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UltraCW Service Manual
UltraCW Service Manual
TM
Model
Version
UltraCW
HELMER SCIENTIFIC
14400 Bergen Boulevard
Noblesville, IN 46060 USA
PH +1.317.773.9073
FAX +1.317.773.9082
USA and Canada 800.743.5637
360113-1/H
Contents
Document History
Revision
Supersession
Revision Description
Supersedes A,
B, C, D, E
H supersedes G
Date
CO
* Date submitted for Change Order review. Actual release date may vary.
360113-1/H
Contents
Contents
Section I: General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1
1.2
1.3
Intended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Copyright and Trademark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1
2.2
2.3
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Avoiding Injury. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1
3.2
Regulatory Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WEEE Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1
5.2
8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1
8.2
8.3
9 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.1
9.2
9.3
360113-1/H
ii
Contents
9.4
Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.4.1 CONTROL - ERROR XX Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.4.2 FU/CCI - ERROR XX Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.4.3 IMBALANCE Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.4.4 LOW SALINE Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.4.5 N > MAX XX Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.4.6 N < MIN XX Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.4.7 POWER INTERRUPT Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.4.8 SER I/O - ERROR XX Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.4.9 TACHO - ERROR XX Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.4.10 VERSION - ERROR XX Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.1
10.2
10.3
10.4
10.5
10.6
10.7
11 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12 Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
360113-1/H
iii
General Information
1.1
Intended Audience
This manual is intended for use by end users of the cell washer and authorized service technicians.
1.2
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.
1.3
2 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.
2.1
Safety Definitions
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.
2.2
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
equipment or danger to operator
360113-1/H
Caution: Biohazard
General Information
2.3
Avoiding Injury
Review safety instructions before installing, using, or maintaining the equipment.
Do not move or bump the cell washer during operation.
Before moving unit, disconnect the AC power cord and secure the cord.
Never physically restrict any moving component.
Avoid removing electrical service panels and access panels unless so instructed.
Use supplied power cords only.
Using the equipment in a manner not specified by Helmer may impair the protection provided by the
equipment.
Decontaminate parts prior to sending for service or repair. Contact Helmer or your distributor for
decontamination instructions and a Return Authorization Number.
Configuration
3.1
This information is shown on the product specification label, located on the right side of the cell washer.
A
Type: UltraCW
Volts
110-127 Vac
Kinetic Energy
250 Nm
Freq
60 Hz
Amps
2.5
Power
200 Watts
2014
Max. Density
1.2 Kg/dm
RPM
3500 R/min
Made in Switzerland
360113-1/H
Label
Description
Model (REF)
Power requirements
Operational information
General Information
3.2
Meaning
CONTROL: XXX h
VERS XX
C/*
00
FU/CCI - 1001
FU/CCI - S. XX.XX
360113-1/H
General Information
4.1
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): 44 dB(A)
4.2
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.
When disposing of this product in countries affected by this directive:
Do not dispose of this product as unsorted municipal waste.
Collect this product separately.
Use collection and return systems available locally.
For more information on the return, recovery, or recycling of this product, contact your local distributor.
5 Warranty
5.1
5.1.1
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.
5.1.2 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.
360113-1/H
General Information
5.1.3 Labor
For a period of one (1) year Helmer 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.
5.1.4
5.2
360113-1/H
Service
7.1
The following table shows the values that would be displayed if the SalWash/ml parameter were set to
the recommended value:
Rotor Type
12-place
24-place
12-place
24-place
Tube Size
Volume Setting
(Per Tube)
10 mm x 75 mm 3.2 mL
12 mm x 75 mm 4.7 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.
360113-1/H
Service
Use the volumetric measuring device to capture the dispensed saline solution.
6 On the control panel, press the CHECK button. The Saline lamp illuminates. The volume of saline
solution that was displayed is 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
7.2
To stop the flow of saline solution, press the STOP button on the control panel.
360113-1/H
10
Service
2 Determine if an adjustment is needed. If the measured volume is within 5% of the displayed value,
an adjustment is not needed.
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.
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.
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 If an adjustment is needed, determine the difference in volume.
Displayed - Measured = Difference
Example 1: 38.4 - 41.0 = -2.6 mL
Example 2: 112.8 - 106.8 = 6.0 mL
4 Determine the adjustment value, rounded to the nearest whole number.
Difference Measured 200 = Adjustment Value
Example 1: -2.6 41.0 200 = -12.7 -13
Example 2: 6.0 106.8 200 = 11.2 11
7.3
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.
8 Maintenance
NOTE
8.1
360113-1/H
11
Service
360113-1/H
12
Service
Middle section
of pump tubing
oriented in
tubing holder.
360113-1/H
13
Service
8.2
Refer to chapter 8.4 (Supplies) for replacement tube holder part numbers.
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
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.
360113-1/H
15
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.
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.
