increase vacuum turn the red knob between the desiccant tubes counterclockwise To decrease vacuum turn the red knob clockwise Figure 3 8 3 12 MP1100 Freezer Operator and Service Manual 37 00 053 B p 3 Installation thermogenesis Figure 3 8 Desiccant Tube Assembly Verifying Operating Temperature After the freezer has reached the operating temperature verify the temperature by following the steps listed in Section Verification of Operating Temperature Chapter 4 After this verification the MP1100 is now ready for validation and operation MP1100 Freezer Operator and Service Manual 37 00 053 B 3 13 Chapter 4 Operating Instructions TABLE OF CONTENTS Introduction ER ak 4 1 Factors Influencing Plasma Freeze Times 4 2 Operational Input Codes 4 2 Setting the Operating Temperature 4 3 Verifying Operating Temperature Calibration 4 4 Recalibrating the Operating Temperature 4 4 Setting the Freeze Cycle 4 5 Running the Freeze 4 6 Running the Night 4 7 p thermogenesis 4 Operating Instructions Introduction NOTE In order to maintain a consistent temperature when the condensing unit is on the pump motor will st
26. use MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 5 Maintenance 9 A repaired pocket should be used as an interim solution A repaired pocket should be replaced with a new pocket NOTE Place the opened container of Aquaseal in the refrigerator for later pocket repairs Once mixed Cotol 240 and Aquaseal can be used until the glue becomes thick Cleaning the Freezer On a weekly basis clean the freezer Using a mild detergent in warm water wipe all outer surfaces the control panel the inner surfaces of the lid and gasket and the deck Checking Desiccant Filters The desiccant filter tube s are located on the back of the freezer Figures 3 1 3 2 The blue indicating pellets in the desiccant material need to be replaced when all the blue pellets fade to a gray color To replace desiccant material 1 Unsnap the clips holding the tube and remove the tube of desiccant 2 Remove the top coupling on the desiccant filter that holds the desiccant beads Dispose of contents according to local regulations Fill clear tubes completely with new desiccant P N 7 01 038 Replace top coupling and tighten Place the tube back into the clamps and snap closed Repeat for the other desiccant tube P N s 8 1100 27 and 8 1101 27 8 Verify proper tubing connection or inlet and outlet of tubes Ot BO Checking the Pump Motor Cooling Fans 1 Hold a piece of paper agains
27. 00 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement 6 Remove the motor mount bracket using a Phillips screwdriver to remove the screws 7 Remove middle vacuum seal bracket located between the motorbox assemblies 8 Lift out motorbox assembly by pulling straight up on the assembly 9 Once motorbox assembly has cleared the top of the chassis place assembly on top of chassis at an angle which would allow access to pump hose connection 10 Loosen pump discharge hose clamp with 5 16 nutdriver and remove hose from pump Remove hose clamp from hose and store with motorbox assembly 11 Remove motorbox assembly enough so that it just clears the coolant Tip assembly on discharge side and allow remaining coolant in pump to drain back into reservoir 12 Remove motorbox assembly completely from reservoir and place on its side CAUTION Motorbox assembly is top heavy and will easily fall over if placed upright on pump housing Installation 1 Place assembly on top of chassis at an angle Orient the 2 opu 10 assembly so that motor will be toward the back when replaced Install hose and hose clamp on pump discharge fitting and tighten with 5 16 nutdriver Apply a bead of silicone caulking on the underside of the flanges and lower motorbox assembly down into position Install middle vacuum seal bracket Install the motor mount bracket s Install probe box acco
28. 100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement Chamber Tools and Supplies Required e 2 Phillips screwdriver e 5 16 nutdriver or socket wrench e 7 16 nutdriver or socket wrench e l5 nutdriver or socket wrench Removal 1 Turn unit power off at switch located on primary power panel Figure 7 7 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove deck per the instructions in this section Remove middle deck support bar 5 Remove four 14 20 hex cap screws and lock washers which mount chamber splash plate using 7 16 nutdriver 6 Remove two 20 hex cap screws and lock washers which mount chamber 7 Remove chamber by gripping sides and lifting straight up Pw Installation 1 Lower chamber onto chamber support bracket 2 Align mounting holes and install two hex cap screws and lock washers Do not tighten at this time 3 Align splash plate mounting holes with that of chamber and chamber support bracket and install four hex cap screws and lock washers 4 Tighten all six mounting screws 5 Install deck support bracket onto chassis mounting clips 6 Install deck per Section Deck 7 Reconnect unit to power source 8 Turn power onto unit and verify operation per startup process in Section Starting the MP1100 Plasma Freezer Chapter 3 Condensing Unit CAUTION Only a licensed refrigeration serv
29. 1100 Freezer Operator and Service Manual 37 00 053 B p thermogenesis 4 Operating Instructions 7 The freeze cycle is complete when the countdown on the Time Function Display reaches 0 The control panel will display DRN 8 When the 75 second drain cycle is completed an alarm will sound 9 Lift the lid While the lid is open the display will alternate between LID and OPEN 10 Remove the frozen blood components from the pockets CAUTION To reduce the possibility of damaging the pockets slowly remove product from pockets Running the Night Cycle NOTE ThermoGenesis Corp recommends running the MP1100 in night cycle mode if unit is not being used for more than a 24 hour period such as weekends or holidays The night cycle prevents temperature variances when the unit is not being used to freeze blood components The night cycle operation allows the user to place a load of blood components in a chamber or all chambers before leaving for the night or a weekend When the night cycle is activated the unit performs a normal freeze cycle for the length of time last set on the control panel Upon completion of the freeze cycle the freezer will then cycle the pumps for five minutes every half hour to maintain the temperature of the frozen blood components Perform the following steps to run a night cycle 1 Open the lid to an idle chamber and place the blood components
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31. 53 B 2 1 9 thermogenesis Ambient Operating Temperature Temperature 15 C to 27 C 59 F to 80 F Relative humidity 10 to 80 RH Altitude lt 2000m IP 40 Pollution Degree 2 2 2 MP1100 Freezer Operator and Maintenance Manual 37 00 053 B P thermogenesis 2 Overview Overview The ThermoGenesis Corp MP1100 Freezer is a low temperature freezing system Blood components are frozen using a liquid coolant which circulates around specially designed pockets containing the blood product The MP1100 Freezer consists of the following components Figure 2 1 e MicroCascade ultra low temperature condensing unit Two 2 coolant circulating pumps Deck and deck heater Pockets Pocket springs P N s 8 1100 20 21 23 and 8 1101 20 21 23 Primary and secondary power panels e Control panel Figure 2 1 MP1100 Freezer Control Arm Control Motor Box Cover Chamber Lids and Indicator Deck Light Drain Port Housing 1100 Freezer Operator and Maintenance Manual 37 00 053 B 2 3 2 Overview thermogenesis Safety Devices The Safety Thermostat The MP1100 freezer consistently monitors the temperature of the coolant with a temperature sensor and safety thermostat see Section InstaCoolant IV for a description of the coolant If the coolant temperature exceeds the safety thermostat temperature setting the thermostat turns off power to the major
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33. 9 Install motorbox cover per Section Motorbox Removal and Installation 10 Reconnect unit to power source 11 Turn power onto unit and verify operation per startup process in Section Starting the MP1100 Plasma Freezer Chapter 3 p Adjusting the Safety Thermostat Temporarily adjust the safety thermostat for a higher temperature see Section Safety Precautions Chapter 1 The thermostat is normally set to 80 F 2790 The coolant is usually at room temperature 75 F to 85 F 24 C to 29 C when it is added to the freezer Therefore the safety thermostat must be set slightly higher than the coolant temperature during the freezer pull down to operating temperature 1 Remove the motor box cover by the following method 2 Remove the four screws holding the rear of the motor box cover 3 Atthe front of the freezer gently lift the rear of the motor box cover about 2 and gently pull the cover toward you until you can lift it upward from the front 4 Tilt the motor box cover on its right side Figure 7 11 5 At the right front of the motor box is the safety thermostat Figure 7 11 7 20 MP1100 Freezer Operator and Service Manual 37 00 053 B 4 thermogenesis 7 Parts Replacement Figure 7 11 Safety Thermostat Thermostat 6 With a small flat head screwdriver remove the small round gray plastic cover over the adjusting screw for the temperature 7 Insert a small flat blade screwdriver in the adjus
34. LLATI ON Unpacking and Inspection 3 1 Connecting the Desiccant Filter Assembly P N s 8 1100 20 21 23 and 8 1101 20 21 23 3 1 1100 Plasma Freezer Operator and Maintenance Manual 37 00 053 B 1 P Table of Contents thermogenesis Connecting Desiccant Filter Assembly and Vacuum Pump P N s 8 1100 27 and 8 1101 27 only 3 2 Placing the Freezer in Position 3 3 Electrical Installation and Specifications 3 5 Installing the Control Arm and Control Panel Housing 3 5 Connecting all the Wires 3 7 Adding the InstaCoolant IV to the Freezer 3 8 Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 3 8 Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 3 9 Adjusting the Safety Thermostat 3 10 Starting the MP1100 Freezer 3 10 Temperature 3 11 Verifying Operating Temperature 3 13 Chapter 4 OPERATING INSTRUCTI ONS Introduction penne tem ERES 4 1 Factors Influencing Plasma Freeze Times 4 2 Operational Input 5 4 2 Setting the Operating Temperature
35. MP LIGHT POWER IN CONTACTOR POWER OUT 7 Rotate motorbox to its side and place on top of condensing housing NOTE If a circuit is disconnected see Figure 7 9 to reconnect Installation 1 Place motorbox cover on its side on top of condensor housing 2 Lower motorbox cover over motor assembly until tie brackets contact top of freezer chassis Make sure spiral wrapped cables are routed over the left side of motor mounting plate 3 Slide motorbox cover toward front of unit approximately two inches While lifting front align slot in motorbox cover flange with chassis mounting guide holddown 7 10 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement 4 5 Lower front of motorbox cover and slide it toward rear allowing tie brackets to drop down into place at back of unit Lift up on the front of motorbox cover to make sure slotted flange engaged chassis mounting guide holddown If it does not perform steps 8 10 taking care to ensure engagement of slot and guide holddown Install four screws that mount tie brackets to chassis P N s 8 1100 27 and 8 1101 27 The vacuum hose will need to be installed before installing the four screws that mount the brackets to the chassis N CAUTION DO NOT over tighten Control Panel Reconnect to power source Turn power to unit on and verify operation per startup process in Section Starting the
