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UltraCW Automatic Cell Washing System Service Manual

1. Control display board with detail of the trimming potentiometer To adjust the display contrast 1 Remove the rotor from the cell washer and leave the lid open Turn off the cell washer and disconnect it from power Remove the front panel For instructions see Section 4 4 Removing and installing the front panel ON On the control display board use the screwdriver to turn the trimming potentiometer Turning the potentiometer clockwise makes the screen darker decreases the contrast Install the front panel For instructions see Section 4 4 Removing and installing the front panel Connect the cell washer to power Turn on the cell washer and check the contrast ONO Repeat as necessary until the contrast level is acceptable 360113 1 E Helmer 4 6 Servicing the cell washer 20 Viewing and changing the fill speed You can change the value for the rpm parameter which 1s used to control the rotor speed during Fill and Suspension steps in non cleaning processes The Fill rpm parameter is factory preset to 1100 r min 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 are 100 to 1500 inclusive For more information about how the rotor speed is controlled for other steps and instructions to change the rotor speed for those steps refer to the Operation Manual
2. A1 POWER SUPPLY BOARD 1 7Q at cold motor 130 10 4 101 A4 xi SERVICE X101 1 JUMPER X100 B A4 CONTROL DISPLAY A2 5501 BOARD K1 MOTOR RELAY BRAKING RESISTOR OVERTEMPERATURE R1 BRAKING SWITCH RESISTOR 1 2 TRANSFORMER FUSE iz A2 FREQUENCY a CONVERTER 50 i 1 2 51 1 M2 FLOW SPEED IMBALANCE LID PUMP METER SENSOR SWITCH LOCK 360113 1 E gt Helmer Helmer 1EN TIF HELMER SCIENTIFIC 14400 BERGEN BOULEVARD NOBLESVILLE IN 46060 USA PHONE 1 317 773 9073 FAX 1 317 773 9082 USA and CANADA 800 743 5637 www helmerinc com
3. Helmer SCIENTIFIC UltraCw Automatic Cell Washing System Service Manual 4 Helmer 4 UltraCw Version B Model UltraCWw S N HELMER SCIENTIFIC 14400 BERGEN BOULEVARD NOBLESVILLE 46060 USA PHONE 1 317 773 9073 FAX 1 317 773 9082 USA and CANADA 800 743 5637 www helmerinc com 360113 1 E Contents i Contents ADOUUTHIS MANUAL s tace dys BOR EORR a ax 1 Working Safely casn rec dened ema E Sesh deer arie aac 6 dee en 1 1 1 General Safely s cux deed oe ks 1 1 2 Electrical Safety 2034402454 e RR sade eer ae eens bese ED 1 1 3 Chemical and biological safety 1 2 Reviewing information about your cell 2 2 1 Finding model and input power information ills 2 2 2 Finding software and part version 2 3 Troubleshooting iuo tox HERE Rus us Re RR RP E US 3 3 1 Troubleshooting general operation 3 3 2 Addressing error 4 4 Servicing the cell 15 4 1 Testing whether the rotor s
4. calibrated and capable of measuring r min CAUTION Prior to using the laser tachometer review all safety and usage instructions provided by the manufacturer To test whether the rotor speed is within the design tolerance NOTE Regulations for your organization may recommend test methods different from what appear here Use the appropriate methods for your organization 1 Install the rotor 2 Program the Spin S program with a spin speed of 3500 r min and a spin time that is long enough for you to measure the speed 3 Start the Spin S program by pressing the SPIN button 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 If the speed is not within the tolerance of 3500 r min 20 r min follow the appropriate troubleshooting steps to determine how to proceed 360113 1 E Helmer 4 2 Servicing the cell washer 16 Testing whether the imbalance value is in the permissible range 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 that lies between 5 g and 10 g when the rotor
5. circuit is faulty 4 1 Testing whether the rotor speed is within the design tolerance Try the following tasks in order testing after each to determine if it solved the problem Replace the speed sensor Replace the motor Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Tubes are breaking Tube holder inserts were Install the tube holder inserts and repeat the process to during processes witha not installed correctly determine if the problem was solved Decant step before processing 10 mm x 75 mm tubes The top of the tube does Ensure that the height of the tubes is within the not move freely around acceptable tolerance of 75 mm 1 5 mm the fill port 3 2 Addressing error messages In the event of an error condition the cell washer displays an error message to assist in troubleshooting This section provides possible causes associated with each error message and actions that should be taken XX represents the error message number CONTROL ERROR XX When a message of this type appears there is a problem with the lid closing or locking or a problem with the control panel Error Possible cause Action message number 4 The lid lock is faulty Clear the error message Open the lid then turn off the bi to 09 power After about 10 seconds turn the power back on Check if the lid can be opened while the cell washer is turned off If it can replace t
6. on schematic A 254 E2268 360113 1 E gt Helmer 5 4 Parts 29 Parts on the bowl and rotor Parts on the bowl and rotor Replacement part numbers Part of Drainage system kit E2535 which includes the splash guard Bowl Part of Bowl assembly E2104 A which includes the metal drain connector Rotor shaft motor hub E2370 Rotor 12 place 450001 1 includes 12 tube holders Tube holder insert E2551 G Tube holder 12 mm 75 mm E2197 Also available in a Kit 12 pieces 400596 1 and as part of the rotor Rotor shaft motor hub E2370 Not Rotor 24 place 450002 1 includes 24 tube holders shown 360113 1 E Helmer Parts 30 Parts behind the front panel Part of Control panel E2148 which includes the LCD display and touchpad Ribbon cable 140 16 pole E1332 Ribbon cable 130 10 pole E1333 Part of the Frequency converter E1184 which includes the underlying heat sink Power supply board interiorhousing fe 360113 1 E Helmer Parts 31 5 6 Parts behind the rear panel Part of Bowl assembly E2104 A which includes the bowl Pump tubing assembly 450005 1 TI E2096 M2 Supply connector Part of Flow meter E2103 360113 1 E gt Helmer 5 7 Parts 32 Parts under the bowl 1 nor operate an UNBALANCED LOAD 1 Top view of cell washer with bowl removed Replacement part numbers Label on sch
