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UltraCW Cell Washer Service Manual

1. RR 14 8 3 1 Externo ee ee eee nee eee ee eens 14 Oso AMNION cuidara oo OPE ne eo ea oe nee he ae oe obo eee oe ed a 15 623 0 FILPO lt lt oom Ro 40 9 Ow oe a be we es ew ee hn es ea ho ba ees 16 8 3 4 Flush the System a cco 2 ce 34 553 4 bees boss wd oeeeee 29429 2294 5 821 9 5 2 nud WE SN S 17 OA 00 MR EIA 19 9 Troubleshooting 66620446 checccccecernedeheedendaws A RR d eee 20 9 1 General Operation PEOD IGITIS x acu dre eun Re Roe ceeds cds ge Bao Bae we dC edi e ag 20 92 Performance Problems usu use ba de STRIKE ht TR RU eR Roe con a a CR de wee as 2 21 9 9 Equipment ProDlefs auos edo mb enne RR SE Tex hg cux a mach PS SX CHR bese ur o ox as 22 360113 1 H li E Helmer Contents OA IEITOFDBIGSSQUSS tw nae Vg Ioh 2372 39 5 2 373 entidad ias ala do e pre 23 9 4 1 CONTROL ERROR XX Error Message 0 0 0 n 23 9 4 2 FU CCI ERROR XX Error Message lselee rns 24 9 43 IMBALANCE Error Message 0 00 RR hn 26 944 LOW SALINE Error Message uuum apesar ra aa e ECCE n B a Ca 27 9 4 5 N gt MAX XX Error Message o o ooooocooooon ee et ee hann 28 9 4 6 N lt MIN XX Error Message rss 29 9 4 7 POWER INTERRUPT Error Message i es re dadedckueY wuqx aa des rama e RS 29 9 4 8 SER I O ERROR XX Error Message oooooooorr hrs 30 9 4 9 TACHO ERROR XX Error Message 0 00 ccc hrs 31 9 4 10 VERSION ERROR
2. Lower drainage ring placed in Drain holes aligned the bowl 360113 1 H 15 gt Helmer Service 2 Working in sections at a time around the bowl fold back the gasket and press the ring downwards so the edge of the drainage ring rests on the lip of the bowl The edge of the ring should slightly overlap the lip of the bowl 8 3 3 360113 1 H Lower drainage ring in the proper position in the bowl Arrow points to the edge of the ring 3 With the labeled side up place the upper drainage ring into the bowl on top of the lower ring Label on upper drainage ring Drainage rings installed Fill Ports Clean the fill ports on the rotor regularly to remove any debris that was not removed when the system was flushed Debris can clog the fill ports preventing saline solution from entering the tubes If the rotor is allowed to dry after washing or suspension processes debris may accumulate in the fill ports more quickly If this is the case the rotor may need to be cleaned more frequently than is recommended in the preventive maintenance schedule Adjust the cleaning frequency based on usage patterns Required tools gt Acontainer large enough to hold the rotor gt A source of warm water to soak or flush the rotor gt The bypass tool This tool is included but packaged separately from the cell washer Bypass tool 16 E Helmer Service Clean the fill ports NOTICE Cleaning the fill ports using any metho
3. gt Press and release the parameter selection button lt for approximately eight seconds gt Ihe VOLUME ADJUST XX parameter is displayed 3 Press and release the parameter selection button lt to cycle through the global parameters gt Parameter information contained within the table above is displayed 4 Exitthe Global menu P Press the STOP button or gt Do not press any buttons for approximately 16 seconds The screen returns to Display mode 360113 1 H 6 E Helmer General Information 4 4 1 4 2 360113 1 H References and Compliance Regulatory Compliance Pollution degree 2 for use in USA and Canada only This product is certified to applicable UL and CSA standards by a NRTL Sound level dependent on rotor lt 44 dB A WEEE Compliance The WEEE waste electrical and electronic equipment symbol right indicates compliance with European Union Directive WEEE 2002 96 EC and applicable provisions The directive sets requirements for labeling and disposal of certain products in affected countries E When disposing of this product in countries affected by this directive gt Do not dispose of this product as unsorted municipal waste gt Collect this product separately gt Use collection and return systems available locally For more information on the return recovery or recycling of this product contact your local distributor Warranty USA and Canada For technical service needs ple
4. de Helmer E N T Automatic Cell Washing System Service Manual UltraCw Model Version UltraCWw B HELMER SCIENTIFIC 14400 Bergen Boulevard Noblesville IN 46060 USA mA PH 1 317 773 9073 FAX 1 317 773 9082 USA and Canada 800 743 5637 360113 1 H ISO 13485 2003 CERTIFIED E Helmer Contents Document History Revision Date Supersession Revision Description 05 SEP 2013 8686 ROLE Ps Revised layout for ease of navigation and locating information Defined safety statements according to ANSI Z535 4 s standards Of ENS di Added troubleshooting and error message statements to sections 9 3 and 9 4 1 respectively 05 JUN 2014 9553 H supersedes G Corrected mathematical example in section 7 2 and typographical error in section 8 3 1 Date submitted for Change Order review Actual release date may vary 360113 1 H E Helmer Contents Contents Section I General Information ee nne 4 1 About this Manual err RII hh rrr 4 1 4 Intended Audience RR RR RR Rss 4 1 2 Model References i 26 suos zu esuercmaeiea ko pox k C ts beer o X EUR E Rom m mos baad wea dia a 3G E Ro Yo 4 1 3 Copyright and Trademark s usar d urit nt Do ir dir e pat bp dem daa beens dee Rn io pa 4 Mac s 4 21 Safety DENNNIONS 2648 20 e026 34 450 arab oe bra E ewe bed rd c pedo rio E UR dowd ai ttt 4 22 Prod ct Labels z cai
5. EUROS Eh oS EDR ERAS RSH OEE d 47 11 7 Under the AR 48 IES ACCOSSOMNES cras corpus vdd Eu v9 dr pa rd a a a o al aa a ae e a 50 PA RENNES RETE ES SENA d E SEES ES 51 360113 1 H ii E Helmer General Information Section I General Information 1 1 1 2 1 3 2 1 2 2 2 360113 1 H About this Manual Intended Audience This manual is intended for use by end users of the cell washer and authorized service technicians Model References Generic references are used throughout this manual to group models that contain similar features For example UltraCW refers to both the 115 V and 230 V models If a feature or procedure applies to a specific voltage it is stated as such Copyright and Trademark Helmer and UltraCW are registered trademarks or trademarks of Helmer Inc in the United States of America Copyright O 2014 Helmer Inc All other trademarks and registered trademarks are the property of their respective owners Helmer Inc doing business as DBA Helmer Scientific and Helmer Safety The operator or technician performing maintenance or service on Helmer Scientific products must a inspect the product for abnormal wear and damage b choose a repair procedure which will not endanger his her safety the safety of others the product or the safe operation of the product and c fully inspect and test the product to ensure the maintenance or service has been performed properly Safety Definitions
6. Eros sex EM wien a Urs a a ee Oe Bee eee a Ee s 4 2 3 Avoiding An 5 3 Configuration aszozcccase sore raid raras aaa era 5 9 1 Model and Inpult POWOLE suis doin d Sag desta se ao a db e a la ga dite de dcin 5 32 Software Version Information css 6 4 References and ComMpliance 0 0ccocococ nnns 7 4 1 Regulatory CompllanCes acis aane d Gud dew dowd ew oum edna de E a ave a BU es T de WEEECOMPlIANCO 2225 correos dass rodas e a oo T S WAI cerraron cera ARA AA aan 7 5 1 USAand Canada suus ada so a o a a seh oe ee eee bw ess a cd T 9 1 1 Rapid ResolUlION scu a uin dried qoom pcm n a QS SE Pob ELE a eee os eee cS ans T IMP PA ee Sn NRO T E 8 5 1 4 Additional warranty information o ooo 8 5 2 Outside or USA and Canada 44 nzecn uum ea a de Dom En dele bom ee ew e eoe End 8 Section ll Service o ooo hrs 9 6 Install and Remove the Rotor eee RR I IRI I kc 9 7 Calibrate Saline Volume hh nh rss 9 7 1 Dispense and Measure Saline Volume aaaea 9 7 2 Determine Saline Volume Adjustment oo eras 10 To Change the Saline Volume us acon ee ooo ORE a wee Run stc hd wale qua S REO eb abuse ee re 11 8 Maintenance creer hh 11 8 1 Replace the Pump Tubing is susce Re eR SEGETES db a E ODE S ROS ad oh SUE jg 11 8 2 Replace Tube TORIS s 460 su ou donde E EHI RES we Adee See ee o tas ad RR Er 14 83 Clean the Cell Washer
7. Number Label s M Motor mount E2915 o 360113 1 H 49 gt Helmer Service 11 8 Accessories Cell washer accessories Label Description Part Number Included in the drain fill tubing assembly 450006 1 gt Included in the tubing kit 450003 1 which includes the drain fill tubing assembly C Transport bolt removal tool E613 NOTE This tool is also used to remove the rotor shaft motor hub Not Power cord 115 V 6083 shown 230 V 120156 Not Pump tubing assembly 450005 1 shown Included in the tubing kit 450003 1 which includes the drain fill tubing assembly Not Drain fill tubing assembly 450006 1 shown Included in the tubing kit 450003 1 which includes the pump tubing assembly Not Tubing kit 450003 1 includes fill drain and pump tubing shown 360113 1 H 50 Helmer 12 Schematic MAIN POWER 100 120 V 50 60 Hz 200 240 V 50 60 Hz L N X1 POWER CONNECTOR F1 VARISTOR BOARD SWITCH T1 TRANSFORMER 3B A3 x3 Y B1 FLOW METER END OF MANUAL 360113 1 H Service A1 POWER SUPPLY A3 LIQUID HANDLING BOARD A1 x9 A1 x2 C3 M1 RIBBON C1 DRIVE MOTOR CABLE RIBBON C2 EE 250 10p CABLE RIBBON 140 16p CABLE 130 10p A4 x101 A4 x1 JUMPER pX101 x1 g Eu posu y 1 A4 CONTROL DISPLAY A2 8501 PARDO K1 MOTOR RELAY F3 BRAKING RESISTOR OVERTEMPERATURE R1 BRAKING SWITCH RESISTOR F2 FUSE