36. MP1100 Plasma Freezer Chapter 3 If during the repair process the temperature of the InstaCoolant has risen significantly refer to Section Temperature Pulldown Chapter 3 Tools and Supplies Required 2 Phillips screwdriver 11 32 nutdriver or socket wrench ESD protective bag Removal 1 Turn unit power off at switch located on primary power panel Figure 7 8 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Using screwdriver remove the panel mounting screws 4 Lift up one edge of panel to get a finger grip then lift panel up to remove it from control box 5 Turn panel over and disconnect ribbon cables at back of panel 6 Using nutdriver unscrew grounding nut and remove ground wire from grounding stud on back of panel 7 Place panel in an ESD bag and seal it Keep sealed in bag until ready to re install Installation 1 2 Remove panel from ESD bag Re install ground wire onto grounding stud Sequence of installation from panel is as follows star washer nut starwasher ground ring terminal starwasher nut MP1100 Freezer Operator and Service Manual 37 00 053 B 7 11 P 7 Parts Replacement thermogenesis 3 Re connect ribbon cables ensuring full engagement of connections 4 Place panel on flange of control box opening 5 Re install the panel mounting screws N CAUTI ON DO NOT over tighten Power Panel Tool
37. SKET PLATE LID FRONT GASKET PLATE SEALANT APPLICATION Figure 7 7 Pocket Pocket Spring Configuration pocket opening deck TOP VIEW pocket spring is held in place by pockel anapcap engaging bottom edge of deck pocket ning pocket spring pocket SECTION SIDE VIEW MP1100 Freezer Operator and Service Manual 37 00 053 B 7 7 P 7 Parts Replacement thermogenesis Deck Tools Required e 2 Phillips screwdriver Removal 1 Raise lid to its fully opened position 2 Remove all the deck mounting screws 3 Disconnect deck heater circuit at connection terminal located at rear of unit under the motor box cover 4 Remove deck by lifting straight up until the bottom of the pockets clear the stainless steel top of chassis 5 Unclip rod at bottom of pocket before removing deck see Section Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 Chapter 5 Installation 1 Place deck over chamber opening and lower onto chassis 2 Align mounting holes of deck to corresponding tapped holes of chassis 3 Install the deck mounting screws 4 For P N s 8 1100 20 21 23 and 8 1101 20 21 23 Check pocket spring installation to ensure they engage under lip of deck opening Figure 7 7 For P N s 8 1100 27 and 8 1101 27 Re attach pockets according to instructions in Section Removing and Replacing a Pocket P N s 8 1100 2 and 8 1101 27 Chapter 5 5 Reconnect deck heater circuit at conn
38. Verify operating temperature calibration Defrost the freezer Quarterly Bi annual e Maintain the refrigeration system Checking and Cleaning Pockets NOTE If there is a blood component leak dispose biohazardous waste in biohazardous waste container accordance with local and national regulations 1 For P N s 8 1100 27 and 8 1101 27 Before using the vacuum gauge the vacuum light needs to be illuminated If the light is not working see Section Troubleshooting Chapter 6 Check the pockets for leaks using the vacuum test gauge provided with the freezer Insert foam part of test gauge into each pocket If the gauge registers any value greater than 0 the pocket has a leak and needs to be repaired or replaced If not immediately replaced a pocket plug can be inserted into the pocket opening temporarily MP1100 Freezer Operator and Service Manual 37 00 053 B 5 1 p 5 Maintenance thermogenesis N CAUTI ON Do not vacuum out the coolant 2 11 coolant is inside the pocket it also indicates a leak Repair or replace the pocket 3 If ice or frost is inside the pocket remove the ice or frost with a small wet dry vacuum cleaner 4 Dry the lids and deck with a soft cloth and close the lids Cleaning the Deck 1 Raise both lids allowing ice to melt off the deck approximately 15 20 minutes 2 Once ice is melted use a wet dry vacuum cleaner or soft cloth to remove water f
39. an electric immersion heater in the coolant see Section Safety Precautions Chapter 1 Initiating the Defrost Cycle 5 8 1 Loosen a pocket and place 4 to 6 drops of dye located in the Accessories Kit in either chamber 2 To start the defrost cycle enter 400 on one of the numeric keypads then press RESET This closes the refrigerant liquid line solenoid valve shutting off refrigeration to the freezer At the same time the pumps begin circulating the coolant through the chambers and the defrost heater is engaged to warm up the coolant to 32C 52C 379F 419F The MP1100 Freezer will take 6 10 hours depending on operating temperature to warm the coolant to termination temperature 3 Once the defrost warm up cycle completes and shuts off the pumps allow the unit to sit for about 5 minutes this will allow the water in the system to settle turn the power switch on the freezer to the OFF position 4 For P N s 8 1100 27 and 8 1101 27 before the defrost cycle completes the warming of the coolant to about 2 C remove the pockets from the front and back of each chamber For P N s 8 1100 20 21 23 and 8 1101 20 21 23 simply open the lip of the pocket NOTE Since the pumps are still running they will circulate the dye throughout the reservoir and the chamber s allowing any water in the freezer to absorb the coloring 5 While still facing the primary power panel remove the 4 screws holding the prim
40. and Service Manual 37 00 053 B 4 3 p 4 Operating Instructions thermogenesis Verifying Operating Temperature Calibration Verifying the operating temperature of the freezer confirms that the digital temperature display is reading the actual coolant temperature around the pocket ThermoGenesis Corp calibrates the operating temperature of the freezer at the factory before shipment Verification and re calibration if required should be performed in the following instances e quarterly maintenance e after relocation of the freezer e if freezer has been turned off for a period of time To verify the temperature calibration 1 The temperature of a freeze cycle must be measured 2 Lift the lid on a chamber The display will display LID OPEN 3 Insert a calibrated thermometer capable of reading to 60 C into a middle pocket of the chamber corresponding to the keypad being used 4 Close the lid 5 Enter 300 reset on the corresponding keypad to initiate the freeze cycle The chamber will fill and NITE will flash on the display 6 After four minutes lift the lid Keeping the thermometer close to the pocket read and record the temperature This will help to prevent false reading due to exposure to ambient temperature Remove the thermometer from the pocket and close the lid Press STOP on the keypad and the chamber will drain 7 f the recorded temperature of the thermometer is not 3 C from the tem
41. art filling and circulating coolant in the left chamber until set operating temperature is reached To remove or insert product during this process start a cycle in the right chamber This chapter outlines the following operations of the freezer using the Control Panel Keypads Figure 4 1 The MP1100 Freezer is easy to adjust and to operate This section outlines the following basic operations of the freezer using the control panel keypads e Setting the operating temperature Verifying the operating temperature calibration e Calibrating the operating temperature e Setting the freeze cycle time e Running a freeze cycle e Running a defrost cycle e Setting the MP1100 freezer for Night Cycle operation Figure 4 1 MP1100 Control Panel TIME FUNCTION G Bar Spal 9 OPERATING TEMPERATURE EEROR MESSAGE 4 5 s 4 5 s ogg MP1100 Freezer Operator and Service Manual 37 00 053 B 4 1 p 4 Operating Instructions thermogenesis Factors Influencing Plasma Freeze Times There are a number of variables which could influence the time it takes to freeze plasma in the MP1100 As additional variables are added to the freeze process the time to freeze plasma solid may be extended Known factors which influence freeze time e Higher volume of plasma in the bag Greater number of bags per freeze cycle Larger size of the collection bag Folding plasma bags during freeze Use
42. ary power panel in place and gently slide the primary power panel out of the console 6 Remove the solenoid fuse from the fuse holder marked SOLENOID or the wire connector next to the fuse holder marked solenoid coil MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 5 Maintenance 7 Replace the primary power panel in the console and secure with the four screws Draining the Water from the System 1 Make sure that pockets at the front and back of the chambers are removed to allow access to the bottom of the chambers for removal of any water collected there 2 Make sure that you have a 5 gallon pail and the hand pump located in the Accessories Kit 3 Take the hand pump and carefully skim any colored water residing on top of the coolant which is in the bottom of each chamber 4 Once the chambers are cleared of any collected water turn the power switch to the ON position start the pumps again and run for a period of 15 minutes This will deposit more water into the chambers 5 After shutting off the pumps allow the unit to sit for a period of 5 minutes to allow the water to settle in the chambers 6 Repeat Steps 1 through 4 until no colored water is seen in the chambers Then turn the Freezer Power switch to the OFF position 7 Remove the small black port cover on the drain port of the freezer located on left hand side of freezer in upper right hand corner Attach the hand pump to the drai
43. assembly 1 First unscrew the four 20x3 4 hex bolts from the rear of the unit hex bolts located next to the power junction box 2 Next position the vacuum pump into place while aligning the four 14 20 tap holes Torque the four 14 20x3 4 hex bolts to 47 3 in Ib 3 Plug vacuum pump connector to pig tail connector on rear on motor box cover assembly left side 4 The reinforced spiral tubing coming out of the motor box cover from rear should be assembled onto the inlet port of the vacuum pump Secure the tubing tightly with the supplied adjustable clamp 3 2 MP1100 Freezer Operator and Service Manual 37 00 053 B 3 Installation thermogenesis Figure 3 2 Desiccant filter and vacuum system arrangement Vacuum System Assembly Desiccant Filter Assembly 24005283 CO eit Pod To install desiccant filter assembly 1 Unscrew the four 10x1 self tapping screws from the rear of the unit screws located on the rear lower right of the unit 2 With the desiccant filter clip on hand thread self tapping screw through the hole of clip 1 screw clip total 4 times Secure the clip to rear of freezer unit as depicted Hand tighten all four desiccant clips into place 3 Snap desiccant filter assembly onto clip 4 With the supplied 50 long reinforced spiral tubing attach one end to the inlet of the desiccant filter the 1 PVC pipe location beneath the gate valve Secure