8.3.3
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:
A container large enough to hold the rotor.
A source of warm water to soak or flush the rotor.
The bypass tool. This tool is included but packaged separately from the cell washer.
Bypass tool.
360113-1/H
16
Service
Cleaning the fill ports using any method 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 If a port is 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 Do one of the following:
If the rotor will not be used immediately, ensure that it is dry before returning it to the cell washer
and closing the lid.
If the rotor will be used immediately, ensure that all fresh water has been purged from the system
and replaced by saline solution before processing.
NOTE
8.3.4
Refer to chapter 8.3.4 (Flush the System) for instructions in purging fresh water from the
rotor.
360113-1/H
17
Service
Flush procedure:
NOTE
1
2
3
4
6
7
8
Load the rotor with tubes, leaving every other position on the rotor empty.
Install the rotor and close the lid. Ensure the Lid Ready lamp is lit.
Connect the supply tube to the bleach solution container.
Select the Clean program.
a 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.
b On the control panel, select a program.
Press and release the parameter value buttons ( or ) until the Clean program is
displayed.
Press the START WASH button.
The cleaning sequence starts.
When the cleaning sequence is complete, OPEN LID is displayed and the Lid Ready lamp
illuminates.
Open the lid.
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.
9 Press and hold the SALINE button for about three seconds.
The Saline lamp illuminated and REFILL process is displayed.
60 mL of residual bleach solution and distilled water is dispensed from the nozzle into the waste
container.
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.
360113-1/H
18
Service
360113-1/H
19
Service
9 Troubleshooting
CAUTION
9.1
360113-1/H
Possible Cause
Action
Rotor is faulty.
20
Service
9.2
Performance Problems
Problem
Results of the wash
process are not
acceptable.
Possible Cause
Action
A component is faulty.
360113-1/H
21
Service
9.3
Equipment Problems
Problem
Nothing is displayed
on the message
screen.
360113-1/H
Possible Cause
Action
Cell washer is
powered off.
During a saline
A component is faulty.
check, pump is not
making any sound
and saline is not being
dispensed.
22
Service
9.4
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.
9.4.1
21 to 26
360113-1/H
Action
23
Service
9.4.2
360113-1/H
Action
60
61
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, 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 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, 1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, power
resulting in an under-voltage
condition to the frequency
the cell washer on.
converter.
2 Verify that the outlet in the facility is operational and
supplying adequate voltage to the cell washer.
3 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.
63
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, 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 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.
24
Service
Error
Message Possible Cause
Number
360113-1/H
Action
64
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, 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 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.
67
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, power
the cell washer on.
2 Perform the following tasks in order, testing after each
to determine if the problem was addressed:
a Test the 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.
68
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, power
the cell washer on.
2 Confirm that the ambient temperature during operation
does not exceed 45 C.
3 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.
69
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, power
the cell washer on.
2 Replace the frequency converter.
84
25
Service
Error
Message Possible Cause
Number
85
9.4.3
Action
1 Clear the error message: Open the lid and power the
cell washer off. After approximately one minute, 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 ribbon cable between the frequency
converter and the power supply board.
b Replace the frequency converter.
c Replace the power supply board.
360113-1/H
Action
Imbalance initialization
parameter was set to the
wrong value after the
frequency converter was
replaced.
26
Service
Error
Message Possible Cause
Number
None
9.4.4
Action
1 Clear the error message: Open the lid and power
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 when the switch is closed (not activated).
If there is resistance, replace the imbalance
microswitch, then set the imbalance tolerance.
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.
360113-1/H
Action
27
Service
9.4.5
360113-1/H
Action
Insulation on the speed sensor 1 Clear the error message: Open the lid and power
cable is faulty.
the cell washer off. After approximately 10 seconds,
power the cell washer on.
2 Check the speed sensor cable for wear. If worn,
replace the speed sensor.
A connection in the speed
sensor circuit is loose.
28
Service
9.4.6
9.4.7
Action
360113-1/H
Action
1 Clear the error message: Open the lid then press the
START WASH button.
2 Check the connection between the control/display
board and the power supply board.
1 Clear the error message: Open the lid then press the
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.
29
Service
9.4.8
33, 34,
and 36
360113-1/H
Action
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 the connection between the frequency
converter and the power supply board.
3 Check the connections between the frequency
converter and the RFI filter and braking resistor overtemperature switch.
30
Service
9.4.9
02
Action
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 Test the 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.
g Replace the power supply board.
360113-1/H
31
Service
9.4.10
Action
10 Maintenance
NOTE
10.1
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:
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.
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.
360113-1/H
32
Service
10.2
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/supplies:
Tubes (enough to fill all available positions on the rotor)
Saline solution (one test run requires 15 g / 15 mL)
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.
360113-1/H
Refer to chapter 10.3 (Adjust the Imbalance Microswitch) for instructions in changing the
imbalance microswitch value.