7. or by not pressing any of the buttons for approximately 16 seconds The message screen returns to display mode for the selected program 360113 1 E Helmer Troubleshooting 3 3 Troubleshooting Before taking actions as described in this section make sure that operational issues have been addressed as described in the Operation Manual Also be sure that the cell washer operator has followed the appropriate laboratory procedures and used the appropriate materials for the task This section describes some problems you may experience explains possible causes and provides actions you can take to correct them UN CAUTION Review all safety instructions prior to completing troubleshooting recommendations For more information see Section 1 Working safely 3 1 Troubleshooting general operation problems The cell washer is turned on but nothing is displayed on the message screen During a saline check the pump is not making any sound and saline is not being dispensed During a saline check the pump is operating but saline is not being dispensed correctly The tubes were not decanted when they were programmed to do so There is no power tothe 1 Verify that the outlet is operational cell washer 2 Try the following tasks in order testing after each to determine if it solved the problem a Replace the fuse b Replace the main power switch c Replace the transformer d Replace the RFI filter The disp
8. range a Starting with empty tubes add a total of 10 g of saline solution to one or more tubes on one side of the rotor Install the rotor Start the Spin program If the program completes without an imbalance error then the imbalance value is too high and must be decreased For instructions see Section 4 3 Adjusting the imbalance microswitch 4 Test whether the imbalance value is above the lower limit of the permissible range a Add a total of 5 g of saline solution to one or more tubes on one side of the rotor b Install the rotor Start the Spin program If an imbalance error occurs then the imbalance value is too low and must be increased For instructions see Section 4 3 Adjusting the imbalance microswitch 360113 1 E Helmer 4 3 Servicing the cell washer 17 Adjusting the imbalance microswitch NOTE For more information about locating and identifying parts see Section 5 Parts and Section 6 Schematic 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 higher the imbalance of the rotor the closer the motor shaft moves toward the microswitch during operation You may need to adjust the imbalance microswitch in the following circumstances The imbalance value is outside of the perm
9. the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Replace the control panel 360113 1 E Helmer Troubleshooting 11 gt MIN XX When this message appears the rotor is rotating too slowly Error Possible cause Action message number 13 A connection in the motor circuit is Clear the error message Open the lid then turn off the loose power After about 10 seconds turn the power back on Check the connection between the motor and the frequency converter A part in the motor circuit is faulty Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Try the following tasks in order testing after each to determine if it solved the problem a Test the motor windings If they are faulty replace the motor b Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter The silicone motor seal is loose Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Check that the motor seal has been installed properly For more information see Section 4 8 Removing and installing the bowl assembly POWER INTERRUPT When this message appears the AC power was interrupted during operation or was sensed as being interrupted Error Possible cause Action message number None A conn
10. the process During the Agitation step ensure that the tubes are being shaken Test whether the imbalance value is in the permissible range For instructions see Section 4 2 Testing whether the imbalance value is in the permissible range 360113 1 E gt Helmer 4 10 Servicing the cell washer 26 Reviewing the preventive maintenance schedule For optimal performance complete maintenance tasks according to the following schedule NOTE These are minimum requirements Regulations for your organization or physical conditions at your organization may require maintenance items to be performed more frequently or only by designated service personnel Follow the guidelines for your organization Weekly Monthly Annually Inspect the tubing and drain and clear obstructions if necessary Inspect the tubing connections and secure them if necessary F Jv Jv During After first month first month of usage of 2 Clean and dry the interior after normal usage to prevent corrosion and contamination gt For more information and instructions see Section 6 2 2 Cleaning the interior Flush the system gt For more information and instructions see Section 6 2 3 Flushing the system Clean the fill ports on the rotor gt For more information and instructions see Section 6 2 4 Cleaning the fill ports Check the saline volume setting and calibrate it if necessary Frequency varies by length of servi
11. turn the power back on Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter A part in the frequency converter Try the following tasks in order testing after each to circuit is faulty resulting the determine if it solved the problem frequency converter detecting excess 1 Replace the ribbon cable between the frequency rotor speed converter and the power supply board 2 Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board A part in the frequency converter Clear the error message Open the lid then turn off the circuit is faulty resulting in a power After about 10 seconds turn the power back on processing error Try the following tasks in order testing after each to determine if it solved the problem a Replace the ribbon cable between the frequency converter and the power supply board b Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board 360113 1 E gt Helmer Troubleshooting 8 IMBALANCE When this message appears there is a problem with the balance of the rotor Error Possible cause Action message number The Imbalance initialization Clear the error message Open the lid then turn off the parameter was set to the wrong value power After about 10 seconds turn the power back on after the fr