44. build up and resulting in the need for more frequent defrost 2 While facing the primary power panel remove the 4 screws holding the primary power panel in place and gently slide the primary power panel out of the console 3 Replace the solenoid fuse in the fuse holder marked SOLENOID and or the wire connector and verify that the fuse holder is securely refastened 4 Replace the primary power panel in the console and secure with the four screws 5 The refrigeration will start and the system will begin to cool down to the set operating temperature 259C to 559C or 3229F to 679F Remember there is a programmed 2 5 minute delay after the defrost cycle is terminated prior to the refrigeration system start up 6 Set freeze cycle times on both keypads for 90 minutes and run continuous freeze cycles to circulate coolant until the unit is down to the set operating temperature 7 After unit comes down to temperature check the coolant level 8 Verify operating temperature calibration and calibrate as needed see Section Calibrating the Operating Temperature Chapter 4 Maintaining the Refrigeration System 5 10 1 Turn the power switch on the right side of the freezer to OFF 2 Remove the screws holding the grille on the front of the condensing unit section of the freezer 3 Remove the grille and carefully place it next to the freezer The inlet side of the refrigeration condenser coil is now visible 4 Using a sof
45. cal Service on the next business day Failure to notify Helmer Technical Service on the next business day after a request for emergency repairs may result in denial of coverage for that service call When calling for service have available 1 detailed information about the problem 2 the serial number of the unit 3 the service record for the unit 4 the date and place of purchase of the unit Limitations EQUIPMENT OR SPARE PART MALFUNCTIONS OTHER THAN THOSE CAUSED BY DEFECTS IN MATERIALS OR WORKMANSHIP INCLUDING MALFUNCTIONS CAUSED BY MISUSE ACCIDENT OR FAILURE TO PERFORM SCHEDULED MAINTENANCE ARE EXCLUDED FROM COVERAGE ANY ALTERATIONS OR MODIFICATIONS MADE TO THE UNIT OTHER THAN MODIFICATIONS OR ALTERNATIONS MADE BY THERMO RENDER THE WARRANTY NULL AND VOID THERMO WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES RESULTING FROM EQUIPMENT MALFUNCTION OR LOSS OF USE OF THE EQUIPMENT THERMO MAY AUTHORIZE INDEPENDENT CONTRACTORS TO PERFORM SERVICE SERVICE PROVIDERS ARE INDEPENDENT CONTRACTORS NOT THERMO EMPLOYEES CONSEQUENTLY THERMO 15 NOT RESPONSIBLE FOR THE ACTS OR OMISSIONS OF THE SERVICE PROVIDERS INCLUDING WITHOUT LIMITATION FAILURE BY A SERVICE PROVIDER TO RESPOND TO CALLS FOR EMERGENCY SERVICE IN A TIMELY FASHION MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 1 7 Chapter A Overview TABLE OF CONTENTS 5 2 1 Overview 2 2 Safety Devic
46. ce blood components in the pockets CAUTION To prevent pocket damage do not drop or force blood components in the pockets If the unit has a vacuum system wait until the vacuum light is ON before loading or unloading the unit with blood components 3 Close the lid and press START The control panel will flash FILL for one minute indicating that coolant is filling the chamber 4 Once the chamber is full the corresponding display will begin a countdown CAUTION Unless absolutely necessary do not raise the lid during the freeze cycle Do not add blood components at any time during the freeze cycle without restarting the freeze cycle from the beginning as this will result in those blood components being incompletely frozen 5 If the lid is opened during the countdown the chamber will drain the display will flash DRN W and then a 5 second alarm will sound After the lid is closed the chamber will fill the display will flash FILL and then the freeze cycle will resume at the point before the lid was opened 6 During the freeze cycle the countdown is displayed on the control panel a To stop the cycle press STOP CLEAR The chamber will drain the display will flash DRN an alarm will sound and INT will flash on the control panel b Press STOP CLEAR again to restart freezing cycle or press START and freezer will resume at the point that the cycle was interrupted 4 6 MP
47. components of the freezer making the freezer inoperable To adjust the safety thermostat see Section Safety Thermostat Chapter 7 Two situations can cause the safety thermostat to turn off power to the major components of the freezer 1 During equipment installation when the coolant is added to the freezer it is most likely at room temperature or about 24 759F If the thermostat sensor detects the coolant is above 272C 809F it automatically shuts off power to the major components of the freezer as a safety measure 2 During a programmed defrost operation the defrost heater warms the coolant from its chilled temperature to about 32C 5 C 372F 41 F If the defrost heater does not shut off and keeps warming the coolant the safety thermostat will automatically shut off power to the major components when coolant reaches 27 C 80 F Major Components of the Freezer Refrigeration System The MP1100 Freezer is equipped with an ultra low temperature refrigeration system Motor Box Located at the right side of the freezer the motor box contains the two 2 coolant circulating pumps electrical components safety thermostat connection for the electrical defrost heating element and the inlet exhaust fans for cooling the motorbox compartment Circulation Pumps Located in the motor box compartment the coolant circulating pumps provide InstaCoolant IV to the freezing chambers during a freeze cycle Each pump runs indepe
48. ct at the wall by a qualified technician The electrician will need to supply an electrical line of ten feet in length This power cord will need to be colored as follows e USA L1 Blue Hot L2 Brown Hot L3 Yellow Green Ground e Europe L1 Brown Hot L2 Blue Neutral L3 Yellow Green Ground e The freezer requires a 50 amp dedicated circuit See Section Specifications Chapter 2 CAUTION A qualified electrician must survey the existing power availability to verify the electrical capabilities at your facility Installing the Control Arm and Control Panel Housing The control panel housing for the MP1100 Freezer is located on a control arm that holds the control panel at eye level for easy viewing and can swivel out of the way to service the motor box cover Install control arm and control panel by following the steps below 1 Remove the plastic wrap from the control arm 2 Make sure the wiring bundle extends out each end of the control arm 3 At the back of the freezer thread the wiring bundle through the support and slide the control arm in place Tighten the setscrew of the support so that it engages the slot of the arm This will limit the throw of the control arm Figure 3 3 4 Unwrap the control panel housing slide it on to the control arm and tighten the setscrew to hold the control panel housing in place Figure 3 3 MP1100 Freezer Operator and Service Manual 37 00 053 B 3 5 4 thermog
49. d ratchet e 7 16 nutdriver or socket and ratchet e 5 8 open end wrench e 2 feet cork insulation tape Removal 1 Turn unit power off at switch located on primary power panel Figure 7 8 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Remove motorbox cover per Section Motorbox Removal and Installation 4 Remove probe box per Section Probe Box 5 Remove cork insulation tape from around both Defrost Heater Temperature Probe and Sensor Temperature Probe 6 Remove foam insulation tube from Sensor Temperature Probe Loosen compression nut from fitting 8 Slide probe and compression nut up through fitting 23 Installation 1 Remove compression nut and plastic ferrule compression bushing from old Sensor Temperature Probe and install on new probe at approximately the same location 2 Slide new Sensor Temperature Probe through compression fitting until ferrule seats into compression fitting 3 Tighten compression nut approximately 3 4 turn beyond tight 4 Wrap both Defrost Heater Temperature Probe and Sensor Temperature Probe with cork insulation tape include fittings 5 Install probe box per Section Probe Box 6 Install motorbox cover per Section Motorbox Removal and Installation 7 Reconnect unit to power source 8 Turn power onto unit and verify operation per startup process in Section Starting the MP1100 Plasma Freezer Chapter 3 7 22 MP1
50. ection terminal located inside metal housing at rear of unit under the motor box cover Motorbox Cover Tools and Supplies Required e 2 Phillips screwdriver Removal 1 Turn unit power off at switch located on primary power panel Figure 7 8 7 8 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement Figure 7 8 Power Panel OFF ON Switch Secondary Power Panel Remove electrical plug from power source If hardwired to power source then turn power off at supply panel Place protective covering over top of condensing housing The condensing housing will act as a temporary workbench for this operation Remove four screws that mount motorbox cover stainless steel tie brackets to freezer chassis located at rear of unit Carefully lift back of motorbox cover until brackets clear top of chassis Slide cover toward front of unit until inner flange of cover clears chassis mounting guide holddown Remove motor box cover P N s 8 1100 27 and 8 1101 27 The vacuum hose will need to be removed before the motor box cover is moved toward the front Figure 7 9 MP1100 Freezer Operator and Service Manual 37 00 053 B 7 9 P 7 Parts Replacement thermogenesis Figure 7 9 Motor Box Schematic VACUUM SYS 8 1100 27 MODEL ONLY DECK HTR TRANSFORMER DISPERSION BOARD PWR PANEL CASTERBASE HTR THERMOSTAT COOLANT OVERTE
51. eezer are outlined below It is important that these precautions be carefully read and understood This information should also be made available to new employees CAUTI ON For greatest assurance of proper and safe operation keep this manual in a place where it is readily accessible for reference NOTE During disassembly keep parts in order to facilitate re assembly CAUTION Prior to starting any electrical work disconnect all power to the freezer NOTE Check all hose and wiring connectors to make sure they are secure and correct NOTE Special tools and materials may be required for certain repairs and maintenance Be sure to use these tools and materials and follow the proper work procedure NOTE When replacing fuses be sure the new fuse has correct amperage rating NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment CAUTION FIRE DANGER Danger of fire if the vapors from the InstaCoolant IV are allowed to reach 42 C 108 F For operational purposes THERMOGENESIS CORP has set the limit on the MP1100 Freezer safety thermostat at 27 C 80 F CAUTION FIRE DANGER When warming the coolant during a defrost operation DO NOT PLACE AN ELECTRIC IMMERSION HEATER IN THE COOLANT MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 1 3 p 1 Introduction thermogenesis A A CAUTION Ma