8. SPIN button gt The Spin S program starts 4 While the rotor is spinning and 3500 is displayed on the message screen point the tachometer s laser beam through the sight window on the lid As the rotor spins the laser momentarily reflects off the optical reference on the rotor 5 Obtain the reading from the tachometer NOTE Refer to chapter 9 Troubleshooting if the speed is not 3500 RPM x 20 RPM 32 E Helmer Service 10 2 360113 1 H Verify Imbalance Value is Within Tolerance The imbalance microswitch senses whether the rotor is balanced during operation If the rotor is not balanced an imbalance error results The weight at which the imbalance error occurs is the imbalance value At the factory the microswitch is positioned to allow an imbalance value between 5 g and 10 g when the rotor is spinning at 1500 RPM EXAMPLE If the imbalance value were 7 g the middle of the range an imbalance error would result only if one side of the rotor were more than 7 g heavier than the other One gram is approximately equal to 1 mL of saline solution Continual operation of the cell washer when the imbalance value of greater than or equal to 10 g may damage the cell washer An imbalance value of less than or equal to 5 g is overly sensitive to the normal variations in weight that occur during operation NOTE For information and instructions to program and use the cell washer refer to the operation manual Required tools supplie
9. The following general safety alerts appear with all safety statements within this manual Read and abide by the safety statement that accompanies the safety alert symbol WARNING The safety statement that follows this safety alert symbol indicates a hazardous situation which if not avoided could result in serious injury CAUTION The safety statement that follows this safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE The safety statement that follows this safety alert symbol indicates a situation which if not avoided could result in damage to the product or stored inventory Product Labels The following general safety and information alerts appear on the product to identify potential hazards to the operator or service technician Caution Risk of damage to Caution Biohazard equipment or danger to operator E Helmer General Information 2 3 3 1 360113 1 H Avoiding Injury gt Review safety instructions before installing using or maintaining the equipment gt Do not move or bump the cell washer during operation gt Before moving unit disconnect the AC power cord and secure the cord gt Never physically restrict any moving component gt Avoid removing electrical service panels and access panels unless so instructed gt Use supplied power cords only gt Using the equipment in a manner not specified by Helmer may impair the protectio
10. as necessary Verify the saline volume is programmed correctly and change it if necessary Verify the amount of saline being dispensed is correct Calibrate the saline volume if necessary Inspect the drain and drain tubing for kinks and obstructions Straighten the tubing and clear obstructions if necessary Verify the drain tubing and waster container are lower than the cell washer for proper drainage Adjust the placement if necessary Change the decant speed Verify the rotor type that is programmed matches what is being used Change it if necessary Contact a qualified service technician Increase the spin speed and repeat the process Change the decant speed Change the decant speed Contact a qualified service technician Contact a qualified service technician Change the decant speed 21 Ep Helmer Service 9 3 360113 1 H Equipment Problems Problem Possible Cause Action Nothing is displayed Cell washer is gt Verify the cell washer is powered on on the message powered off orent No power to the cell Verify the power cord is connected securely washer to the cell washer and the outlet Tighten the connections if necessary Verify the fuse has not blown Replace the fuse if necessary Verify the outlet is operational During a saline check pump is not making any sound and saline is not being dispensed The lid cannot be The lid handle is not Push the lid handle down firmly until comp
11. holder 12 mm x 75 mm gt E2197 single tube holder 400595 1 12 10 mm x 75 mm tube holders and 12 inserts gt 400596 1 12 12 mm x 75 mm tube holders Not Rotor 24 place CW1024 A includes 24 tube holders shown 360113 1 H 46 Helmer Service 11 6 Behind the Front Panel G H J K Cell washer with front panel removed and flipped upward Label Description Part Number Schematic Label amp Control display board Included with control panel E2148 which A4 includes the LCD display and touchpad B Ribbon cable 140 16 pole E1332 C1 C Ribbon cable 130 10 pole E1333 C2 D P with frequency converter E1184 A2 which includes the heat sink G c3 H interorhousing E K Fuse 2 5 A E2268 EZ 360113 1 H 47 Helmer 11 7 Under the Bowl Top view of cell washer with bowl removed Label A B C U IIO Tnm 360113 1 H Description Flow meter 5 Poo nor orenaTE yam an UNBALANCEO LOAD qe Part Number E2103 includes supply connector Braking resistor over temperature switch Motor relay Braking resistor E1461 includes braking resistor over temperature switch E2193 Isolation transformer E2195 Motor hood E2191 Silicone motor seal E2690 Service Schematic Label B1 M2 R1 F3 K1 T1 48 gt Helmer Service Parts on the right side Motor with motor hood removed Motor mount under the bowl Schematic Label Description Part
12. shaft 2 Adjust the silicone motor seal to the correct position a Working around the hole in the bowl gently pull the silicone motor seal toward the motor shaft so that no part of the seal is pinched under the bowl b Working around the seal pull the edges of the seal up and over the edge of the hole Seal partially pinched under Seal pulled toward shaft with Seal correctly the bowl edges partially pulled around adjusted edge of the center hole 360113 1 H 41 Helmer Service 3 Secure the bowl assembly to the housing a While folding back the gasket to access the screw holes on the rim of the bowl assembly use the 2 mm Allen wrench to install and tighten the eight screws NOTICE Do not overtighten the screws Overtightening may damage the bowl assembly b On the rear of the cell washer use the 2 5 mm Allen wrench to install and tighten the two screws that secure the drain connector to the base 4 Install the rotor shaft motor hub a Lower the rotor shaft motor hub onto the motor shaft aligning the slots in the hub with the tongues in the motor shaft b Using the 5 mm Allen wrench turn the bottom nut inside the shaft clockwise to tighten it NOTICE Do not tighten the 6 mm top nut which may damage the rotor shaft and bowl assembly c Apply the clear silicone paste to the underside of the black plastic cap then press the cap onto the top of the rotor shaft 5 Swing the lid assembly back into position and use the 4 mm Allen wren
13. the lid lock Clear the error message Open the lid and power circuit is loose the cell washer off After approximately 10 seconds power the cell washer on Check the contact connection between the lid lock and the control display board Check that the ribbon cable between the control display board and the power supply board is securely connected A part in the lid lock circuit is Clear the error message Open the lid and power faulty the cell washer off After approximately 10 seconds power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the ribbon cable between the control display board and the power supply board b Replace the power supply board c Replace the control panel The lid handle is not closed Clear the error message Open the lid and power correctly the cell washer off After approximately 10 seconds power the cell washer on Push the lid handle down until completely latched Do not attempt to open the lid during a run spin cycle 21to 26 Control panel is faulty 1 Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on 2 Replace the control panel 23 v Helmer Service 9 4 2 FU CCI ERROR XX Error Message When a message of this type is displayed there is a problem related to the frequency converter Error Message Possible Cause Acti
14. A2 FREQUENCY CONVERTER B2 S1 Y1 M2 SPEED IMBALANCE LID PUMP SENSOR SWITCH LOCK 51 HELMER SCIENTIFIC 14400 Bergen Boulevard Noblesville IN 46060 USA PH 1 317 773 9073 FAX 1 317 773 9082 www helmerinc com E Helmer S C E N T F C
15. E LIABILITY IN NO EVENT SHALL HELMER BE LIABLE FOR ANY INDIRECT INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES INCLUDING WITHOUT LIMITATION DAMAGES RELATED TO LOST REVENUES OR PROFITS OR LOSS OF PRODUCTS This warranty does not cover damages caused in transit during installation by accident misuse fire flood or acts of God Further this warranty will not be valid if Helmer determines that the failure was caused by a lack of performing recommended equipment maintenance per Helmer manual or by using the product in a manner other than for its intended use Installation and calibration are not covered under this warranty agreement Outside of USA and Canada Consult your local distributor for warranty information Helmer Service Section Il Service 7 1 360113 1 H Install and Remove the Rotor The rotor must be installed for the cell washer to operate Rotor hub with alignment Grasp the rotor on the slot visible grip area Rotor installation procedure 1 Grasp the rotor on the grip area and place the rotor over the shaft 2 Align the markings on the top of the rotor with the slots on the rotor shaft 3 Lower the rotor onto the shaft Rotor removal procedure 1 Open the lid 2 Grasp the rotor on the grip area and lift the rotor straight up Calibrate Saline Volume Dispense and Measure Saline Volume To calibrate the dispensed saline volume the amount of dispensed saline must be measured and compared to the value t
16. O 1 and 2 Initialize the Cell Washer The cell washer must be initialized after the frequency converter is replaced NOTE If the cell washer is not initialized after the frequency converter is replaced the cell washer will display the VERSION ERROR 12 or IMBALANCE error message Required tools gt 2 5mm Allen wrench gt 20 TORX screwdriver gt Standard 2 pin jumper Initialization procedure 1 On the control display board ensure that the jumpers are set for initialization mode NOTE Refer to chapter 10 7 1 Set Jumpers for instructions in configuring jumpers 2 Connect the cell washer to AC power and power the cell washer on The software version is displayed on the screen and all lamps are illuminated gt After approximately eight seconds INIT MODE is displayed on the screen gt The cell washer is now in initialization mode 3 Press and release the parameter selection button until the IMBALANCE MODE parameter is displayed 4 Press and release either parameter value button A or W until the value is set to 2 5 Press and release the parameter selection button to cycle through the initialization parameters optional 39 E Helmer Service 10 8 360113 1 H 6 Press the START WASH button gt ok is displayed on the screen to indicate that the new values were saved gt PARAM INIT XYYY is displayed on the screen to indicate the number of initialization