12. The cell washer was not initialized after replacing the frequency converter A component on the control panel is not compatible with the frequency converter Clear the error message Turn off the power After about 10 seconds turn it back on Initialize the cell washer For instructions see Section 4 7 2 Initializing the cell washer Reset the power to clear the error message Clear the error message Turn off the power After about 10 seconds turn it back on Replace the control panel 360113 1 E Helmer 4 1 Servicing the cell washer 15 Servicing the cell washer This section explains how to access serviceable parts as well as how to perform some service procedures Testing whether the rotor speed is within the design tolerance NOTE You cannot test the decant speed but you can change it by changing a global parameter value For instructions refer to the Operation Manual You can measure the rotor speed 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 that you can easily measure the speed of the rotor during operation When the rotor is programmed to spin at 3500 r min RPM the measured speed should be 3500 r min 20 r min For more information and instructions to program and use the cell washer refer to the Operation Manual You will need the following to test the rotor speed lt Laser tachometer
13. When a message of this type appears the rotor is not installed or the speed is being controlled or sensed incorrectly Message Possible cause Action number 01 connection in the speed sensor circuit is loose resulting in the interruption of speed sensor pulses A part in the speed sensor circuit is faulty Troubleshooting 13 Clear the error message by doing the following a Open the lid then turn off the power b While spinning the rotor clockwise by hand turn on the power Check the connection between the speed sensor and the power supply board Clear the error message by doing the following a Open the lid then turn off the power b While spinning the rotor clockwise by hand turn on the power Try the following tasks in order testing after each to determine if it solved the problem a Test the speed sensor by measuring the rotor speed For instructions see Section 4 1 Testing whether the rotor speed is within the design tolerance If the speed is not within the tolerance replace the speed sensor Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the control panel Replace the power supply board 360113 1 E gt Helmer connection in the speed se
14. You will need the following to view and change the fill speed gt 2 5 mm Allen wrench 20 TORX screwdriver lt Standard 2 pin jumper To view and change the fill speed 1 Put the cell washer into initialization mode a Remove the rotor from the cell washer and leave the lid open b Turn off the cell washer and disconnect it from power C Use the Allen wrench to remove the front panel For instructions see Section 4 4 Removing and installing the front panel d back of the front panel locate the control display board e On the control display board add the 2 pin jumper and configure the jumpers for initialization mode For instructions see Section 4 7 1 Setting jumpers f Install the front panel For instructions see Section 4 4 Removing and installing the front panel g Connect the cell washer to power h the cell washer The software version appears on the message screen and all lamps are lit After about eight seconds INIT MODE appears on the message screen 2 Press and release the parameter selection button 4 until the Fill rpm parameter appears on the message screen 3 Optional Change the value of the parameter that is displayed by pressing and releasing either parameter value button A or V until the value that you want to use appears 4 Optional Press and release the parameter selection button to view the remaining initialization parameters 5 Press the START WASH button The message
15. ard Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Replace the control panel 360113 1 E Helmer Troubleshooting 6 Error Possible cause Action message number A part in the frequency converter circuit is faulty resulting in an overcurrent condition in the motor 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 overtemperature condition in the motor A part in the frequency converter circuit is faulty resulting in an overvoltage condition in the frequency converter Clear the error message Open the lid then turn off the power After about minute turn the power back on Try the following tasks in order testing after each to determine if it solved the problem a Replace the motor b Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Clear the error message Open the lid then turn off the power After about 1 minute turn the power back on Try the following tasks in order testing after each to determine if it solved the problem a Replace the braking resistor b Replace the ribbon cable between th
16. ating mode Right Initialization mode The control display board has one jumper installed To set the jumpers for initialization mode you will need a second standard 2 pin jumper To set the jumpers for normal operating mode lt On the control display board install a jumper at position 0 and remove jumpers from positions 1 4 To set the jumpers for initialization mode lt On the control display board move the existing jumper to position 3 and add a jumper to position 4 Initializing the cell washer The cell washer must be initialized whenever the frequency converter is replaced otherwise the cell washer displays the IMBALANCE error at all times To initialize the cell washer 1 On the control display board ensure that the jumpers are set for initialization mode For instructions see Section 4 7 1 Setting jumpers 2 Connect the cell washer to power 3 Tum on the cell washer The software version appears on the message screen and all lamps lit After about eight seconds INIT MODE appears on the message screen 4 Press and release the parameter selection button lt until the IMBALANCE MODE parameter appears on the message screen 5 Press and release either parameter value button A or until the parameter is set to 2 6 Optional Press and release the parameter selection button lt to cycle through the initialization parameters 7 Tosave your changes press the START WASH button The message scr