52. efore servicing internal components of the MP1100 turn off all power to the freezer and unplug from the wall NOTE During disassembly keep all parts for later re assembly NOTE Check all hose and wiring connectors to make sure they are secure and correct NOTE Special tools and service material may be required depending on the repair Be sure to use these tools and materials and follow the proper work procedure NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment CAUTION Make sure the InstaCoolant IV is above freezing 32 F 0 C before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger MP1100 Freezer Operator and Service Manual 37 00 053 B 6 1 6 Troubleshooting Problem No Power to Unit Probable Cause Plug is not secured into the wall thermogenesis Solution Secure plug into the wall In the case of a twist lock plug insert into wall and twist clockwise into position Main power switch has been turned off Turn the main power switch on Blown Fuse s Remove primary power panel and replace fuse s Loose wires or snap connectors Remove the motor box cover and check all wire connections and snap connectors to verify that they are secure Coolant temperature is too high Coolant
53. el Figure 7 8 Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove motorbox cover per Section Motorbox Removal and Installation Remove cork insulation tape from around both defrost heater temperature probe and sensor temperature probe Remove rubber stopper from compression fitting of defrost heater temperature probe Remove thermal bulb wire of probe from side of rubber stopper Remove thermal bulb heater bracket from defrost heater Slide probe up through fitting Loosen securing screw of temperature probe thermostat cover Remove two each thermostat mounting screws and remove thermostat MP1100 Freezer Operator and Service Manual 37 00 053 B 7 19 p 7 Parts Replacement thermogenesis Installation 1 Loosen cover securing screw and remove cover from new temperature probe thermostat 2 Locate thermostat over mounting holes of probe box bracket and install two each 6 32x3 8 screws Reinstall cover and set thermostat to 80 F 27 C Slide bulb of probe through compression fitting 5 Install thermal bulb heater bracket onto defrost heater with bulb oriented vertically per drawing P N 7 65 018 in Reference Drawings Chapter 9 6 Feed probe wire through side of rubber stopper and snuggly insert into top of compression nut 7 Wrap sensor temperature probe with cork insulation tape include fittings 8 Install probe box per Section Probe Box
54. elmer Technical Service or the equipment supplier Trademarks ThermoGenesis Corp proprietary trademarks identify products and services of ThermoGenesis Corp are the property of ThermoGenesis Corp and are protected under State and Federal trademark laws and under international treaties Those 1 4 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 1 Introduction proprietary trademarks and service marks may not be used except as provided by law without the prior written consent of ThermoGenesis Corp Trademarks and service marks include ThermoGenesis and MicroCascade Companies own other brand trademarks and tradenames mentioned in this manual Disclaimer ThermoGenesis Corp has thoroughly reviewed the contents of this manual to make it an informative and easy to use guide for the operation of the equipment and devices described herein All statements technical information and recommendations contained in this manual or related documentation are current and believed to be reliable as this document goes to press For this reason the contents of this manual are not intended to be and should not be understood as representations or warranties concerning the equipment and devices described herein The ThermoGenesis Corp products described in this manual are covered by specific and limited warranties as described in this chapter Contact I nformation If there are questions about equipment s
55. emplate and transfer holes to new plate 2 Cut away any loose or raised portions of old bonding sealant from lid surface 3 Apply a continuous 5 32 line of silicone caulking all along the inside edge of the foam to plastic joint Figure 7 6 4 Install threaded barbed elbow removed from old gasket plate on backside of new plate until it is flush with textured surface 5 Install desiccant tube onto barbed elbow NOTE Some slight adjustment tightening loosening of elbow may be necessary to align it with tube 6 Secure tube to elbow with new cable tie Figure 7 5 7 Locate gasket onto new gasket plate and install plate to lid Section Lid Gasket 8 Re install lid per Section Lid Figure 7 5 Installing Gasket Plate CABLE TIE USED TO SECURE DESICCANT TUBE ONTO ELBOW poem s e H FOR INSTALLATION mee M M M M n PULL TUBE THROUGH AS GASKET PLATE IS BEING PLACED REMOVING amp INSTALLING LID GASKE PLATE 7 6 MP1100 Freezer Operator and Service Manual 37 00 053 B p thermogenesis 7 Parts Replacement Figure 7 6 Gasket Plate Sealant Application LID FLANGE SEALANT BEAD _ GASKET LID REAR FLANGE 11125 TEXTURED SIDE Of GA
56. enesis 3 Installation Figures 3 3 3 4 Control Arm Wiring Detail 3 6 MP1100 Freezer Operator and Service Manual 37 00 053 B 4 3 Installation thermogenesis Connecting all the Wires Now that the control arm and control panel housing are in place the temperature probe wiring control cable bundle ground wire and photo sensor cable can be connected 1 Remove the screws holding the control panel in place in the control panel housing Figure 3 5 2 Gently pry the control panel away from the control panel housing and lay upside down in the control panel housing 3 Connect the wires to the back of the control panel Figure 3 5 making sure that all ribbon connectors and cables are pressed firmly in place 4 Replace the control panel back in the housing and tighten the screws in place Figure 3 5 5 At the rear of the freezer under the control arm support remove the screws holding the wiring cover in place remove the cover and connect the wiring Figures 3 3 3 4 making sure all ribbon connectors and cables are pressed firmly in place 6 Replace the wiring protective cover using the screws and tighten the screws in place Figure 3 5 Control Panel Wiring Detail REAR VIEW OF CONTROL PANEL FRONT VIEW OF CONTROL PANEL INDICATOR LAMP CABLE GROUND WIRES CONTROL CABLE BUNDLE
57. er startup process in Section Starting the MP1100 Plasma Freezer Chapter 3 Defrost Heater NOTE See drawing P N 7 65 018 in Reference Drawings Chapter 9 Tools and Supplies Required e 2 Phillips screwdriver e V4 nutdriver or socket and ratchet e 5 16 nutdriver or socket and ratchet e 7 16 nutdriver or socket and ratchet e 5 8 open end wrench e 2 each 4 inch cable ties Removal 1 Turn unit power off at switch located on primary power panel Figure 7 8 1 Unplug unit from power source If hardwired to power source then turn power off at supply panel 2 Remove motorbox cover per Section Motorbox Removal and Installation 3 Remove probe box per Section Probe Box 4 Remove thermal bulb heater bracket from heater Secure bulb out of way 5 Cut cable ties from coil nipples rubber boots and remove from heater terminals 6 Remove nuts washers electrical wires and insulators from heater terminals Note sequence of removal 7 Using 5 8 wrench remove compression nuts from heater 8 Slide heater up to reveal ferrules compression bushings Loosen ferrules and remove from heater 9 Slide heater down through compression fittings to remove Installation 1 Slide new heater up through compression fittings until approximately 3 of heater including terminals protrudes above fittings 2 Install new ferrules onto heater and lower heater into compression fittings until approxi
58. ervice or device warranties call Helmer Technical Service weekdays except U S holidays from 8 00 a m to 5 00 p m Eastern Standard Time The fax line and website are accessible 24 hours a day Helmer Scientific 14400 Bergen Boulevard Noblesville IN 46060 Tel 800 743 5637 U S Canada Direct 1 317 773 9092 non U S Canada Fax 1 317 773 9082 Web www helmerinc com European Union Authorized Representative Medical Device Safety Service GmbH MDSS Schiffgraben 41D 30175 Hannover Germany Web www mdss com MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 1 5 1 Introduction thermogenesis Limited Warranty ThermoGenesis Corp THERMO products are designed and manufactured to provide reliable trouble free performance when properly maintained and used in accordance with the operating instructions provided with each unit Each unit is carefully inspected tested and found to be in good working order prior to shipping Warranty THERMO warrants to the original purchaser that the unit will be free from defects in materials or workmanship for one year from the date of shipment THERMO also warrants that spare parts will be free from defects in material workmanship for a period of ninety 90 days or the maximum time required by applicable local law from the date of shipment of the spare part Equipment failure due to reasons other than manufacturing defects such as accident misuse or fai
59. es 2 3 Major Components of the Freezer 2 3 InstaCoolant 2 9 Installation Service and Maintenance Forms 2 9 p thermogenesis 2 Overview Specifications FEATURE Height SPECI FI CATI ON 111 cm 44 inches Height with lid open 175 cm 69 inches Height with control arm 185 cm 73 inches Width 201 cm 80 inches Depth P N s 8 1100 20 21 23 and 8 1101 20 21 23 82 cm 33 inches Depth P N s 8 1100 27 and 8 1101 27 95 cm 38 inches Electric defrost heater 1000 W Freezer weight 475 kg 1055 Ibs Freezer weight with coolant 715 kg 1585 Ibs Coolant volume 284 Liters 75 US Gallons Compressor refrigerant High Side R 507 Allied Signal AZ 50 Low Side R 508b DuPont SUVA 95 Compressor operating temperature 62 C 80 F Saturated Suction Temperature Condensing unit heat output 24 000 BTU Temperature at inlet of condensing unit coil lt 27 C 80 F Line voltage amperage 200 240V Current Max 35 A Frequency 50 60 Hz Minimum Circuit breaker 50A Noise level 83 db Installation Category Vacuum range P N s 8 1100 27 and 8 1101 27 only 10 12 inches vacuum For Indoor Use Only MP1100 Freezer Operator and Maintenance Manual 37 00 0
60. genesis Figure 2 3 Deck for P N 8 1100 21 and 8 1101 21 Figure 2 4 Deck for P N 8 1100 23 and 8 1101 23 2 6 MP1100 Freezer Operator and Maintenance Manual 37 00 053 B d thermogenesis 2 Overview Figure 2 5 Deck for P N 8 1100 27 and 8 1101 27 The Pocket Springs available for P N s 8 1100 20 21 23 and 8 1101 20 21 23 only The pocket spring is a metal insert that acts as a stiffener for the pocket and provides easy access for inserting and removing the bags Figure 2 6 The pocket spring adds tension to the pocket producing a consistently flat frozen bag while decreasing freeze time e ay i e o Mi Figure 2 6 Pocket spring Am AM dA Freezing Chambers Located below the deck are the two freezing chambers During the freezing cycle these chambers are filled with low temperature InstaCoolant IV that circulates around the pockets freezing the blood components MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 2 7 9 thermogenesis Power Panels Located on the housing at the right end of the freezer these panels contain the electronics that operate the freezer Figure 2 7 The main power switch is located on the primary power panel and the vacuum disable switch is located on the secondary power panel Fuses for the various electrical components are located in these two panels Fi