17. XX Error Message 0 0 rn 32 10 Maintenance nc 404s 60000 005i Gd beached booed ew td pete ee edo dade a ees 32 10 1 Verify Rotor Speed is Within Tolerance 0 0 hr 32 10 2 Verify Imbalance Value is Within Tolerance o o oooooonernar RI III 33 10 3 Adjust the Imbalance MicroswWitCh o o ooooooro Rs 34 10 4 Remove and Install the Front Panel ooooccocccnonon RII 35 10 5 Adjust the Display Contrast oa ica diam ura dass petiso m dice dedos ode CR 8 b wads e ER dra ril dd 36 10 6 View and Change the Fill Speed ooooooooror RR IR rn 36 10 7 Replace the Frequency Converter esee hr 38 TO Ld SOPJUDEESS ad umeris et eet iaa a Dui daos ward Noi icd aud oe Ba 39 10 7 2 Initialize the Cell Washer o oooooooonr RR RR RR R I 4r 39 10 8 Remove and Install the Bowl Assembly o o ooooocooconanoo nn 40 10 0 P stRepar CREK nt anes asec aes wees oe mete aoe cede e a aE Headed ete bee ee eee eae ees 42 ee eee ee ee ee ee ee ee ee ee ada ee ee ee ee ee 43 11 1 Front Lid and BOWl AS 43 14 2 Rearand BOHOM gt 4005586052 iredi us ooue eee sions depa aeaee booed o GU 44 11 3 Behind the Rear Panel iie ucicoss RE eR RE a om Pe a dc Gu e S ETE da de 45 ES oe wee od E ee ee eee eee bee eae E T 45 11 0 Bowland ROO oot coupe 193v Wo ewe es ui were dE PS a Gade so eee de tees 46 11 6 Behind the Front Panel iius dex eme eme 2 oe REG owe a x
18. anging the imbalance microswitch value 33 iz Helmer Service 10 3 360113 1 H Adjust the Imbalance Microswitch The imbalance microswitch senses whether the rotor is balanced during operation If the rotor is not balanced an imbalance error results The proximity of the microswitch to the motor shaft determines the value at which the rotor is considered to be imbalanced The closer the motor shaft moves toward the microswitch during operation the higher the imbalance of the rotor The imbalance microswitch may require adjustment under the following circumstances gt The imbalance value is outside of the permissible range gt Imbalance errors are displayed even after other possible causes have been addressed gt The imbalance microswitch has been replaced Required tools gt 3mm Allen wrench Adjust the microswitch 1 Power the cell washer off and disconnect it from AC power 2 Remove the rotor and close the lid 3 Rotate the cell washer so that it rests on the left side 4 On the bottom of the cell washer use the Allen wrench to loosen the screw in the slot This screw secures the imbalance microswitch bracket to the base Bottom of cell washer Imbalance adjustment screw 5 Perform one of the following gt Decrease the imbalance value Slide the screw toward the center of the cell washer The switch moves toward the motor shaft gt Increase the imbalance value Slide the screw away from the center o
19. art up the cell washer on Check the connection between the speed sensor and the power supply board Check the motor connections A part in the speed sensor and 1 Clear the error message by doing the following motor circuit is faulty a Open the lid and power the cell washer off b While spinning the rotor clockwise by hand power the cell washer on 2 Perform the following tasks in order testing after each to determine if the problem was addressed a lestthe motor windings If they are faulty replace the motor b Test the speed sensor by measuring the rotor speed If the speed is not within the tolerance replace the speed sensor c Replace the ribbon cable between the control display board and the power supply board d Replace the ribbon cable between the frequency converter and the power supply board e Replace the frequency converter f Replace the control panel Replace the power supply board 360113 1 H 31 E Helmer Service 9 4 10 10 10 1 360113 1 H VERSION ERROR XX Error Message When a message of this type is displayed there is a problem with the control panel Error Message Possible Cause Action Number 12 Cell washer was not initialized 1 Clear the error message Open the lid and power after replacing the frequency the cell washer off After approximately 10 seconds converter power the cell washer on 2 Initialize the cell washer Reset the power to clear the error
20. ase contact Helmer at 800 743 5637 or www helmerinc com Be sure to have the model and serial number available Rapid Resolution When a warranty issue arises it is our desire to respond quickly and appropriately The service department at Helmer is there for you Helmer will oversee the handling of your warranty service from start to finish Therefore Helmer must give advance authorization for all service calls and or parts needs relating to a warranty issue Any repeat service calls must also be authorized as well This allows for proper diagnosis and action Helmer will not be responsible for charges incurred for service calls made by third parties prior to authorization from Helmer Helmer retains the right to replace any product in lieu of servicing it in the field Parts For a period of two 2 years Helmer will supply at no charge including freight any part that fails due to defects in material or workmanship under normal use with the exception of expendable items Expendable items include specimen tubes saline supply tubing drain tubing internal saline supply tubing pump tubing and saline supply fittings Defective parts must be returned prepaid with previous return authorization Inspection of defective parts by Helmer will be final in determining warranty status Warranty procedures must be followed in all events E Helmer General Information 9 1 3 9 1 4 9 2 360113 1 H Labor For a period of one 1 year Hel
21. b Replace the ribbon cable between the control display board and the power supply board c Replace the power supply board d Replace the control panel 9 4 4 LOW SALINE Error Message When this message is displayed there is a problem with the flow of saline into the cell washer Error Message Possible Cause Action Number None A connection in the liquid 1 Clear the error message Open the lid and power handling system circuit is the cell washer off After approximately 10 seconds loose power the cell washer on Check the connection between the liquid handling board and the power supply board A part in the pump system is Clear the error message Open the lid and power faulty the cell washer off After approximately 10 seconds power the cell washer on Remove the pump tubing from the pump With the pump tubing removed perform a saline check gt Ifthe pump does not operate replace the pump gt If the pump does operate replace the pump tubing which may have hardened over time A part in the liquid handling 1 Clear the error message Open the lid and power system circuit is faulty the cell washer off After approximately 10 seconds power the cell washer on 2 Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the flow meter b Replace the liquid handling board 360113 1 H 27 Helmer 9 4 5 N gt MAX XX Error Message Service When thi
22. base 35 iz Helmer Service 10 5 10 6 360113 1 H Adjust the Display Contrast The display screen contrast may be changed Required tools P Small flathead screwdriver with insulated shank a M Mr T ni e D LA uS M es NS uL 1 4 D E i Control display board display contrast potentiometer Contrast adjustment procedure Power the cell washer off and disconnect it from AC power Open the lid Remove the three screws that secure the bottom of the front panel to the base Gently pull the bottom of the panel away from the base Lift the front panel until the groove on the panel disengages from the tongue on the housing On the control display board use the screwdriver to turn the potentiometer gt Turn the potentiometer clockwise to decrease the contrast darker gt Turn the potentiometer counterclockwise to increase the contrast lighter 6 Place the front panel on the front of the housing Align the groove on the panel so it fits around the tongue on the housing 7 Press front panel downward to engage the tongue and groove Press the bottom of the panel against the base 9 Slide the front panel sideways until the sides of the panel align with the base and the screw holes are aligned 10 Install the three screws to secure the panel to the base 11 Connect the cell washer to AC power and power the cell washer on Check the display contrast 12 Repeat steps 1 through 12 a
23. cess to determine if the problem was solved Ensure that the height of the tubes is within the acceptable tolerance of 75 mm x 1 5 mm 20 Helmer Performance Problems Possible Cause Problem Results of the wash process are not acceptable Rotor type that is gt programmed does not match what is being used One or more fill ports is clogged Saline flow is blocked too low or being sensed incorrectly Too much or not enough saline solution is being dispensed Drain is blocked Causing excessive saline to accumulate in the bowl and enter the tubes during the wash process Decant speed is too high or low Cell button has not formed or is too small 12 place rotor is being gt used but a 24 place rotor is programmed Tube holder is stuck in gt the decant position Spin speed is too low gt Too much residual Decant speed is too saline remains in the tube after washing low Tubes were not decanted Decant speed is too low A component is faulty Rotor lock did not gt engage After tubes are decanted contents are streaking Decant speed is too high Service Action Verify the rotor type is set correctly Change it if necessary Flush the system to clear blockages Check the fill ports on the rotor for obstructions Clean the fill ports as necessary On the message screen check if LOW SALINE is displayed Address message