17. ce gt For more information and instructions see Section 5 2 Calibrating the saline volume Inspect the tube holders for wear and damage Replace tube holders if they are worn or damaged or after they have been in use for 2 years gt For more information and instructions see Section 6 4 Replacing tube holders Clean the exterior gt For more information and instructions see Section 6 2 1 Cleaning the exterior Replace the supply and drain tubing gt For more information and instructions see Section 3 7 1 Installing and removing the supply and drain tubing Replace the pump tubing gt For more information and instructions see Section 6 3 Replacing the pump tubing Replace the tube holder inserts for 10 mm x 75 mm tubes gt For more information and instructions see Section 5 1 2 Installing and removing the tube holder inserts Inspect the rotor for wear corrosion and damage Replace the rotor if these conditions exist or after the rotor has been in use for 4 years 360113 1 E gt Helmer 5 5 1 Parts 27 Parts The Troubleshooting section recommends replacing parts in certain situations This section shows where to find replaceable parts and lists part numbers for them It also includes references to the parts on the electrical schematic as appropriate See Section 6 Schematic for more information Parts on the front and lid F Part
18. cee 1 30 5 6 Parts behind the rear 31 5 7 Parts under the 32 5 8 Pen 34 6 66 35 360113 1 E Helmer About ii About this manual Welcome to the UltraCW Automatic Cell Washing System Service Manual This section explains the symbols and conventions used in this manual copyright information about this document and trademark information for products supplied by Helmer Intended audience This manual is intended for use by end users of the UltraCW cell washing system and authorized service technicians This manual is to be used in conjunction with the UltraCW Automatic Cell Washing System Operation Manual Symbols and conventions Several symbols and conventions are used in this manual Cautions A Caution is used to call attention to a condition or possible situation that could damage or destroy the equipment or the operator s work Sample caution identified as follows AN CAUTION Be sure that the tubing is free of obstructions Blocked tubing can cause fluid to back up and cause motor failure Notes Notes contain additional information about a topic Notes are used to provide information about how a topic relates to another topic or background information about a design characteristic Sample note identified as follows NOTE Tubing kits are available for purchase th
19. cturer s safety instructions for them gt Perform only the maintenance described in this manual Maintenance other than that specified in this manual should only be performed by technical service representatives authorized by Helmer Electrical safety CAUTION The cell washer has the potential of being a shock hazard Review all safety instructions Review the following safety instructions before troubleshooting repairing or replacing parts in the cell washer gt Before removing covers from the cell washer disconnect the power to the cell washer lt Use appropriate grounding precautions when replacing circuit boards and other electrical parts lt Use power cords and other electrical parts that are designed for use with the cell washer Chemical and biological safety Review the safety instructions in the Operation Manual before using cleaning or servicing the cell washer AN CAUTION lt In addition to the instructions included in this manual and the Operation Manual follow all chemical handling and disposal requirements and procedures specified by your organization gt Before sending parts to Helmer or your distributor for service or repair decontaminate them as appropriate Any items that have not been decontaminated appropriately will not be accepted Documentation stating that the contents are not contaminated and are safe to handle must accompany all returns Contact Helmer or your distributor for decontamination inst
20. e frequency converter and the power supply board c Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Clear the error message Open the lid then turn off the power After about 1 minute turn the power back on Try the following tasks in order testing after each to determine if it solved the problem Test the motor windings If they are faulty replace the motor Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Clear the error message Open the lid then turn off the power After about 1 minute turn the power back on Confirm that the ambient temperature during operation does not exceed 45 C Try the following tasks in order testing after each to determine if it solved the problem Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board 360113 1 E Helmer Troubleshooting 7 Possible cause Action The frequency converter is faulty Clear the error message Open the lid then turn off the power After about minute
21. ection between the control Clear the error message Open the lid then press the display board and the power supply START WASH button board is loose Check the connection between the control display board and the power supply board A part in the control panel and power Clear the error message Open the lid then press the supply circuit is faulty START WASH button Try the following tasks in order testing after each to determine if it solved the problem 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 E Helmer SER I O ERROR XX Troubleshooting 12 When a message of this type appears there is a problem with communication between components Error Possible cause message number 30 and 31 A connection in the frequency converter circuit is loose The connections between the frequency converter and the RFI filter and braking resistor overtemperature switch are wrong The braking resistor overtemperature switch has opened A part in the frequency converter circuit is faulty 33 34 and A part in the frequency converter and control panel circuit is faulty Action Clear the error message Turn off the power After about 10 seconds turn it back on Check the connection between the frequency converter and the power supply board Check the connections between the frequency converter and the RFI filt