61. gure 2 7 Power panels Secondary Power Panel Control Panel The control panel is located on the control arm Figure 2 8 The commands for operation defrost calibration and temperature setpoint are entered using the keypads Error messages are shown on the temperature display Vacuum System available for P N s 8 1100 27 and 8 1101 27 only The vacuum system expands the pocket to allow for easy insertion of bottles 2 8 MP1100 Freezer Operator and Maintenance Manual 37 00 053 B d thermogenesis 2 Overview Figure 2 8 Control arm and control panel Control Arm Vacuum Indicator Light Temperature Display Indicator Lights Coolant Overtemperature Light Located at the front right end of the machine in the upper right corner of the housing is a small red light When lit this light indicates that the safety thermostat has shut off power to the major components of the freezer due to high coolant temperature Indicator Lights Vacuum Indicator Light Located on top of the control panel is the vacuum indicator light This light when not illuminated indicates that the vacuum system has been turned off or falls below 10 of vacuum When this light is illuminated it indicates that the operator may load or unload the blood components NOTE The vacuum indicator light is activated only on P N s 8 1100 27 and 8 1101 27 InstaCoolant IV InstaCoolant IV is a silicone based hea
62. he top of the pocket has a snap seal ring which is used to attach it to the deck 1 Turn off the vacuum disable switch on the secondary power panel 2 Grab the inside front seam of the pocket approximately 1 inch 2 5 cm below the snap seal ring 3 Lift up to pop the snap seal ring loose from the deck lip 4 Holding the pocket push the pocket down below the deck and reach into the chamber Grab the clip at the bottom of the pocket and twist to detach it from the rod CAUTION Use care when removing the pockets Placing hands in coolant when coolant temperature is below freezing can cause frostbite 5 Remove the pocket Replacing a pocket models 8 1100 1101 27 1 Holding the top of the pocket push the new pocket through the opening in the deck 2 Attach the clip located on the bottom of the pocket to the rod located at the bottom of the chamber by twisting the clip until it locks onto the rod MP1100 Freezer Operator and Service Manual 37 00 053 B 5 3 5 Maintenance Repairing a Pocket A thermogenesis 3 Bring the top of the pocket up through the opening in the deck being careful not to twist the pocket Seams of the pocket should always be aligned toward the front and rear of the freezer 4 Place the snap seal ring onto the deck lip 5 Press the snap seal ring into place on the deck lip Starting at the side seam work around both sides of the snap seal ring going toward the
63. icate items to be carried out but not necessarily in sequence example Check the fuses e Make sure all snap connectors are tight Bold Typeface Calls attention to a CAUTION WARNING Uppercase or DANGER Bold Typeface Emphasizes any term or component that is lowercase being described or referred to Italics Used in designating another section in this Operator and Maintenance Manual that should be consulted for example e See Troubleshooting Chapter 6 Electrical Safety Protection Class IEC The chassis of the system is connected to ground by means of a cable and surfaces on the system that the operator may come in contact with are connected to the chassis by means of screw connections For protection against electrical hazards the system must be directly connected to a properly grounded electrical source approved by a qualified electrician Contact Helmer Technical Service for assistance if you have any questions concerning the electrical connection for the MP1100 Freezer When servicing the MP1100 Freezer make sure the power switch is turned off If unit is hardwired turn off circuit breaker to unit CAUTION The MP1100 Freezer is designed accordance with 1 2 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 1 Introduction Safety Precautions Safety precautions that necessary when operating maintaining and troubleshooting the MP1100 Fr
64. icators The Pen in Hand icon in the sidebar indicates to pay close attention to the indicated text The Exclamation icon in the sidebar indicates a Caution or Warning about a potential hazard For example injury to the operator or other personnel and potential damage to the equipment The Lightning Bolt icon in the sidebar indicates a Caution or Warning about a potential electrical hazard For example injury to the operator or other personnel and potential damage to the equipment The Flame icon in the sidebar indicates a Caution or Warning about a potential fire or explosion hazard For example injury to the operator or other personnel and potential damage to the equipment N AN The Freeze icon in the sidebar indicates a Caution or Warning about a potential hazard to cold or frostbite For example injury to the operator or other personnel and potential damage to the equipment MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 1 1 1 Introduction thermogenesis Text Conventions To convey information readily and consistently certain text conventions are used throughout this manual These conventions are as follows TEXT CONVENTION USED FoR Numbered Lists Numbered lists should be carried out in the order listed for example 1 Remove the screws from the rear of the motor box 2 Remove the screws from the Control Panel Bulleted Lists Bulleted Lists ind
65. ice technician should service the condensing unit NOTE For service of the condensing unit follow standard refrigeration practices and refer to the condensing unit manufacturer s service procedures MP1100 Freezer Operator and Service Manual 37 00 053 B 7 23 Chapter Parts List TABLE OF CONTENTS esed et eta delat 8 1 Ordering 8 2 9 thermogenesis d Parts List Please Note Parts that are ordered but not listed here are considered a Special Order and are subject to availability and variable pricing Although we will do everything in our power to expedite delivery there could bea lead time of up to 6 weeks to receive these parts In the event that you frequently order parts not on this list we highly encourage you to maintain a small stock at your facility 8 Parts List MP 1100 s Models 20 21 23 27 Part Description Part number 2 White Foam Tape 2 33 002 Breaker Switch 1 27 020 Condenser Fan 1 15 030 Contactor 30 amp 1 23 031 Desiccant Pack Replacement 1 lb package 5 31 001 Display Front Panel Two Timer 7 51 077 Dye Blue Coloring 5 34 001 Fan 1 15 001 Gasket Magnetic Left Lid 6 53 01 1 Gasket Magnetic Right Lid 6 53 010 Hand Siphon Pump 2 72 026 Hinge Lid 7 41 004 InstaCoolant IV Cubitainer 4 5 Gallons 17 70024 Liters
66. ide front seam of the pocket approximately one inch 2 5 cm below the snap seal ring 3 Lift up to pop the snap seal ring loose from the deck lip 4 Holding the pocket push the pocket down below the deck and reach into the chamber Grab the clip at the bottom of the pocket and twist to detach it from the rod MP1100 Freezer Operator and Service Manual 37 00 053 B 3 9 thermogenesis 3 Installation CAUTION Use care when removing the pockets Placing hands in coolant when coolant temperature is below freezing can cause frostbite 5 Remove the pocket Replacing a pocket 1 Holding the top of the pocket push the new pocket through the opening in the deck 2 Attach the clip located on the bottom of the pocket to the rod located at the bottom of the chamber by twisting the clip until it locks onto the rod 3 Bring the top of the pocket up through the opening in the deck being careful not to twist the pocket Seams of the pocket should always be aligned toward the front and rear of the freezer 4 Place the snap seal ring onto the deck lip 5 Press the snap seal ring into place on the deck lip Starting at the side seam work around both sides of the snap seal ring going toward the opposite side 6 Close lid and turn vacuum disable switch back on Adjusting the Safety Thermostat The safety thermostat is a safety feature which is set at the factory to 80 F Though InstaCoolant is usually stored
67. imum defrosting the freezer every 90 days If humidity in the room where the freezer is located is higher than the specified humidity range or the freezer pockets have not been properly maintained the freezer may require more frequent defrost and filter cycles NOTE The MP1100 is equipped with an electric defrost heater to aid in warming up the coolant The following steps will guide the user through the defrost cycle procedure Before Starting the Defrost Cycle There are two items to verify before starting a defrost cycle Non compliance of either of these may cause the sensing bulb of the safety thermostat to be exposed above the coolant and cause the termination of the defrost cycle As a result of the termination of the cycle the control panel will go black The system will automatically return to the refrigeration cycle the control panel will reinitiate just as though the user had turned off then turned MP1100 Freezer Operator and Service Manual 37 00 053 B 5 7 5 Maintenance AN thermogenesis on the freezer The unit will start to pull down to set operating temperature 1 It is important to make sure that the freezer is level both front to back and side to side 2 The coolant level in each chamber should be about 2 5 63 5 mm above the bottom of the chamber when the unit is at rest There must be sufficient coolant in the freezer WARNING FIRE DANGER DO NOT place
68. in the pockets The corresponding keypad will alternate between LID and OPEN 2 Close the lid The display will change back to the cycle time 3 Enter 300 on keypad corresponding to the chamber where the blood components have been loaded 4 Press RESET The corresponding display will flash NITE 5 The night cycle is in operation While the pumps are running the display will flash NITE and when the pumps are not running NITE will not flash 6 The user can return to normal operating mode by simply pressing the STOP CLEAR button on the keypad 7 To run a night cycle in more than one chamber repeat these steps on each keypad corresponding to the chamber being used MP1100 Freezer Operator and Service Manual 37 00 053 B 4 7 Chapter Maintenance TABLE OF CONTENTS Maintenance Schedule 5 1 Checking and Cleaning the Pockets 5 1 Cleaning the 5 2 Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 5 2 Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 5 3 Repairing a 5 4 Cleaning the Freezer 5 5 Checking the Desiccant Filters 5 5 Checking the Pump Motor Cooling Fans
69. ke sure the InstaCoolant IV is above freezing 0 C 32 F before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger CAUTION The 508b SUVA 95 is a high pressure refrigerant Standard refrigeration components gauges and hoses cannot be used with this refrigerant because of the high pressure When servicing the condensing unit use protective gloves and protective eyewear to prevent frostbite from exposure to refrigerant NOTE This refrigerant would only need to be checked if all other systems are working but the freezer is not holding temperature CAUTION The condensing unit should only be serviced by a technician trained in cascade high pressure refrigeration systems CAUTION The user shall be made aware that if the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired Copyright Notice 2005 2010 ThermoGenesis Corp All Rights Reserved The material in this manual is intended for use by the purchaser of the equipment covered by the manual Permission is granted to the purchaser to make one copy of the manual for record retention and internal personal use This does not create a license to the purchaser under any copyright trademark patent or other intellectual property right For additional copies of this manual contact H