24. ch to tighten the screws that 10 9 360113 1 H secure the hinges to the housing Post Repair Check Perform functional and safety checks of the cell washer after repairing or replacing parts NOTE gt For information and instructions to program and use the cell washer refer to the operation manual gt Organizational regulations may require different test methods than those included in this manual Use the appropriate test methods if they are different than the following procedure Perform a functional check oO 00 WN Oo N 10 11 12 Ensure that the cell washer is connected to AC power and powered on Load the rotor with tubes and install the rotor Verify that the buttons display and indicator lamps are working correctly Start a multiple cycle wash process During the Fill step press the CHECK button to pause the process Open the lid and verify that the tubes are equally filled with the programmed amount of saline solution within a range that is acceptable according to organizational guidelines If too much or too little liquid is dispensed the fill volume may need to be adjusted Press the START WASH button to resume the process During the Decant step press the CHECK button to pause the process Open the lid and verify the following gt The tubes are decanted equally within a range that is acceptable according to organizational guidelines gt The amount of liquid if any is within a range tha
25. d not described in this manual damage the fill ports and negatively impact the performance of the cell washer and may void the warranty 1 Soak the rotor in clean warm water or run warm water directly into the top of the rotor for several minutes Ensure water is flowing freely out of all the fill ports 2 Ifa portis blocked gently slide the bypass tool into the fill port from the outside toward the center of the rotor Gently slide the bypass tool in and out several times to clean the port 3 Doone of the following gt Ifthe rotor will not be used immediately ensure that it is dry before returning it to the cell washer and closing the lid gt Ifthe rotor will be used immediately ensure that all fresh water has been purged from the system and replaced by saline solution before processing NOTE Refer to chapter 8 3 4 Flush the System for instructions in purging fresh water from the rotor 8 3 4 Flush the System To clean and disinfect the cell washer as well as remove blockages due to salt crystallization use the Clean program to flush the system with bleach solution and again with distilled water The Clean program consists of two parts the clean sequence and the refill sequence These sequences cannot be changed and they cannot be stopped before completion The Clean sequence consists of the following steps 1 Fill Dispenses 10 mL of bleach solution per place on the rotor while spinning at 1100 RPM Fora 12 place rotor 120 mL
26. es to the housing 4 Pivot the lid assembly away from the cell washer gt This provides clearance for removing the bowl assembly pin TS a Lid loosened and swung away from the cell washer 40 E Helmer Service 5 Remove the rotor shaft motor hub a Using the flathead screwdriver pry the black plastic cap off the top of rotor shaft b Using the 5 mm Allen wrench loosen bottom nut inside the shaft by turning it counterclockwise NOTICE Do not loosen the 6 mm top nut which may damage the rotor shaft and bowl assembly c Lift the rotor shaft motor hub off of the motor shaft Rotor shaft motor hub Rotor shaft motor with black plastic cap hub removed 6 Separate the bowl assembly from the housing a Using the 2 mm Allen wrench remove the eight screws that secure the top of the bowl to the housing Fold back the gasket to access the screws c On the rear of the cell washer use the 2 5 mm Allen wrench to remove the two screws that secure the drain connector to the base d Working around the hole in the bowl gently pull the silicone motor seal toward the motor shaft 7 Lift the gasket drainage rings and bowl assembly from the housing tilting the bowl so that the drain connector clears the housing Install the bowl assembly 1 Lower the gasket drainage rings and bowl assembly into the housing gt The drain connector should protrude through the hole in the base gt The bowl should be centered over the motor
27. f the cell washer The switch moves away from the motor shaft 6 Tighten the Allen screw to secure the imbalance bracket to the base 7 Testthe imbalance value to ensure that it in the permissible range NOTE Refer to chapter 10 2 Verify Imbalance Value is Within Tolerance for instructions in determining if the imbalance value is within the permissible range 34 Helmer 10 4 360113 1 H Service Remove and Install the Front Panel Several serviceable parts are located behind the front panel MAR e Bottom view of the cell washer Front panel removed and front edge shown pivoted upward Required tools gt 2 5mm Allen wrench Remove the front panel 1 2 3 4 Power the cell washer off and disconnect it from AC power Open the lid Remove the three screws that secure the bottom of the front panel to the base Gently pull the bottom of the panel away from the base Lift the front panel until the groove on the panel disengages from the tongue on the housing Install the front panel 1 2 IA Open the lid Place the front panel on the front of the housing Align the groove on the panel so it fits around the tongue on the housing Press front panel downward to engage the tongue and groove Press the bottom of the panel against the base Slide the front panel sideways until the sides of the panel align with the base and the screw holes are aligned Install the three screws to secure the panel to the
28. hat is displayed The displayed value is the saline volume setting per tube multiplied by the number of places in the rotor NOTE Refer to the operation manual for the recommended calibration interval The following table shows the values that would be displayed if the SalWash ml parameter were set to the recommended value Volume Setting Total Saline Volume Rotor Type Tube Size Per Tube Dispensed 15 12 place 38 4 mL 10 mm x 75 mm 3 2 mL 24 place 76 8 mL 12 place 56 4 mL 12 mm x 75 mm 4 7 mL 24 place 112 8 mL A volumetric measuring device such as a graduated cylinder of the appropriate capacity is necessary to accurately measure the amount of solution Dispensing and measurement procedure 1 Confirm the rotor type is set to the same as the rotor installed in the cell washer 12 place or 24 place 2 Select the program that contains the desired saline volume value iz Helmer Service 3 Open the lid 4 On the control panel press and hold the SALINE button for about four seconds gt CALIBRATE XXX X ml is displayed gt The cell washer is now in Calibration mode P XXX X represents the total saline volume that is dispensed 5 Hold the measuring device under the nozzle in the lid of the cell washer Use the volumetric measuring device to capture the dispensed saline solution 6 Onthe control panel press the CHECK button The Saline lamp illuminates The volume of saline solution that was displayed i
29. isplayed the rotor is not installed or the speed is being controlled or sensed incorrectly Error Message Possible Cause Action Number 01 A connection in the speed 1 Clear the error message by doing the following sensor circuit is loose a Open the lid and power the cell washer off resulting in the interruption of b While spinning the rotor clockwise by hand power speed sensor pulses the cell washer on Check the connection between the speed sensor and the power supply board A part in the speed sensor Clear the error message by doing the following circuit is faulty a Open the lid and power the cell washer off b While spinning the rotor clockwise by hand power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Testthe speed sensor by measuring the rotor speed If the speed is not within the tolerance replace the speed sensor b Replace the ribbon cable between the control display board and the power supply board c Replace the ribbon cable between the frequency converter and the power supply board d Replace the frequency converter e Replace the control panel f Replace the power supply board 02 A connection in the speed Clear the error message by doing the following sensor and motor circuit is a Open the lid and power the cell washer off loose resulting in no speed b While spinning the rotor clockwise by hand power sensor pulses after st
30. letely opened closed correctly latched A component is faulty gt Contact a qualified service technician 22 E Helmer Service 9 4 9 4 1 360113 1 H Error Messages When the cell washer is in error mode the cell washer is not operational The error must be addressed and cleared When the cell washer is in error mode an error message is displayed and an audible alert sounds The pattern is a beep every 30 seconds A message also is displayed on the message screen to aid in troubleshooting and correction Some error messages are the result of operational issues Operational issues may be cleared by addressing the error message If the problem remains contact a qualified service technician to troubleshoot and address the problem Several actions require the cell washer to be powered off and powered back on To reset the cell washer power the cell washer off for approximately 10 seconds before powering the cell washer back on CONTROL ERROR XX Error Message When a message of this type is displayed there is a problem with the lid closing or locking or a problem with the control panel Error Message Possible Cause Action Number 04 06 to Lid lock is faulty 1 Clear the error message Open the lid and power 09 the cell washer off After approximately 10 seconds power the cell washer on Check if the lid can be opened while the cell washer is powered off If it can replace the lid lock Connection in