22. een changes to ok to indicate that the new value was saved PARAM INIT XYYY appears on the message screen to indicate the number of initializations that have been performed 8 Remove the extra jumper and move the other one back to its original position to resume normal operation 360113 1 E Helmer 4 8 Servicing the cell washer 23 Removing and installing the bowl assembly NOTE For more information about locating and identifying parts see Section 5 Parts and Section 6 Schematic You will need the following to remove or install the bowl assembly gt Small flathead screwdriver gt Allen wrenches in the following sizes 2 mm 2 5 mm 4 mm and 5 mm The transport bolt removal tool is a 5 mm Allen wrench gt Clear silicone paste To remove the bowl assembly Remove the rotor from the cell washer and leave the lid open Turn off the cell washer and disconnect it from power on Using the 4 mm Allen wrench remove three screws that secure the lid hinges to the housing then swing the lid assembly away from the cell washer This provides clearance for removing the bowl assembly a Lid loosened and swung away from the cell washer 4 Remove the rotor shaft motor hub Left Rotor shaft motor hub with black plastic cap Right Rotor shaft motor hub removed a Using the flathead screwdriver pry the black plastic cap off the top of rotor shaft b Using the 5 mm Allen wrench turn the bottom nut i
23. ematic Several serviceable parts are located behind the front panel This section explains how to access them Bottom view of the front of the cell washer ees mo Cell washer with front panel removed and flipped upward You will need the following to remove or install the front panel gt 2 5mm Allen wrench To remove the front panel 1 2 3 4 Open the lid turn off the cell washer and disconnect it from power 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 To install the front panel a WN With the lid open place the front panel on the front of the housing so that the groove on the panel 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 align Install the three screws to secure the panel to the base 360113 1 E Helmer 4 5 Servicing the cell washer 19 Adjusting the display contrast NOTE For more information about locating and identifying parts see Section 5 Parts and Section 6 Schematic You will need the following to adjust the display contrast gt Small flathead screwdriver with insulated shank
24. ematic A Flow meter E2103 includes supply Bl connector C Braking resistor E1461 includes braking resistor overtemperature switch Braking resistor overtemperature F3 switch 6 S 7n 360113 1 E Helmer Parts 33 Parts under the bowl Left Parts on right side Middle Motor with motor hood removed Right Motor mount Replacement part numbers Label on schematic E1463 ET 360113 1 E gt Helmer 5 8 Parts 34 Accessories 207 5x00 Cell washer accessories Replacement part numbers A Saline adapter Part of the Drain fill tubing assembly 450006 1 Also part of the Tubing kit 450003 1 which includes the Drain fill tubing assembly Bypass tool E003 Transport bolt removal tool 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 Also part of the Tubing kit 450003 1 which includes the Drain fill tubing assembly Not Drain fill tubing assembly 450006 1 shown Also part of the Tubing kit 450003 1 which includes the Pump tubing assembly 360113 1 E Helmer Schematic 35 6 Schematic MAIN POWER 100 120 V 50 60 Hz 200 240 V 50 60 Hz L N X1 POWER CONNECTOR E A3 LIQUID HANDLING BOARD F1 A1 x9 3 1 1 DRIVE MOTOR RIBBON CABLE RIBBON C2 250 10p CABLE RIBBON 140 16p CABLE
25. equency converter was Check that the Imbalance parameter is set to 2 For replaced more information and instructions see Section 4 7 Replacing the frequency converter The imbalance tolerance is set too Clear the error message Open the lid then turn off the low power After about 10 seconds turn the power back on Check the imbalance tolerance and adjust it if necessary For instructions see Section 4 2 Testing whether the imbalance value is in the permissible range One or more motor mounts is worn Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Check the motor mounts for wear Replace them if necessary A connection in the imbalance Clear the error message Open the lid then turn off the microswitch circuit is loose power After about 10 seconds turn the power back on Check the connection between the imbalance microswitch and the power supply board Check that the ribbon cable between the control display board and the power supply board is securely connected A part in the imbalance microswitch Clear the error message Open the lid then turn off the circuit is faulty power After about 10 seconds turn the power back on Try the following tasks in order testing after each to determine if it solved the problem a Check the continuity of the imbalance microswitch which is normally closed The resistance should be 0 when the switch is closed no
26. er after repairing or replacing parts For more information and instructions to program and use the cell washer refer to the Operation Manual To perform a functional check NOTE Regulations for your organization may recommend test methods different from what 10 11 12 appear here Use the appropriate methods for your organization Ensure that the cell washer is connected to power and turned 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 the guidelines for your organization 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 The tubes are decanted equally within a range that is acceptable according to the guidelines for your organization gt The amount of liquid if any is within a range that is acceptable according to the guidelines for your organization If too much liquid remains the decanting speed may need to be adjusted Press the START WASH button to resume
27. er and braking resistor overtemperature switch Clear the error message Turn off the power After about 10 seconds turn it back on Check that the connections on the frequency converter at connector S102 are correct Clear the error message Turn off the power After about 10 seconds turn it back on Replace the braking resistor overtemperature switch Clear the error message Turn off the power After about 10 seconds turn it back on Try the following tasks in order testing after each to determine if it solved the problem a Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the control panel Replace the power supply board Clear the error message Turn off the power After about 10 seconds turn it back on Try the following tasks in order testing after each to determine if it solved the problem a Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the control panel Replace the power supply board 360113 1 E Helmer TACHO ERROR XX