70. lamps or replace coolant hose A CAUTI ON Always warm coolant to at least 0 C before working around the coolant The freeze cycle is out of adjustment Adjust the freeze cycle time according to facility validated procedures The freezer is out of calibration See Section Calibrating the Operating Temperature Chapter 4 Coolant temperature is too high Condensing unit is not running Have a qualified refrigeration technician check the refrigeration system Freezer is out of calibration Calibrate the temperature of the coolant Coil has excessive ice build up Defrost the freezer Condensing unit refrigerant system shuts down Maintenance on the condensing unit not done Have a qualified refrigeration technician check the refrigeration system Blown solenoid fuse Check the fuses in the primary power panel Room temperature is out of specification Turn off the main power switch and contact Helmer Technical Service for assistance Pockets tearing or ripping Blood components are being dropped or forced into pockets Insert blood components smoothly into pockets Bags containing frozen blood products have sharp edges Pay careful attention when placing frozen product into pockets Protective caps missing from pocket springs Verify protective caps are on the pocket spring Replace if missing Vacuum light is not activating P N s
71. lure to timely perform scheduled maintenance in accordance with the maintenance schedule included with the operating instructions for the unit is excluded from Warranty coverage This Warranty covers only the cost of parts needed to make Warranty repairs Labor charges and shipping charges for replacement parts will be billed to the purchaser THERMO reserves the right to replace any malfunctioning unit or part with a new or refurbished unit in lieu of repairing such unit This warranty and THERMO s obligation to repair or replace defective parts is the sole and exclusive remedy of purchaser Under no circumstances shall THERMO be liable for consequential or economic damages that might arise from a defective part NOTE The use of coolant other than what is recommended by ThermoGenesis Corp could void product warranty THERMO WARRANTIES AS SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF AND PURCHASER HEREBY WAIVES ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR WARRANTY OF NON INFRINGEMENT 1 6 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 1 Introduction Procedure If Warranty repairs are needed contact Helmer Technical Service for emergency repairs at night or on weekends or holidays contact your THERMO Authorized Service Provider Service Provider directly and notify Helmer Techni
72. mately of heater remains above fitting not including terminals 3 Install compression nuts and tighten Be sure to keep heater stationary in order to maintain 1 4 location indicated in step 2 4 Install insulators onto heater terminals 5 Install in sequence nut washer terminal washer nut 7 18 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement NOTE Be sure to connect BROWN and BLUE wires to heater terminals according to drawing P N 7 65 018 in Reference Drawings Chapter 9 90 10 Turn power onto unit and verify operation per startup process 11 Safety Thermostat Install coil nipples over heater terminals and secure with cable ties Install thermal bulb heater bracket with bulb oriented vertically Install probe box per Section Probe Box Install motorbox cover per Section Motorbox Removal and Installation Reconnect unit to power source Section Starting the MP1100 Plasma Freezer Chapter 3 NOTE See drawing P N 7 65 018 in Reference Drawings Chapter 9 Tools and Supplies Required Razor Blade 2 Phillips screwdriver V4 nutdriver or socket and ratchet 5 16 nutdriver or socket and ratchet 7 16 nutdriver or socket and ratchet 5 8 open end wrench 2 each ESD protective bags 2 feet cork insulation tape Removal 1 2 FO eoe Turn unit power off at switch located on primary power pan
73. n port 8 Pump fluid until it becomes clear then run pump for 15 minutes Allow fluid to sit 5 minutes then pump again If no colored water comes out then the water has been drained If not then repeat this process again 9 Remove the hand pump from the drain port and replace the small black port cover on the drain port 10 Allow the fluid in the 5 gallon pail to settle for about 5 minutes Place the pail into a walk in freezer In approximately one hour the water will freeze but the coolant will not freeze This will separate the water from any coolant in the pail Properly dispose of the colored water Pour the remaining coolant into the unit see previous Section Checking the Coolant Level Store the hand pump to prevent damage or loss you will need the hand pump for future use in defrost cycles NOTE Freeze pail overnight Remove ice and pour coolant back into the freezer MP1100 Freezer Operator and Service Manual 37 00 053 B 5 9 5 Maintenance thermogenesis Restoring Freezer to Operating Temperature 1 Replace all pockets removed in the defrost process to their proper positions making sure the snap seals are firmly in place Also check all the pockets for tears or holes NOTE Remember that improperly sealed or torn pockets allow moisture to enter the freezer chamber This moisture enters the system quickly when the freezer is down to operating temperature contributing to ice
74. nd Installation 7 14 Motorbox Disassembly and Assembly 7 16 Defrost 7 18 Safety Thermostat 7 19 Sensor Temperature 7 22 CHAMBER sc date dee desees s 7 23 Condensing Unit 7 23 Chapter 8 PARTS LIST PartS EISEz rede oce oe vn Ide EXE 8 1 Ordering 8 2 Chapter 9 REFERENCE DRAWINGS 7 24 033 Condensing System 9 1 7 35 118 Electrical Box 9 2 7 65 018 Temp Probe 9 6 7 65 046 Motorbox Assembly 9 7 TOC 4 MP1100 Plasma Freezer Operator and Service Manual 37 00 053 B thermogenesis Table of Contents Appendix A FORMS Installation A 1 Daily Maintenance Checklist A 2 Weekly Maintenance Checklist A 3 Monthly Maintenance Checklist A 4 Quarterly Maintenance Checklist A 5 Bi Annual Maintenance Checklist A 6 Parts Order A 7 Service A 8 MP1100 Plasma Freezer Operator and Service Manual 37 00 053 B TOC 5 Chapter 1 Introduction TABLE OF CONTENTS Intended 5
75. ndently of the other If the unit is not being used the left pump motor will start if the refrigeration comes on to circulate the coolant and maintain a consistent temperature 2 4 MP1100 Freezer Operator and Maintenance Manual 37 00 053 B d thermogenesis 2 Overview NOTE In order to maintain a consistent temperature when the condensing unit is on the pump motor will start filling and circulating coolant in the left chamber until set operating temperature is reached To remove or insert product during this process start a cycle in the right chamber Deck and Pockets The deck of the MP1100 Freezer is located under the two left hand lids and contains the pockets in which the blood products are placed for freezing Figures 2 2 2 5 The pockets are made of a polyurethane material capable of maintaining flexibility at low temperatures The pockets hang down into the two chambers and during a freezing cycle provide the enclosure for the blood products during coolant circulation The deck and pockets provide a tight seal to insulate the low temperature reservoir from the warmer room environment Figure 2 2 Deck for P N 8 1100 20 and 8 1101 20 o o o o o are X a ae aC orn DD S V7 C m 4 2 x 3 ai S X pe 4 2 1100 Freezer Operator and Maintenance Manual 37 00 053 B 2 5 4 2 Overview thermo
76. nder washers Do not tighten screws at this time Figure 7 9 3 Bundle together chassis and pump motor cables and defrost heater terminal wires and install spiral wrap NOTE Do not include temperature control cable in the bundle 4 Bundle together temp control and chassis cables and install multi cable loop clamp 5 Install truss head screw 6 Repeat for single loop clamp attached to temperature control cable 7 Install two remaining probe box mounting screws 8 Install guide holddown NOTE Fender washer should be up against head of screw with brass spacer between fender washer and motor support bracket 9 Install two remaining motor support bracket mounting screws 10 Tighten all eight truss head mounting screws 11 Install motorbox cover per Section Motorbox Cover Removal and Installation Motorbox Removal and Installation Tools and Supplies Required e 2 Phillips screwdriver Y 4 nutdriver or socket wrench e 5 16 nutdriver or socket wrench e 7 16 inch nutdriver or socket wrench Removal 1 Turn unit power off at switch located on primary power panel Figure 7 8 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Place covering on top of condensor housing to protect surface 4 Remove motorbox cover per Section Motorbox Removal and Installation 5 Remove probe box per Section Probe Box 7 14 MP11
77. nel Figure 7 7 Unplug unit from power source If hardwired to power source turn power off at supply panel Place covering on top of condensor housing to protect surface Remove motorbox cover per Section Motorbox Removal and Installation Remove four truss head motor support bracket mounting screws including guide holddown and loop clamp Figure 7 10 Motor Mounting Bracket Remove two hex cap head motor support bracket mounting screws Figure 7 10 Remove motor support bracket Remove remaining four truss head screws which mount both stainless steel seal plate and probe box to chassis Remove plastic spiral cable wrap and multi cable loop clamp from cables and wire Separate wires and cables to their corresponding assemblies This will aid in removal of probe box and motorbox Lift out probe box and metal cover plate assembly by pulling straight up until the assembly clears top of freezer chassis CAUTION If storing probe box assembly for later installation lay in flat position and support the heater and probes to keep weight of assembly off these components MP1100 Freezer Operator and Service Manual 37 00 053 B 7 13 P 7 Parts Replacement thermogenesis Installation 1 Lower the probe box and metal cover assembly into the reservoir through opening at right side of unit 2 Position motor support bracket over motor mounting plate and install two 14 20 hex cap head screws and fe
78. of motor 8 Orient Motor relative to pump discharge as shown in drawing P N 7 65 046 in Reference Drawings Chapter 9 9 Tighten the three hex head screws that secure the motor to the column 10 Inspect impeller for damage or excessive wear and replace if necessary 11 Install impeller on to drive shaft 12 Inspect white caulked sealing surface between pump head and pump base Sealing surface should be continuous with no breaks or junctions If breaks exist then clean old caulk from pump head and or base and apply a continuous new bead of caulk NOTE Let caulk cure for 15 minutes before proceeding to next step 13 Install pump base to pump head 14 Orient pump assembly in motorbox as shown in drawing P N 7 65 046 in Reference Drawings Chapter 9 15 Slide pump assembly through motorbox until hub of motor rests approx 24 from inner bottom of motorbox 16 Hand tighten compression nut on threaded nipple at motorbox bottom to secure column from movement N CAUTI ON Compression nut will break if over tightened 17 Install motorbox per Section Motor Box Removal and Installation 18 Install probe box per Section Probe Box 19 Install motorbox cover per Section Motorbox Removal and Installation 20 Reconnect unit to power source MP1100 Freezer Operator and Service Manual 37 00 053 B 7 17 P 7 Parts Replacement thermogenesis 21 Turn power onto unit and verify operation p