31. mbalance tolerance is set too Clear the error message Open the lid and power low the cell washer off After approximately 10 seconds power the cell washer on Check the imbalance tolerance and adjust it if necessary One or more motor mounts is Clear the error message Open the lid and power worn the cell washer off After approximately 10 seconds power the cell washer on Check the motor mounts for wear Replace them if necessary A connection in the imbalance 1 Clear the error message Open the lid and power microswitch circuit is loose the cell washer off After approximately 10 seconds power the cell washer on 2 Check the connection between the imbalance microswitch and the power supply board 3 Check that the ribbon cable between the control display board and the power supply board is securely connected 360113 1 H 26 E Helmer Service Error Message Possible Cause Action Number None A part in the imbalance 1 Clear the error message Open the lid and power microswitch circuit is faulty the cell washer off After approximately 10 seconds power the cell washer on 2 Perform the following tasks in order testing after each to determine if the problem was addressed a Check the continuity of the imbalance microswitch which is normally closed The resistance should be 0 O when the switch is closed not activated If there is resistance replace the imbalance microswitch then set the imbalance tolerance
32. mer will cover repair labor costs provided the product is returned to Helmer for warranty service Alternatively your service staff may work with a Helmer technician to make repairs on site Labor costs for repairs performed at a location other than Helmer or for repairs made without the assistance of a Helmer technician will be the responsibility of the end user Helmer will not be responsible for charges incurred for service calls made by third parties prior to authorization from Helmer Helmer retains the right to replace any product in lieu of servicing it in the field Additional warranty information The time periods set forth above begin two 2 weeks after the original date of shipment from Helmer Warranty procedures set forth above must be followed in all events THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE SHALL APPLY THE LIABILITY IF ANY OF HELMER FOR DIRECT DAMAGES WHETHER ARISING FROM A BREACH OF ANY SALES AGREEMENT BREACH OF WARRANTY NEGLIGENCE OR INDEMNIT Y STRICT LIABILITY OR OTHER TORT OR OTHERWISE WITH RESPECT TO THE GOODS OR ANY SERVICES IS LIMITED TO AN AMOUNT NOT TO EXCEED THE PRICE OF THE PARTICULAR GOODS OR SERVICES GIVING RISE TO TH
33. message A component on the control 1 Clear the error message Open the lid and power panel is not compatible with the cell washer off After approximately 10 seconds the frequency converter power the cell washer on 2 Replace the control panel Maintenance NOTE Refer to the operation manual for the preventive maintenance schedule Verify Rotor Speed is Within Tolerance NOTE The decant speed cannot be tested but it can be changed with a global parameter value For instructions in changing global parameters refer to the operation manual The rotor speed can be measured to determine whether it is within the design tolerance The cell washer has a sight window in the lid and an optical reference on the rotor so the speed of the rotor can be easily measured during operation When the rotor is programmed to spin at 3500 RPM the measured speed should be 3500 RPM 20 RPM Required tools gt Laser tachometer calibrated and capable of measuring RPM CAUTION Prior to using the laser tachometer review all safety and usage instructions provided by the manufacturer Test rotor speed NOTE Organizational regulations may require different test methods than those included in this manual Use the appropriate test methods if they are different than the following procedure 1 Install the rotor 2 Program the Spin S program with a spin speed of 3500 RPM and a spin time that is long enough for the speed to be measured 3 Press the
34. n provided by the equipment gt Decontaminate parts prior to sending for service or repair Contact Helmer or your distributor for decontamination instructions and a Return Authorization Number Configuration Model and Input Power NOTE Service information varies depending on the model and power requirements This information is shown on the product specification label located on the right side of the cell washer Type UltraCW qu Helmer 14400 Bergen Boulevard Serial Number 000000 Noblesville IN USA www helmerinc com Volts Freq Amps Power 110 127 Vac 60 Hz 2 5 200 Watts 2014 Kinetic Energy Max Density RPM 250 Nm 1 2 Kg dm 3500 R min Made in Switzerland Label Description A Model REF B Serial number SN C Power requirements D Operational information Helmer General Information 3 2 Software Version Information The software version is displayed when the cell washer is powered on Additional information is available through the Global menu as follows Parameter Meaning CONTROL XXX h Number of operating hours VERS XX C 00 XX is the software version FU CCI 1001 Frequency converter type FU CCI S XX XX Frequency converter software version View version information in the Global menu 1 Ensure the screen is in Display mode gt Ifthe screen displays a completion message open the lid to clear the message and return to Display mode 2 On the control panel view global parameters
35. n the lid plus the hinges J Lid hinge E1563 Included in the lid assembly E2184 which includes all parts on the lid plus the hinges Not Lid spring E1565 shown 360113 1 H 43 ee Helmer Service 11 2 Rear and Bottom Parts on the rear and bottom of the cell washer Schematic Label Description Part Number Label B Drain connector Included in the bowl assembly E2104 A which includes the bowl C Supply connector Included with flow meter E2103 B1 Not Foot 3680 o shown 360113 1 H 44 iz Helmer Service 11 3 Behind the Rear Panel Cell washer with rear panel removed Schematic Label Description Part Number Label A Isolation transformer E2195 T1 B Included in bowl assembly E2104 A C Pump tubing assembly 450005 1 D E2096 M2 E Supply connector Included with flow meter E2103 B1 11 4 Side 2 Schematic Label Description Part Number Label A Fuse 2 5 A E2268 F2 B Main power switch E1009 Q1 c E507 xi D Product specification label 360113 1 H 45 E Helmer Service 11 5 Bowl and Rotor Parts on the bowl and rotor Label Description Part Number A Drainage rings Included in drainage system kit E2535 which includes the splash guard B Bowl Included in bowl assembly E2104 A which includes the drain connector C Gasket E2105 D H Rotor shaft motor hub E2370 E Rotor 12 place CW1012 A includes 12 tube holders F Tube holder insert E2551 G Tube
36. nd power the cell washer on The software version is displayed on the screen and all lamps are illuminated gt After approximately eight seconds INIT MODE is displayed on the screen gt The cell washer is now in initialization mode 8 Change the fill speed a Press and release the parameter selection button until the Fill rpm parameter is displayed b Change the value of the parameter that is displayed by pressing and releasing either parameter value button A or W to change the value optional c Press and release the parameter selection button lt to view the remaining initialization parameters optional d Press the START WASH button gt ok is displayed on the screen to indicate that the new values were saved gt PARAM INIT XYYY is displayed on the screen to indicate the number of initializations that have been performed e To view or change the initialization parameters again power the cell washer off and back on then repeat steps a through d optional 9 Remove the 2 pin jumper and move the original jumper to its original position to resume normal operation 10 Install the front panel a Open the lid b Place the front panel on the front of the housing Align the groove on the panel so it fits around the tongue on the housing c Press front panel downward to engage the tongue and groove Press the bottom of the panel against the base e Slide the front panel sideways until the sides of
37. nds gt Ihe VOLUME ADJUST XX parameter is displayed 3 Press and release the parameter value buttons A or W until the desired value is displayed 4 Press the START WASH button to save the parameter setting Maintenance NOTE Refer to the operation manual for the preventive maintenance schedule Replace the Pump Tubing Replace the tubing at the interval specified in the operation manual to prevent failure The tubing may need to be replaced more often than recommended if the cell washer is used frequently or organizational requirements dictate more frequent replacement The pump tubing assembly is required to replace the pump tubing The pump tubing assembly may be ordered from Helmer Technical Service NOTE Refer to chapter 8 4 Supplies for replacement tubing part numbers 11 iz Helmer Service Replace the tubing 1 Power the cell washer off and disconnect it from AC power 2 Disconnect the supply tubing from the saline supply 3 On the rear of the cell washer open the access door Access door open Pump tubing detail Pump tubing detail tubing connected with pump visible routed from pump to flow meter through grommet to lid 4 Remove the existing tubing assembly a On the top of the pump turn the locking lever clockwise until the tubing holder loosens Free the tubing and tubing holder from around the pump Remove the tubing from the tubing holder Disconnect the ends of the tubing from the fittings Pull