28. he lid lock A connection in the lid lock circuit is Clear the error message Open the lid then turn off the loose power After about 10 seconds turn the power back 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 faulty Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Try the following tasks in order testing after each to determine if it solved the problem Replace the ribbon cable between the control display board and the power supply board Replace the power supply board Replace the control panel 360113 1 E gt Helmer Troubleshooting 5 Error Possible cause Action message number The control panel is faulty 1 Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on 2 Replace the control panel FU CCI ERROR XX When a message of this type appears there is a problem related to the frequency converter Error Possible cause Action message number A part in the frequency converter lt Try the following tasks in order testing after each to circuit is faulty resulting in a false lid determine 1f it solved the problem lock release signal Replace the ribbon cable between the control display board and the power suppl
29. is spinning at 1500 r min For 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 For more information and instructions to program and use the cell washer refer to the Operation Manual You will need the following to test whether the imbalance value is in the permissible range gt Tubes enough to fill all available positions on the rotor gt Saline solution One test run requires 15 g approximately 15 ml gt Scale calibrated and capable of measuring 10 g To test whether the imbalance value is in the permissible range NOTE Regulations for your organization may recommend test methods different from what appear here Use the appropriate methods for your organization 1 Add tubes to all the available positions in the rotor If you are using 10 mm x 75 mm tubes confirm that the tube inserts are installed correctly in all the tube holders 2 Program the Spin S program with a spin speed of 1500 r min and a spin time of 20 seconds 3 Test whether the imbalance value is below the upper limit of the permissible
30. issible range gt Imbalance errors continue to appear even after you have addressed other possible causes You replaced the imbalance microswitch You will need the following to adjust the position of the imbalance microswitch gt 15 TORX screwdriver To adjust the imbalance microswitch 1 Remove the rotor from the cell washer and close the lid 2 Turn off the cell washer and disconnect it from power 3 Turn the cell washer so that it rests on the left side 4 On the bottom of the cell washer use the screwdriver to loosen the screw in the slot This screw secures the imbalance microswitch bracket to the base Bottom of cell washer with imbalance adjustment screw circled 5 Do one of the following To decrease the imbalance value slide the screw toward the center of the cell washer The switch moves closer to the motor shaft gt increase the imbalance value slide the screw away from the center of the cell washer The switch moves farther away from the motor shaft 6 Tighten the screw to secure the imbalance bracket to the base 7 Testthe imbalance value to ensure that it in the permissible range For instructions see Section 4 2 Testing whether the imbalance value is in the permissible range 360113 1 E Helmer 4 4 Servicing the cell washer 18 Removing and installing the front panel NOTE For more information about locating and identifying parts see Section 5 Parts and Section 6 Sch
31. king your way 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 your way around pull the edges of the seal up and over the edge of the hole 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 until they are snug AN CAUTION Do not overtighten the screws Overtightening them 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 AN CAUTION Tightening the top nut which is a 6 mm nut may damage the rotor shaft and bowl assembly 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 wrench to tighten the screws that secure the hinges to the housing 360113 1 E Helmer 4 9 Servicing the cell washer 25 Performing post repair checks Perform functional and safety checks of the cell wash
32. lay contrast is gt Adjust the display contrast For instructions see Section set too low 4 5 Adjusting the display contrast A part in the LCD circuit lt Try the following tasks in order testing after each to is faulty determine 1f it solved the problem 1 Replace the control panel 2 Replace the power supply board A part in the pump gt Remove the pump tubing from the pump With the system is faulty pump tubing removed perform a saline check gt Ifthe pump does not operate replace the pump lt Ifthe pump does operate replace the pump tubing which may have hardened over time A part in the liquid lt Try the following tasks in order testing after each to handling system circuit determine if it solved the problem is faulty 1 Replace the flow meter 2 Replace the liquid handling board The rotor is faulty lt Verify that all the rotor locks decant hooks are intact If any are broken off or damaged replace the rotor A part in the motor lt Try the following tasks in order testing after each to circuit is faulty determine if it solved the problem 1 Replace the motor 2 Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board 360113 1 E Helmer Troubleshooting 4 Possible Cause The rotor speed seems to A part in the speed Measure the rotor speed For instructions see Section be too high or too low sensor