79. on one keypad does not affect the setting on the other keypad 1 Press the RESET key on the keypad corresponding to the freezing chamber being used The chamber must be idle and the lid closed 2 The current cycle time will flash on the display The default is 90 minutes 3 Enter the desired cycle time on the keypad The new time is displayed non flashing on the display For example enter 3000 to set the time to 30 minutes and 00 seconds The maximum time that can be entered is 99 minutes and 59 seconds a To erase an entry and start over press the RESET key b To exit without saving press the STOP CLEAR key 4 Press the START key within 10 seconds to save the new setting The new setting will be displayed 5 The new freeze cycle time is now set To change the freeze cycle time for another chamber repeat the steps listed above on the appropriate keypad Each chamber can have different freeze cycle times depending on customer requirements MP1100 Freezer Operator and Service Manual 37 00 053 B 4 5 p 4 Operating Instructions thermogenesis Running the Freeze Cycle NOTE Load right freezing chamber first and begin freeze cycle before loading product into left chamber and starting a freeze cycle in the left chamber Perform the following steps to run a freeze cycle on the MP1100 1 Open a lid The corresponding display will alternate between LID OPEN 2 Pla
80. p thermogenesis MP1100 MP1101 Plasma Freezers Low Temperature Freezing System for Blood Components Operator amp Service Manual 0197 37 00 053B ThermoGenesis Corp 2001 2005 thermogenesis Revision History Rev A August 2005 Rev B January 2013 thermogenesis Table of Contents Table of Contents Chapter 1 INTRODUCTION Intended Use ie dei xs 1 1 How to Use this Manual 1 1 Text Conventions esses 1 2 Electrical 1 2 Safety Precautions 1 3 Copyright 1 4 Trademarks vives irr ER xen ix ER 1 4 Disclaimer aA Pea es 1 5 Contact Information 1 5 Limited Warranty 1 6 Warranty isis dele 1 6 Procedure dex pee ET 1 7 Limitations ied tx ieee Fun EXE 1 7 Chapter 2 OVERVIEW 5 2 1 Overview xke ERU EY RE DR XR ee 2 2 Safety Devices 2 3 Major Components of the Freezer 2 3 InstaCoolant IV 2 9 Installation Service and Maintenance Forms 2 9 Chapter 3 INSTA
81. peration 400 Defrost cycle RESET Set or reset freeze cycle time START Begins freeze cycle and or loads commands to memory STOP CLEAR Interrupts or cancels a function Setting the Operating Temperature The operating temperature is the set temperature of the InstaCoolant IV during normal freezer operation During a freeze cycle the coolant temperature may rise a few degrees for a period of time as it absorbs the heat from the blood product The MP1100 Freezer software allows the user to set the operating temperature from 25 C to 55 C The following steps will guide you through adjusting the operating temperature to the desired setpoint 1 Enter 200 on a numeric keypad 2 Press the RESET key 3 The current operating temperature setting will flash on the operating temperature display 4 Enter the desired operating temperature on the keypad For example enter to set the operating temperature to 42 C The new temperature is displayed on the keypad The temperature range to be entered must be between 25 C and 55 C a To erase any entry press the RESET key b To exit without saving press the STOP CLEAR key 5 To save the new setting press the START key within 10 seconds of the entry 6 The coolant operating temperature is now set The coolant operating temperature is now set To change the setpoint for the coolant operating temperature at any time repeat steps 1 through 5 above MP1100 Freezer Operator
82. perature displayed on the control panel the freezer operating temperature should be recalibrated see below Recalibrating the Operating Temperature To recalibrate the temperature enter 200 on an idle keypad Press the RESET key The temperature display will flash OO On the keypad enter the temperature obtained from the thermometer The new temperature will be displayed For example if the calibrated thermometer reading was 352C and the display showed 429C enter 35 to set the operating temperature to the calibrated temperature a To exit without saving press the STOP CLEAR key Peon gt 4 4 MP1100 Freezer Operator and Service Manual 37 00 053 B p thermogenesis 4 Operating Instructions b To erase any entry and start over press the RESET key 5 Press the START key within 10 seconds to save the new setting The new setting will flash on the display panel for 10 seconds 6 The operating temperature is calibrated To recalibrate the operating temperature at anytime repeat the steps above Setting the Freeze Cycle Time The freeze cycle time can be adjusted from 1 second to 99 minutes and 59 seconds depending upon the user s requirements It is important to follow the validation requirements set by your company to determine the freeze time required to produce the desired final core temperature of the product Perform the following steps to set the freeze cycle time NOTE Setting the time
83. pocket approximately one inch 2 5 cm below the snap seal ring 3 Lift up to pop the snap seal ring loose from the deck lip 4 Remove the pocket Replacing a pocket 1 Holding the top of the pocket push the new pocket through the opening in the deck 2 Seams of the pocket should always be aligned toward the front and rear of the freezer 3 Place the snap seal ring onto the deck lip 4 Press the snap seal ring into place on the deck lip Starting at the front seam work around both sides of the snap ring going toward the opposite side 5 If using pocket springs remember to replace them Make sure the pocket spring is firmly in place under the snap seal of the pocket and the protective caps are on the ends of the spring Figure 3 6 CAUTION The protective caps must remain on the ends of the spring when in use Failure to do so will compromise the integrity of the pocket 6 When the pocket spring is in place the tips of the pocket spring should press against the ends of the pocket under the deck 7 Close lid Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 Removing a pocket Each pocket has two seams down the sides and a clip at the bottom The clip holds the pocket to the rod at the bottom of the freezing chamber The top of the pocket has a snap seal ring which is used to attach it to the deck 1 Turn off the vacuum disable switch on the secondary power panel 2 Grab the ins
84. r Serial Number Date of Purchase Connecting the Desiccant Filter Assembly N s 8 1100 20 21 23 and 8 1101 20 21 23 only The Desiccant Filter System on the MP1100 Freezer is located on the back of the freezer Before placing the freezer in position it is necessary to connect the desiccant filter tubing To connect the desiccant filter tubing 1 Remove the plastic protective caps from the inlet and outlet of the couplings attached to the desiccant filter 2 Slide the tubing from the lid onto the inlet fitting on the bottom coupling of the desiccant filter Figure 3 1 3 Slide the tubing from the chassis to the outlet fitting on top of the coupling of the desiccant filter Figure 3 1 MP1100 Freezer Operator and Service Manual 37 00 053 B 3 1 thermogenesis 3 Installation Figure 3 1 Desiccant Filter assembly control arm and control panel not installed Desiccant Filter Assembly Connecting Desiccant Filter Assembly and Vacuum Pump P N s 8 1100 27 and 8 1101 27 only The vacuum pump and the desiccant filter assembly on the MP1100 Freezer are located on the back of the unit Before placing the freezer in position it is necessary to connect these assemblies The vacuum pump assembly should be mounted on the rear upper left of the freezer The desiccant filter assembly should be mounted on the rear lower right side of the freezer Figure 3 2 To install vacuum pump
85. rding to instructions in Section Probe Box Install motorbox cover Reconnect unit to power source Turn power onto unit and verify operation per startup process in Section Starting the MP1100 Plasma Freezer Chapter 3 If during the repair process the temperature of the InstaCoolant has risen significantly refer to Section Temperature Pulldown Chapter 3 MP1100 Freezer Operator and Service Manual 37 00 053 B 7 15 P 7 Parts Replacement thermogenesis Motorbox Disassembly and Assembly NOTE See drawing P N 7 65 046 in Reference Drawings Chapter 9 Tools and Supplies Required e 2 Phillips screwdriver e V4 nutdriver or socket and ratchet e 5 16 nutdriver or socket and ratchet 7 16 nutdriver or socket and ratchet 1 8 Allen wrench 1 tube high vacuum grease 1 each caulking tube of Bostik 1100FS Disassembly 1 Turn unit power off at switch located on primary power panel Figure 7 8 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Remove motorbox cover per Section Motorbox Removal and Installation 4 Remove probe box per Section Probe Box 5 Remove motorbox per Section Motor Box Removal and Installation and place it on its side 6 Using 5 16 nut driver remove the eight hex head screws that secure the pump base to the pump head 7 Remove pump impeller from end of drive shaft 8 Loosen 1 compression n
86. rom the deck and around the pockets Removing and Replacing a Pocket P N s 8 1100 20 21 23 and 8 1101 20 21 23 Removing a pocket Remove the pocket spring by reaching in the pocket and grasping the ends and pressing them slightly together as the spring is removed Figure 5 1 Protective Caps Figure 5 1 Pocket springs 1 Grab the inside front seam of the pocket approximately 1 inch 2 5 cm below the snap seal ring 5 2 1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 5 Maintenance 2 Lift up to pop the snap seal ring loose from the deck lip 3 Remove the pocket Replacing a pocket 1 Holding the top of the pocket push the new pocket through the opening in the deck 2 Seams of the pocket should always be aligned toward the front and rear of the freezer 3 Place the snap seal ring onto the deck lip 4 Press the snap seal ring into place on the deck lip Starting at the front seam work around both sides of the snap ring going toward the opposite side 5 Replace pocket springs and ensure that black protective caps are firmly seated on spring before placing into pockets Figure 5 1 6 Close lid Removing and Replacing a Pocket P N s 8 1100 27 and 8 1101 27 Removing a pocket Each pocket has two seams down the sides and a clip at the bottom The clip holds the pocket to the rod at the bottom of the freezing chamber T
87. ry control panel secondary control panel control panel deck heater assembly and motor box assembly Ordering Information Contact Helmer Technical Service at 800 743 5637 U S Canada or 1 317 773 9092 non U S Canada or fax your purchase order to 1 317 773 9082 Use the form in Appendix A to itemize your order MP1100 Freezer Operator and Maintenance Manual 37 00 053 B Chapter 9 Reference Drawings TABLE OF CONTENTS SOS S38 dND V130 NUIVavd3s TO 3NITLRDI ed1vawd3s 110 D 5002 4002 5 uone n24m 10 JON Kuo 104 TWILNAGISNOD 1 6 0111 538845 60 02 2 I LL LE YOSS4adWoOI 39915 HOIH I 9L 23 E a 75 YALLITKS i ou im SIDSS 3e dA 801 33 29915 19 431131 3D 123NNUJ 3 83113 8D 193NND2 2 431131 Ji IN SNDL 3NNDO3 6 ZW ONY IW I 9L CENIOUON31 2 1 7 61 OL VE QNIGNL 8 1 1ND AD1LIINNDI 0 831131 ANY 80123NNDJ CEN 067 29 431131 8113 3NND3 831131 311123NND3 831131 719130 401 43435 10 335 4 ONY 8 W3LD NOI23NNUO 3A 3708 2 ANY 3 WA34 TIVISNI ANY E x 21 OL SIAMA TW 1023 ST WALD 00 96 N d ONISN ATHW3SSV 30 SINIO ONILLI4 119 430105