38. nly use cleansers and disinfectants with a pH of 5 to 8 8 3 1 Exterior Clean exterior surfaces with a soft cotton cloth and non abrasive liquid cleaner Dry the exterior with a dry cloth 360113 1 H 14 ee Helmer Service 8 3 2 Interior To prevent blockages and maintain rotor balance ensure the bowl is clean and free of debris which may include salt crystals or broken glass To prevent condensation that may lead to corrosion dry the interior thoroughly after normal daily usage Using a damp cloth or sponge wipe the bowl removing all debris It is not necessary to remove the bowl or to clean under the bowl Using a dry cloth or sponge wipe the entire inside of the lid including the drainage system and painted surfaces Use the following procedures to remove and install the drainage rings Remove drainage rings 1 Remove the upper drainage ring labeled this side up by pulling it upward until it clears the gasket 2 Remove the lower drainage ring by folding back the gasket to expose the edge of the ring then gently lifting the ring Do this in sections at a time until the entire ring is clear of the gasket and can be lifted out of the bowl LJ Ae Gasket folded back and Entire lower drainage ring section of lower drainage loosened ring removed Install drainage rings 1 Place the lower drainage ring in the bowl so the drain hole in the ring is directly above the drain in the bowl
39. oard A part in the control panel and 1 Clear the error message Open the lid then press the power supply circuit is faulty START WASH button 2 Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the power supply board b Replace the ribbon cable between the control display board and the power supply board c Replace the control panel 360113 1 H 29 Helmer SER I O ERROR XX Error Message When a message of this type is displayed there is a problem with communication between components 9 4 8 360113 1 H Error Message Possible Cause Number 30 and 31 Aconnection in the frequency 33 94 and 36 converter circuit is loose Connections between the frequency converter and the RFI filter and braking resistor over temperature switch are wrong Braking resistor over temperature switch has opened A part in the frequency converter circuit is faulty A part in the frequency converter and control panel circuit is faulty Service Action Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Check the connection between the frequency converter and the power supply board Check the connections between the frequency converter and the RFI filter and braking resistor over temperature switch Clear the error message Open the lid and power the cell washe
40. of bleach solution is dispensed for a 24 place rotor 240 mL is dispensed The fill volume exceeds the capacity of the tube to aid in flushing the drainage system 2 Spin Spins for 10 seconds at 1500 RPM 3 Decant Spins in the opposite direction at 600 RPM 4 Agitation Agitates for 5 cycles 5 Decant Spins in the opposite direction at 600 RPM The Refill sequence dispenses 60 mL of bleach solution to purge the system Required supplies gt A container filled with approximately 500 mL of fresh bleach solution Solution is a 10 bleach solution 1 9 ratio of household bleach to water or 1 part commercial sodium hypochlorite NaOCl 5 to 9 parts water gt A container filled with approximately 1 L of distilled water gt An empty waste container such as a volumetric measuring device that has a minimum capacity of 80 mL 360113 1 H 17 Helmer Flush procedure 360113 1 H Service NOTE gt Repeat this procedure as many times as necessary according to organizational Aa WO DN regulations gt When the system is flushed the rotor must be loaded with tubes Every other position on the rotor must be empty This allows some bleach solution to be dispensed directly into the bowl to aid with cleaning and some bleach solution to flow into the drainage system during the Decant step Load the rotor with tubes leaving every other position on the rotor empty Install the rotor and close the lid Ensure the Lid Read
41. on Number 60 A part in the frequency gt Perform the following tasks in order testing after each converter circuit is faulty to determine if the problem was addressed resulting in a false lid lock 1 Replace the ribbon cable between the control release signal display board and the power supply board 2 Replace the ribbon cable between the frequency converter and the power supply board 3 Replace the frequency converter 4 Replace the power supply board 5 Replace the control panel 61 A part in the frequency Clear the error message Open the lid and power the converter circuit is faulty cell washer off After approximately one minute power resulting in a processing error the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the ribbon cable between the control display board and the power supply board b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Replace the power supply board e Replace the control panel 62 Main supply voltage is too low Clear the error message Open the lid and power the resulting in an under voltage cell washer off After approximately one minute power condition to the frequency the cell washer on converter Verify that the outlet in the facility is operational and supplying adequate voltage to the cell washer Perform the following tasks in order
42. panel Th D 28 F Helmer Service 9 4 6 N lt MIN XX Error Message When this message is displayed the rotor is rotating too slowly Error Message Possible Cause Action Number 13 A connection in the motor 1 Clear the error message Open the lid and power circuit is loose the cell washer off After approximately 10 seconds power the cell washer on Check the connection between the motor and the frequency converter A part in the motor circuit is Clear the error message Open the lid and power faulty the cell washer off After approximately 10 seconds power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a lestthe motor windings If they are faulty replace the motor b Replace the frequency converter Silicone motor seal is loose 1 Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on 2 Check that the motor seal has been installed properly 9 4 7 POWER INTERRUPT Error Message When this message is displayed the AC power was interrupted during operation or was sensed as being interrupted Error Message Possible Cause Action Number None A connection between the Clear the error message Open the lid then press the control display board and the SIART WASH button power supply board is loose Check the connection between the control display board and the power supply b
43. place the power supply board Clear the error message Open the lid and power the cell washer off After approximately one minute power the cell washer on Replace the frequency converter Perform the following tasks in order testing after each to determine if the problem was addressed 1 Replace the ribbon cable between the frequency converter and the power supply board 2 Replace the frequency converter 3 Replace the power supply board 25 E Helmer Service Error Message Possible Cause Action Number 85 A part in the frequency 1 Clear the error message Open the lid and power the converter circuit is faulty cell washer off After approximately one minute power resulting in a processing error the cell washer on 2 Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the ribbon cable between the frequency converter and the power supply board b Replace the frequency converter c Replace the power supply board 9 4 3 IMBALANCE Error Message When this message is displayed there is a problem with the balance of the rotor Error Message Possible Cause Action Number None Imbalance initialization Clear the error message Open the lid and power parameter was set to the the cell washer off After approximately 10 seconds wrong value after the power the cell washer on frequency converter was Check that the Imbalance parameter is set to 2 replaced I
44. purge distilled water from the system Supplies Tube holder insert E2551 1 Tube holder 12 mm x 75 mm E2197 12 Tube holders 12 mm x 75 mm 400596 1 Pump tubing assembly 450005 1 Drain fill tubing assembly 450006 1 Tubing kit includes pump tubing assembly and drain fill tubing assembly 450003 1 Service 19 Helmer 9 A CAUTION 9 1 360113 1 H Troubleshooting General Operation Problems Problem Cell washer is powered on but nothing is displayed on the message screen During a saline check pump is not making any sound and saline is not being dispensed During a saline check pump is operating but saline is not being dispensed correctly Tubes were not decanted when they were programmed to do so Rotor speed seems too high or too low Tubes are breaking during processes with a Decant step Possible Cause No power to the cell washer Display contrast is set gt too low A part in the LCD circuit is faulty A part in the pump system is faulty A part in the liquid handling system circuit is faulty Rotor is faulty A part in the motor circuit is faulty A part in the speed Service Review all safety instructions prior to troubleshooting Refer to chapter 2 Safety Action 1 2 sensor circuit is faulty 2 Tube holder inserts were not installed correctly before processing 10 mm x 75 mm tubes Top of the tube does not move freel
45. r off After approximately 10 seconds power the cell washer on Check that the connections on the frequency converter at connector S102 are correct Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Replace the braking resistor over temperature switch Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the frequency converter b Replace the ribbon cable between the control display board and the power supply board c Replace the ribbon cable between the frequency converter and the power supply board d Replace the control panel e Replace the power supply board Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the frequency converter b Replace the ribbon cable between the control display board and the power supply board c Replace the ribbon cable between the frequency converter and the power supply board d Replace the control panel e Replace the power supply board 30 Helmer Service 9 4 9 TACHO ERROR XX Error Message When a message of this type is d