33. more information see Section 6 Schematic Using the TORX screwdriver remove the four screws that secure the frequency converter board and underlying heat sink to the interior housing then remove the frequency converter and heat sink together Left Frequency converter Right Detail of one of four TORX screws that secure the frequency converter to the interior housing Install the new frequency converter and reinstall the screws making sure that there is sufficient heat conduction paste between the heat sink and the interior housing If necessary scrape off the paste from the old frequency converter and apply it on the new one Reconnect the wiring On the back of the front panel locate the control display board On the control display board add the 2 pin jumper and configure the jumpers for initialization mode For instructions see Section 4 7 1 Setting jumpers Install the front panel For instructions see Section 4 4 Removing and installing the front panel Initialize the cell washer For instructions see Section 4 7 2 Initializing the cell washer Perform a functional check of the cell washer For instructions see Section 4 9 Performing post repair checks 360113 1 E Helmer 4 7 1 4 7 2 Servicing the cell washer 22 Setting jumpers The jumper settings on the control display board must be changed to enter initialization mode 524 ie Jumper settings Left Normal oper
34. nside the shaft counter clockwise to loosen it AN CAUTION Loosening the top nut which is a 6 mm nut may damage the rotor shaft and bowl assembly Liftthe rotor shaft motor hub from the motor shaft 5 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 b Ontherear of the cell washer use the 2 5 mm Allen wrench to remove the two screws that secure the drain connector to the base Working your way around the hole in the bowl gently pull the silicone motor seal toward the motor shaft 360113 1 E gt Helmer Servicing the cell washer 24 6 Liftthe gasket drainage rings and bowl assembly from the housing tilting the bowl so that the drain connector clears the housing AN CAUTION If the drain connector is damaged the bowl assembly must be replaced To install the bowl assembly 1 Lower the gasket drainage rings and bowl assembly into the housing The drain connector should emerge through the hole in the base and the bowl should be centered over the motor shaft AN CAUTION If the drain connector is damaged the bowl assembly must be replaced 2 Adjust the silicone motor seal to the correct position Left Seal partially pinched under the bowl Middle Seal pulled toward shaft with the edges partially pulled around the edge of the center hole Right Seal correctly adjusted a Wor
35. nsor and motor circuit is loose resulting in no speed sensor pulses after start up A part in the speed sensor and motor circuit is faulty VERSION ERROR XX Troubleshooting 14 Message Possible cause Action number Clear the error message by doing the following a Open the lid then turn off the power b While spinning the rotor clockwise by hand turn on the power Check the connection between the speed sensor and the power supply board Check the motor connections Clear the error message by doing the following a Open the lid then turn off the power b While spinning the rotor clockwise by hand turn on the power Try the following tasks in order testing after each to determine if it solved the problem a Test the motor windings If they are faulty replace the motor b Testthe speed sensor by measuring the rotor speed For instructions see Section 4 1 Testing whether the rotor speed is within the design tolerance If the speed is not within the tolerance replace the speed sensor Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the control panel Replace the power supply board When a message of this type appears there is a problem with the control panel
36. peed is within the design 15 4 2 Testing whether the imbalance value is in the permissible range 16 4 3 Adjusting the imbalance 4 17 4 4 Removing and installing the 18 4 5 Adjusting the display contrast 1 19 4 6 Viewing and changing the fill 1 20 4 7 Replacing the frequency converter 1 4 21 4 8 Removing and installing the bowl assembly 23 4 9 Performing post repair 25 4 10 Reviewing the preventive maintenance schedule 26 2 Pants oh t eee eae eee 27 5 1 Parts on the front and 27 5 2 Parts on the rear and bottom usas rm abate ee ba Mea eee 28 5 3 Parts the Side 4 044 4 ua pan behead DAS eae eR ROAR Rae bee LES 28 5 4 the bowland FOlOF 22 29 5 5 Parts behind the front panel 00 inse
37. place the flow meter b Replace the liquid handling board 360113 1 E gt Helmer N gt MAX XX When this message appears the rotor speed being detected exceeds the maximum allowable speed Error message number Possible cause The insulation on the speed sensor cable is faulty connection in the speed sensor circuit is loose A part in the speed sensor circuit is faulty Troubleshooting 10 Action Clear the error message Turn off the power After about 10 seconds turn it back on Check the speed sensor cable for wear If worn replace the speed sensor Clear the error message Turn off the power After about 10 seconds turn it back 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 Turn off the power After about 10 seconds turn it back on Try the following tasks in order testing after each to determine if it solved the problem a Test the speed sensor by measuring the rotor speed For instructions see Section 4 1 Testing whether the rotor speed is within the design tolerance If the speed is not within the tolerance replace the speed sensor Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace
38. rough Helmer 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 information Copyright 2013 Helmer Inc UltraCW is a registered trademark of Helmer Inc in the United States of America other trademarks and registered trademarks are the property of their respective owners Helmer Inc doing business as DBA Helmer Scientific and Helmer 360113 1 E gt Helmer 1 1 1 2 1 3 Working safely 1 Working safely This section describes general safety information for servicing the UltraCW Automatic Cell Washing System cell washer The Operation Manual includes additional safety information for operating and cleaning the cell washer Your organization may provide additional safety information General safety To avoid injury to yourself and the cell washer follow these safety instructions gt Do not use the cell washer if its components are damaged Never attempt to physically restrict any of the moving components Do not move or bump the cell washer during operation Before performing the procedures in this manual review the specific safety instructions for them Before using tools materials and equipment to perform procedures in this manual review the manufa