88. s and Supplies Required e 2 Phillips screwdriver e 1 4 nutdriver or socket wrench Removal 1 Turn unit power off at switch located on power panel Figure 7 8 2 Unplug unit from power source If hardwired to power source turn power off at supply panel 3 Place covering on top of condensing housing to protect surface 4 Remove four screws that mount power panel to condensor housing Figure 7 7 5 Disconnect all wires and cables from back of power panel 6 Using nutdriver remove grounding wire from grounding terminal 7 Remove panel by lifting out of condensor housing opening Installation 1 Remove panel from packaging 2 Place panel through opening in right side of condensing housing 3 Re install ground wire onto grounding stud Sequence of installation from panel is as follows star washer nut starwasher ground ring terminal starwasher nut 4 Reconnect wires and cables ensuring full engagement of connections 5 Re install the four panel mounting screws N CAUTI ON DO NOT over tighten Probe Box Tools and Supplies Required e 2 Phillips screwdriver e 1 4 nutdriver or socket wrench e 7 16 inch nutdriver or socket wrench 7 12 MP1100 Freezer Operator and Service Manual 37 00 053 B 4 thermogenesis 7 Parts Replacement Removal 1 2 Figure 7 10 Motor Mounting Bracket Connections 10 11 Turn unit power off at switch located on primary power pa
89. t the intake fans on the right side of the motor box cover The paper should be drawn into the fans indicating a good airflow 2 Hold a piece of paper against the exhaust fans at the back of the motor box cover The paper should be blown away from the cover 3 If there is no airflow turn the freezer off immediately and contact Helmer Technical Service MP1100 Freezer Operator and Service Manual 37 00 053 B 5 5 5 Maintenance thermogenesis Checking the Coolant Level NOTE Coolant level should only be checked with freezer at operating temperature with none of the chambers running 1 No chambers should be in use and it should be at least 5 minutes from the last freeze cycle 2 Open a lid and remove one of the front pockets 3 Look down into the chamber The coolant level should be about 2 5 63 5 mm above the bottom of the chamber Use a ruler or other measuring device to check the level 4 Add coolant if level is less than 2 5 63 5 mm Pour coolant into the chamber through the removed pocket opening using a funnel until coolant level is at 2 5 63 5 mm 5 Replace the pocket and close the lid Checking the Lid Gasket Seals 1 All lids should be closed 2 Visually inspect to make sure there are no gaps between the lid and the gasket and the deck 3 If a gap is found then check hinges on the appropriate lid to make sure the hinge is not loose If hinge is loose adjust hinge until seal
90. t transfer fluid specifically designed for use in low temperature systems While the fluid operating range is 100 C to 2609C 1509F to 5002F the vapors of the fluid have a flashpoint at 42 C 1089F 1 The lowest temperature at which the vapor of a combustible liquid can be made to ignite momentarily in air This assumes an ignition source is present such as a flame or electric heater element MP1100 Freezer Operator and Maintenance Manual 37 00 053 B 2 9 9 thermogenesis NOTE ThermoGenesis Corp provides a safety thermostat that automatically shuts off power to the major components of the freezer when the coolant temperature exceeds the safety temperature setting ThermoGenesis Corp sets the safety temperature limit at 27 C 80 F Installation Service and Maintenance Forms The forms shown in Appendix A are checklists designed to aid the user in installation service and maintenance of the MP1100 Freezer 2 10 MP1100 Freezer Operator and Maintenance Manual 37 00 053 B Chapter 3 Installation TABLE OF CONTENTS Unpacking and Inspection 3 1 Connecting the Desiccant Filter Assembly P N s 8 1100 20 21 23 and 8 1101 20 21 23 3 1 Connecting Desiccant Filter Assembly and Vacuum Pump P N s 8 1100 27 and 8 1101 27 Only ores rea PRESE DPI 3 2 Placing the Freezer in Position
91. t vacuum brush vacuum any dust and dirt off the fins of the condenser coil being careful not to bend any of the fins on the coil Then vacuum the grille MP1100 Freezer Operator and Service Manual 37 00 053 B Chapter 6 Troubleshooting TABLE OF CONTENTS introductio M 6 1 No Power to Unit sees 6 2 Freezer Display is Lit but Pumps Do Not Work 6 2 Coolant Chamber Fills Initially but During the Cycle the Coolant Level Drops Off 6 2 Product is not Completely Frozen 6 2 Coolant Temperature is too High 6 3 Condensing Unit Refrigerant System Shut DOWn ria nivni 6 3 Pockets Tearing or Ripping 6 3 Vacuum Light is Not Activating P N s 8 1100 27 and 8 1101 27 only 6 3 4 thermogenesis 6 Troubleshooting Introduction The following chart outlines common problems that could occur and solutions to those problems The chart indicates repair and or replacement procedures to accommodate the solutions indicated For further technical assistance contact Helmer Technical Service 14400 Bergen Boulevard Noblesville IN 46060 Tel 800 743 5637 U S Canada Direct 1 317 773 9092 non U S Canada Fax 1 317 773 9082 service helmerinc com WARNING Fuse replacement and troubleshooting the freezer s electrical system should only be performed by qualified technician B
92. tightly using the supplied adjustable clamp 5 Attach other end of tubing to the outlet port of the vacuum pump Again secure tightly with one of the supplied adjustable clamp 6 Remove the plastic protective cap on the desiccant filter assembly exposing the barbed portion of the fitting Attach the free end of the clear flexible tubing the one tubing in conjunction with the lids to the barbed portion of the fitting Placing the Freezer in Position The MP1100 freezer must be located on a level floor The freezer must be located in a room where the ambient temperature is in MP1100 Freezer Operator and Service Manual 37 00 053 B 3 3 thermogenesis 3 Installation the range of 15 C to 26 C 59 F to 79 F with the condensing unit running and the humidity is in the range of 10 to 60 RH Under no circumstances is the MP1100 to be located in an outside environment see Section Specifications Chapter 2 NOTE This freezer puts out approximately 24 000 BTU heat output while the condensing unit is operating Use this heat output specification along with any other equipment in the room when calculating the amount air conditioning needed to conform to the operating temperature requirements CAUTION DO NOT add InstaCoolant IV to the freezer before placing the freezer in its final location NOTE For ease of movement and accessibility to the place of location allow 4 15 cm clearance on both
93. tment screw and adjust the temperature to indicate 80 F Adjust the temperature higher if the coolant is higher than 80 F The lights on the unit will come on when you reach the right temperature 8 Replace the motorbox cover over the motorbox but do not secure the cover to the MP1100 chassis 9 Make sure the unit is properly plugged into the wall then turn on the power switch NOTE There is a built in 2 to 5 minute time delay once the power is turned on before the high stage compressor turns on along with the condenser cooling fans Thirty seconds after the high stage compressor starts the low stage compressor will start 10 After the MicroCascade refrigeration system starts the MP1100 Freezer will begin to chill the InstaCoolant to the set operating temperature NOTE In order to maintain a consistent temperature while the unit is not being used the pump motor will start filling and circulating coolant in the left chamber until set operating temperature is reached To remove or insert product start a cycle in the right chamber MP1100 Freezer Operator and Service Manual 37 00 053 B 7 21 P 7 Parts Replacement thermogenesis Sensor Temperature Probe NOTE See drawing P N 7 65 018 in Reference Drawings Chapter 9 Tools and Supplies Required e Razor Blade e 2 Phillips screwdriver e 1 4 nutdriver or socket and ratchet e 5 16 nutdriver or socket an
94. ut located at base of motorbox Column of pump assembly should now slide freely through gray PVC nipple 9 Slide column up through motorbox enough to provide access to Hex head bolts that secure motor to column Loosen the three bolts It is not necessary to remove them 10 Pull motor drive shaft coupler and drive shaft out through column pump head assembly 11 Using 1 8 Allen wrench loosen the coupler set screw which secures the pump drive shaft Remove the drive shaft 12 Loosen the coupler set screw which secures the motor drive shaft and remove the coupler from the motor 13 Remove the aluminum bushing seal from the motor drive shaft 14 Remove column pump head assembly from motorbox by sliding out through nipple 7 16 MP1100 Freezer Operator and Service Manual 37 00 053 B thermogenesis 7 Parts Replacement Assembly 1 Inspect aluminum bushing seal for damage or excessive wear and replace if necessary 2 Fill seal trough with high vacuum grease and install bushing on motor drive shaft with bushing flange toward motor 3 Install coupler onto motor shaft and tighten coupler set screw 4 Install pump drive shaft in coupler and tighten coupler set screw 5 Inspect bearing of pump head for damage or excessive wear Replace if necessary 6 Slide column pump head assembly through bottom of motorbox 7 Install motor drive shaft assembly down through column ensuring that column end fully seats into hub
95. ute freeze cycles to circulate the coolant Initiate a freeze cycle by doing the following 1 Set a 90 minute freeze cycle in both chambers 2 On each keypad press RESET 3 Then enter 9000 4 Press START within 10 seconds to confirm the selection 5 Check to make sure the display reads 9000 for a 90 Minute freeze cycle 6 Begin a freeze cycle by pressing START again 7 Then control panel will show FILL and the after 1 minute the timer will start to count down in seconds 8 By running a freeze cycle during the temperature pull down the coolant is continuously circulated resulting in a faster pull down 9 Run subsequent freeze cycles until the unit has reached operating temperature Once the unit has reached operating temperature and the MicroCasade Condensing Unit has turned off terminate the freeze cycle by pressing STOP CLEAR 10 The control panel will show DRN for drain for 1 minute Then at the end of the drain cycle the display will show INT press STOP CLEAR again to reset the display for the next freeze cycle MP1100 Freezer Operator and Service Manual 37 00 053 B 3 11 thermogenesis 3 Installation 11 P N s 8 1100 27 and 8 1101 27 only Open lid and check vacuum system gauge on the back of the freezer Figure 3 7 Figure 3 7 Vacuum system gauge The required operational vacuum range is 10 12 inches vacuum If the vacuum gauge reading is more or less

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