46. r paste between the heat sink and the interior housing b If necessary scrape off the paste from the old frequency converter and apply it on the new one 8 Reconnect the wiring from the frequency converter to the electrical components 9 On the back of the front panel locate the control display board 10 On the control display board install the 2 pin jumper 11 Configure the jumpers for initialization mode NOTE Refer to chapter 10 7 1 Set Jumpers for instructions in configuring jumpers 12 Initialize the cell washer NOTE Refer to chapter 10 7 2 Initialize the Cell Washer for instructions in initializing the cell washer 13 Perform a functional check of the cell washer NOTE Refer to chapter 10 9 Post Repair Check for instructions in performing a post repair check of the cell washer 38 Ep Helmer Service 10 7 1 10 7 2 360113 1 H Set Jumpers The jumper settings on the control display board must be changed to enter initialization mode y APA Jumpers configured for normal operating Jumpers configured for initialization mode mode The control display board has one jumper installed To set the jumpers for initialization mode a second standard 2 pin jumper is required Set jumpers for normal operating mode gt Install a jumper at position 0 gt Remove jumpers from positions 1 2 3 and 4 Set jumpers for initialization mode gt Install jumpers at positions 3 and 4 gt Remove jumpers from positions
47. s gt Tubes enough to fill all available positions on the rotor gt Saline solution one test run requires 15 g 15 mL gt Scale calibrated and capable of measuring 10 g Test rotor imbalance NOTE Organizational regulations may require different test methods than those included in this manual Use the appropriate test methods if they are different than the following procedure 1 Install tubes in all available positions in the rotor If 10 mm x 75 mm tubes are installed tube inserts must also be installed 2 Program the Spin S program with a spin speed of 1500 RPM and a spin time of 20 seconds 3 Test whether the imbalance value is below the upper limit a With all tubes empty add a total of 10 g of saline solution to one or more tubes on one side of the rotor b Install the rotor c Start the Spin S program If the program completes without an imbalance error then the imbalance value is too high and must be decreased NOTE Refer to chapter 10 3 Adjust the Imbalance Microswitch for instructions in changing the imbalance microswitch value 4 Test whether the imbalance value is above the lower limit a With all tubes empty add a total of 5 g of saline solution to one or more tubes on one side of the rotor b Install the rotor c Start the Spin S program If an imbalance error occurs the imbalance value is too low and must be increased NOTE Refer to chapter 10 3 Adjust the Imbalance Microswitch for instructions in ch
48. s dispensed from the nozzle into the volumetric measuring device When the process is complete the Saline lamp clears 7 Observe the saline volume in the volumetric measuring device Use this value to adjust the volume NOTE To stop the flow of saline solution press the STOP button on the control panel 7 2 Determine Saline Volume Adjustment After measuring the total saline volume compare the displayed value to the measured value If the measured value is within 5 of the displayed value no change is needed If the measured value varies more than 5 from the displayed value the saline volume must be calibrated The saline volume can only be adjusted it in increments equivalent to 0 5 of the measured value Adjustment determination procedure 1 Compare the total volume displayed to the total volume measured gt Example 1 A check is performed for a 12 place rotor with 10 mm x 75 mm tubes and a volume of 3 2 mL per tube The displayed value is 38 4 mL but the measured volume is 41 0 mL gt Example 2 A check is performed for a 24 place rotor with 12 mm x 75 mm tubes and a volume of 4 mL per tube The displayed value is 112 8 mL but the measured volume is 106 8 mL gt Example 3 A check is performed for a 12 place rotor with 10 mm x 75 mm tubes and a volume of 3 2 mL per tube The displayed value is 38 4 mL but the measured volume is 38 6 mL 360113 1 H 10 E Helmer Service 7 3 8 1 360113 1 H 2 Determine if an adju
49. s message is displayed the rotor speed being detected exceeds the maximum allowable speed Error Message Possible Cause Number 05 Insulation on the speed sensor 1 cable is faulty A connection in the speed sensor circuit is loose A part in the speed sensor circuit is faulty 360113 1 H Action Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Check the speed sensor cable for wear If worn replace the speed sensor Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Check the connection between the speed sensor and the power supply board Check that the ribbon cable between the control display board and the power supply board is securely connected Clear the error message Open the lid and power the cell washer off After approximately 10 seconds power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Test the speed sensor by measuring the rotor speed If the speed is not within the tolerance replace the speed sensor b Replace the ribbon cable between the control display board and the power supply board c Replace the ribbon cable between the frequency converter and the power supply board d Replace the frequency converter Replace the power supply board Replace the control
50. s necessary until the contrast level is acceptable ah WON 00 View and Change the Fill Speed The value for the Fill rpm parameter can be changed The Fill rpm parameter controls the rotor speed during Fill and Suspension steps in non cleaning processes The Fill rpm parameter is factory preset to 1100 RPM for use in cell washing processes This parameter should only be changed if the cell washer is being used for other applications that may require a different fill speed Available values range from 100 to 1500 NOTE Refer to the operation manual for instructions in changing the rotor speed 36 Helmer Required tools 360113 1 H gt Service 2 5 mm Allen wrench gt 20 TORX screwdriver gt Standard 2 pin jumper Change the fill speed 1 Power the cell washer off and disconnect it from AC power Open the lid 2 Remove the rotor Leave the lid open 3 Remove the front panel a Remove the three screws that secure the bottom of the front panel to the base b Gently pull the bottom of the panel away from the base c Lift the front panel until the groove on the panel disengages from the tongue on the housing 4 On the back of the front panel locate the control display board 5 On the control display board install the 2 pin jumper 6 Configure the jumpers for initialization mode NOTE Refer to chapter 10 7 1 Set Jumpers for instructions in configuring jumpers 7 Connect the cell washer to AC power a
51. s that have been performed 7 Power the cell washer off and disconnect it from AC power Open the lid Remove the rotor Leave the lid open 8 Remove the front panel a Remove the three screws that secure the bottom of the front panel to the base b Gently pull the bottom of the panel away from the base c Lift the front panel until the groove on the panel disengages from the tongue on the housing 9 Configure the jumpers for normal operation mode NOTE Refer to chapter 10 7 1 Set Jumpers for instructions in configuring jumpers 10 Install the front panel a Open the lid b Place the front panel on the front of the housing Align the groove on the panel so it fits around the tongue on the housing c Press front panel downward to engage the tongue and groove Press the bottom of the panel against the base e Slide the front panel sideways until the sides of the panel align with the base and the screw holes are aligned f Install the three screws to secure the panel to the base Remove and Install the Bowl Assembly Required tools gt Clear silicone paste gt Small flathead screwdriver gt Allen wrenches in the following sizes 2 mm 2 5 mm 4 mm 5 mm NOTE The transport bolt removal tool is a 5 mm Allen wrench Remove the bowl assembly 1 Power the cell washer off and disconnect it from AC power Open the lid 2 Remove the rotor Leave the lid open 3 Using the 4 mm Allen wrench remove three screws that secure the lid hing
52. stment is needed If the measured volume is within 5 of the displayed value an adjustment is not needed gt Example 1 5 of 38 4 1 92 38 4 1 92 36 5 to 40 4 Because 41 0 is above the tolerance an adjustment is needed gt Example 2 5 of 112 8 5 64 112 8 5 64 107 2 to 118 4 Because 106 8 is below the tolerance an adjustment is needed gt Example 3 5 of 38 4 1 92 38 4 1 92 36 5 to 40 4 Because 38 6 is within the tolerance an adjustment is not needed 3 Ifan adjustment is needed determine the difference in volume Displayed Measured Difference gt Example 1 38 4 41 0 2 6 mL gt Example 2 112 8 106 8 6 0 mL 4 Determine the adjustment value rounded to the nearest whole number Difference Measured x 200 Adjustment Value gt Example 1 2 6 41 0 x 200 12 7 gt 13 gt Example 2 6 0 106 8 x 200 11 2 gt 11 Change the Saline Volume After the saline adjustment volume has been determined change the value of the VOLUME ADJUST XX global parameter by the determined amount EXAMPLE If the VOLUME ADJUST parameter was set to 10 and the adjustment value was determined to be 1 change the VOLUME ADJUST parameter to 9 Volume change procedure 1 Ensure the screen is in Display mode If the screen displays a completion message open the lid to clear the message and return to Display mode 2 Onthe control panel press and hold the parameter selection button for about eight seco
53. t is acceptable according to organizational guidelines If too much liquid remains the decanting speed may need to be adjusted Press the START WASH button to resume the process During the Agitation step ensure that the tubes are being shaken Test whether the imbalance value is in the permissible range 42 gt Helmer Service NOTE Refer to chapter 10 2 Verify Imbalance Value is Within Tolerance to determine if the imbalance value is within the permissible range 11 Parts 11 1 Front Lid and Bowl Parts on the front and lid Label Description Part Number A Outer lid E2186 Included in the lid assembly E2184 which includes all parts on the lid plus the hinges B Sight window E1323 includes gluing ring C Lid handle E2189 Included in the lid assembly E2184 which includes all parts on the lid plus the hinges J G Control panel E2148 Includes the control display board LCD display and touchpad Front panel E2188 F Inner lid E2185 Included in the lid assembly E2184 which includes all parts on the lid plus the hinges Lid handle latch Included in the lid assembly E2184 which includes all parts on the lid plus the hinges m H Nozzle Included in the lid assembly E2184 which includes all parts on the lid plus the hinges Splash guard gt Included in the drainage system kit E2535 which includes the drainage rings gt Included in the lid assembly E2184 which includes all parts o