39. ructions and a return authorization number 360113 1 E Helmer 2 1 2 2 Reviewing information about your cell washer 2 Reviewing information about your cell washer This section explains how to find identification information about your cell washer Finding model and input power information The Product Specification label is located on the right side of the cell washer next to the power connector A Type UltraCW 4 Helmer B Serial Number 0000000 Noblesville INUSA www helmerinc com Volts Freq Amps Power 110 127Vac 60 Hz 2 5 200 Watts E 2013 RPM Kinetic Energy Max Density 250Nm 1 2Kg dm 3500R min Made in Switzerland Product Specification label sample Type Mode B Serial number S N Finding software and part version information The software version appears on the control panel when you turn on the power Additional information is available through the Global menu as follows C Parameter y CONTROL h Number of operating hours FU CCI 1001 Frequency converter type FU CCI S XX XX Frequency converter software version To view version information in the Global menu 1 On the control panel press and hold the parameter selection button 4 for about eight seconds until VOLUME ADJUST XX appears on the message screen 2 Press and release the parameter selection button lt to cycle through the global parameters 3 Exitthe Global menu by pressing the STOP button
40. s on the front and lid Replacement part numbers A Outer lid E2186 Also part of 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 Also part of the Lid assembly E2184 which includes all parts on the lid plus the hinges Control panel E2148 includes the control display board LCD display and touchpad F Inner lid E2185 Also part of the Lid assembly E2184 which includes all parts on the lid plus the hinges G Lid handle latch Part of the Lid assembly E2184 which includes all parts on the lid plus the hinges H Nozzle Part of the Lid assembly E2184 which includes all parts on the lid plus the hinges I Splash guard Part of Drainage system kit E2535 which includes the drainage rings Part of the Lid assembly E2184 which includes all parts on the lid plus the hinges J Lid hinge E1563 Also part of the Lid assembly E2184 which includes all parts on the lid plus the hinges Not Lid spring E1565 shown 360113 1 E Helmer 5 2 5 3 Parts 28 Parts on the rear and bottom Parts on the rear and bottom of the cell washer Replacement part numbers Label on schematic E2107 a MEE Drain connector Part of Bowl assembly E2104 A which includes the bowl Supply connector Part of Flow meter E2103 Parts on the side A B Parts on the right side of the cell washer Replacement part numbers Label
41. screen changes to ok to indicate that the new values were saved PARAM INIT XYYY appears on the message screen to indicate the number of initializations that have been performed 6 Optional To view or change the initialization parameters again turn the cell washer off and back on again then repeat steps 2 5 7 Remove the extra jumper and move the other one back to its original position to resume normal operation 360113 1 E Helmer 4 7 Servicing the cell washer 21 Replacing the frequency converter NOTE For more information about locating and identifying parts see Section 5 Parts and Section 6 Schematic 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 If there is a problem with the frequency converter it may need to be replaced You will need the following to replace the frequency converter gt gt gt 2 5 mm Allen wrench 20 TORX screwdriver Standard 2 pin jumper To replace the frequency converter on 10 11 12 Remove the rotor from the cell washer and leave the lid open Turn off the cell washer and disconnect it from power Use the Allen wrench to remove the front panel For instructions see Section 4 4 Removing and installing the front panel Disconnect the wiring to other components For
42. t activated If there is resistance replace the imbalance microswitch then set the imbalance tolerance For instructions see Section 4 3 Adjusting the imbalance microswitch Replace the ribbon cable between the control display board and the power supply board Replace the power supply board Replace the control panel 360113 1 E Helmer LOW SALINE When this message appears there is a problem with the flow of saline into the cell washer Possible cause Action Error message number None A connection in the liquid handling system circuit is loose A part in the pump system is faulty A part in the liquid handling system circuit is faulty Troubleshooting 9 Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Check the connection between the liquid handling board and the power supply board Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Remove the pump tubing from the pump With the pump tubing removed perform a saline check lt Ifthe pump does not operate replace the pump Ifthe pump does operate replace the pump tubing which may have hardened over time Clear the error message Open the lid then turn off the power After about 10 seconds turn the power back on Try the following tasks in order testing after each to determine if it solved the problem a Re
43. y board Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Replace the control panel A part in the frequency converter Clear the error message Open the lid then turn off the circuit is faulty resulting in a power After about 1 minute turn the power back on processing error Try the following tasks in order testing after each to determine if it solved the problem Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply board Replace the frequency converter For instructions see Section 4 7 Replacing the frequency converter Replace the power supply board Replace the control panel The main supply voltage is too low Clear the error message Open the lid then turn off the resulting in an undervoltage condition power After about 1 minute turn the power back on to the frequency converter Verify that the outlet in the facility is operational and supplying adequate voltage to the cell washer Try the following tasks in order testing after each to determine if it solved the problem Replace the ribbon cable between the control display board and the power supply board Replace the ribbon cable between the frequency converter and the power supply bo

UltraCW Automatic Cell Washing System Service Manual

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