54. tecting excess rotor speed Service Action Clear the error message Open the lid and power the cell washer off After approximately one minute power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the braking resistor b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Replace the power supply board Clear the error message Open the lid and power the cell washer off After approximately one minute power the cell washer on Perform the following tasks in order testing after each to determine if the problem was addressed a lestthe motor windings If they are faulty replace the motor b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Replace the power supply board Clear the error message Open the lid and power the cell washer off After approximately one minute power the cell washer on Confirm that the ambient temperature during operation does not exceed 45 C Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the ribbon cable between the control display board and the power supply board b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Re
55. testing after each to determine if the problem was addressed a Replace the ribbon cable between the control display board and the power supply board b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Replace the power supply board e Replace the control panel 63 A part in the frequency 1 Clear the error message Open the lid and power the converter circuit is faulty cell washer off After approximately one minute power resulting in an over current the cell washer on condition in the motor 2 Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the motor b Replace the ribbon cable between the frequency converter and the power supply board c Replace the frequency converter d Replace the power supply board 360113 1 H 24 Helmer 360113 1 H Error Message Possible Cause Number 64 67 68 69 84 A part in the frequency converter circuit is faulty resulting in an overvoltage condition in the braking resistor A part in the frequency converter circuit is faulty resulting in an over temperature condition in the motor A part in the frequency converter circuit is faulty resulting in an overvoltage condition in the frequency converter Frequency converter is faulty A part in the frequency converter circuit is faulty resulting the frequency converter de
56. the panel align with the base and the screw holes are aligned f Install the three screws to secure the panel to the base 37 E Helmer Service 10 7 360113 1 H Replace the Frequency Converter The frequency converter generates and monitors the current supply for the drive motor It also monitors the motor temperature and transfers the electrical energy produced during braking to the braking resistor NOTE If the frequency converter is malfunctioning it must be replaced Required tools gt 2 5 mm Allen wrench gt 20 TORX screwdriver Standard 2 pin jumper Replacement procedure 1 Power the cell washer off and disconnect it from AC power Open the lid 2 Remove the rotor Leave the lid open 3 Remove the front panel a Remove the three screws that secure the bottom of the front panel to the base b Gently pull the bottom of the panel away from the base c Liftthe front panel until the groove on the panel disengages from the tongue on the housing 4 Disconnect the wiring from the frequency converter board to the other electrical components 5 Remove the four screws securing the frequency converter board and heat sink to the housing 6 Remove the frequency converter and heat sink together Left Frequency converter Right One of four TORX screws that secure the frequency converter to the interior housing 7 Install the new frequency converter Reinstall the four TORX screws a Ensure there is sufficient heat transfe
57. the tubing through the grommet toward the pump and remove it from the pump area b C d e Pump with loosened tubing Tubing and holder freed from Tubing removed from holder pump holder 5 Install the new tubing assembly a Orient the tubing assembly so the middle section of tubing is aligned with the tubing holder Press the tubing into the holder Wrap the tubing holder around the pump so the middle section of tubing is against the pump c While squeezing the tubing holder around the pump turn the locking lever counter clockwise until it locks in position Thread the tubing out through the grommet then connect it to the fitting on the back of the lid e Connect the right side of the tubing to the fitting on the flow meter 360113 1 H 12 iz Helmer Service Middle section Holder locked in position of pump tubing and held captive in position around pump Right side of oriented in tubing connected to flow meter tubing holder fitting 6 Connect the supply tubing to the saline supply 7 Connect the cell washer to AC power and power the cell washer on 8 Use the Volume Calibration Check function to dispense liquid check for leaks around the connections to the fittings a Onthe control panel press and hold the SALINE button for four seconds gt Ihe CALIBRATE XXX X ml parameter is displayed XXX X is the saline volume that is dispensed Hold a waste container under the nozzle c Onthe control panel press the CHECK bu
58. tton Solution is dispensed from the nozzle into the waste container purging the system of air Hold the waste container under the nozzle 360113 1 H 13 E Helmer Service 8 2 Replace Tube Holders All available places on the rotor must have tube holders installed for the rotor to be balanced Tube holders may be ordered from Helmer Technical Service NOTE Refer to chapter 8 4 Supplies for replacement tube holder part numbers Bottom of rotor with tube holder Tube holder being being removed installed Remove a tube holder from the rotor 1 Remove the rotor from the cell washer a Open the lid b Grasp the rotor on the grip area and lift the rotor straight up 2 Remove all tubes from the tube holders a Turn the rotor upside down b Move the rotor lock so that it clears the clip c While holding the tube holder to be removed in the vertical position firmly press the tube holder down until the clip snaps free from the ring Install a tube holder on the rotor 1 Remove the rotor from the cell washer a Open the lid b Grasp the rotor on the grip area and lift the rotor straight up 2 Remove all tubes from the tube holders 3 Inthe appropriate position on the rotor align the clip for the tube holder over the ring on the rotor 4 Firmly press the tube holder down until the clip snaps into place around the ring 8 3 Clean the Cell Washer NOTICE gt Do not use an autoclave to clean any components of the cell washer gt O
59. y around the fill port Verify that the outlet is operational Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the fuse b Replace the main power switch c Replace the transformer d Replace the RFI filter Adjust the display contrast Perform the following tasks in order testing after each to determine if the problem was addressed 1 Replace the control panel 2 Replace the power supply board Remove the pump tubing from the pump With the pump tubing removed perform a saline check gt Ifthe pump does not operate replace the pump gt Ifthe pump does operate replace the pump tubing which may have hardened over time Perform the following tasks in order testing after each to determine if the problem was addressed 1 Replace the flow meter 2 Replace the liquid handling board Verify that all the rotor locks decant hooks are intact If any are broken off or damaged replace the rotor Perform the following tasks in order testing after each to determine if the problem was addressed 1 Replace the motor 2 Replace the frequency converter 3 Replace the power supply board Measure the rotor speed Perform the following tasks in order testing after each to determine if the problem was addressed a Replace the speed sensor b Replace the motor c Replace the frequency converter Install the tube holder inserts and repeat the pro
60. y lamp is lit Connect the supply tube to the bleach solution container Select the Clean program a Ensure the screen is in Display mode Ifthe screen displays a completion message open the lid to clear the message and return to Display mode b On the control panel select a program gt Press and release the parameter value buttons A or V until the Clean program is displayed Press the START WASH button gt The cleaning sequence starts gt When the cleaning sequence is complete OPEN LID is displayed and the Lid Ready lamp illuminates Open the lid gt The Lid Ready lamp clears and Clean proc DONE is displayed Connect the supply tubing to the distilled water container Hold the waste container in front of the nozzle Capture residual bleach solution and distilled water with the waste container Press and hold the SALINE button for about three seconds gt The Saline lamp illuminated and REFILL process is displayed gt 60 mL of residual bleach solution and distilled water is dispensed from the nozzle into the waste container gt When the process is complete the Saline lamp clears and REFILL proc DONE is briefly displayed The display returns to Display mode for Program 1 10 Dispose of the purged liquid 18 Helmer 8 4 360113 1 H 11 Repeat step 4 to flush the system with distilled water 12 Connect the supply tubing to the container of saline solution 13 Repeat step 9 to

UltraCW Cell Washer Service Manual

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