33
Service
10.3
360113-1/H
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
Service
10.4
Required tools:
2.5 mm Allen wrench
Remove the front panel:
1 Power the cell washer off and disconnect it from AC power. Open the lid.
2 Remove the three screws that secure the bottom of the front panel to the base.
3 Gently pull the bottom of the panel away from the base.
4 Lift the front panel until the groove on the panel disengages from the tongue on the housing.
Install the front panel:
1 Open the lid.
2 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.
3 Press front panel downward to engage the tongue and groove.
4 Press the bottom of the panel against the base.
5 Slide the front panel sideways until the sides of the panel align with the base and the screw holes are
aligned.
6 Install the three screws to secure the panel to the base.
360113-1/H
35
Service
10.5
360113-1/H
Refer to the operation manual for instructions in changing the rotor speed.
36
Service
Required tools:
2.5 mm Allen wrench
#20 TORX screwdriver
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
7 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.
After approximately eight seconds, * INIT - MODE * is displayed on the screen.
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 ( or ) to change the value (optional).
c Press and release the parameter selection button () to view the remaining initialization
parameters (optional).
d Press the START WASH button.
***ok*** is displayed on the screen to indicate that the new values were saved.
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.
d 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.
360113-1/H
37
Service
10.7
Required tools:
2.5 mm Allen wrench
#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 Lift the 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 transfer 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 10.7.2 (Initialize the Cell Washer) for instructions in initializing the cell washer.
360113-1/H
Service
10.7.1
Set Jumpers
The jumper settings on the control/display board must be changed to enter initialization mode.
0
1
2
3
4
0
1
2
3
4
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:
Install a jumper at position 0.
Remove jumpers from positions 1, 2, 3, and 4.
Set jumpers for initialization mode:
Install jumpers at positions 3 and 4.
Remove jumpers from positions 0, 1, and 2.
10.7.2
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:
2.5 mm Allen wrench
#20 TORX screwdriver
Standard 2-pin jumper
Initialization procedure:
1 On the control/display board, ensure that the jumpers are set for initialization mode.
NOTE
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.
After approximately eight seconds, * INIT - MODE * is displayed on the screen.
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 ( or ) until the value is set to 2.
5 Press and release the parameter selection button () to cycle through the initialization parameters
(optional).
360113-1/H
39
Service
40
Service
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.
360113-1/H
Seal correctly
adjusted.
41
Service
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 wrench to tighten the screws that
secure the hinges to the housing.
10.9
Post-Repair Check
Perform functional and safety checks of the cell washer after repairing or replacing parts.
NOTE
For information and instructions to program and use the cell washer, refer to the
operation manual.
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.
360113-1/H
42
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
A
B
C
D
I
J
Description
Part Number
Outer lid
E2186 (Included in the lid assembly (E2184), which includes all parts on
the lid plus the hinges)
Sight window
Lid handle
E2189 (Included in the lid assembly (E2184), which includes all parts on
the lid plus the hinges)
Control panel
Front panel
E2188
Inner lid
E2185 (Included in the lid assembly (E2184), which includes all parts on
the lid plus the hinges)
Included in the lid assembly (E2184), which includes all parts on the lid
plus the hinges
Nozzle
Included in the lid assembly (E2184), which includes all parts on the lid
plus the hinges
Splash guard
Lid hinge
E1563 (Included in the lid assembly (E2184), which includes all parts on
the lid plus the hinges)
Not
Lid spring
shown
360113-1/H
E1565
43
Service
11.2
B
C
Part Number
Rear panel
E2107
Drain connector
Supply connector
Not
Foot
shown
360113-1/H
Schematic
Label
Description
3680
B1
-
44
Service
11.3
D
A
B
E
Cell washer with rear panel removed.
Label
Schematic
Label
Description
Part Number
Isolation transformer
E2195
Drain connector
450005-1
Pump
E2096
M2
Supply connector
B1
T1
11.4 Side
A
360113-1/H
Schematic
Label
Label
Description
Part Number
Fuse (2.5 A)
E2268
F2
E1009
Q1
Power connector
E507
X1
45
Service
11.5
A
E
F
B
C
D
Description
Part Number
Drainage rings
Bowl
Gasket
E2105
E2370
Rotor (12-place)
E2551
D, H
E
Not
Rotor, 24-place
shown
360113-1/H
46
Service
11.6
A
B
G
H
I
C
D
360113-1/H
Schematic
Label
Description
Part Number
Control/display board
A4
E1332
C1
E1333
C2
A2
E1888
A1
RFI filter
E1284
Z1
E1327
C3
Interior housing
Lid lock
E1478
Y1
E2130
A3
Fuse (2.5 A)
E2268
F2
47
Service
11.7
A
F
H
C
D
E
Top view of cell washer with bowl removed.
360113-1/H
Label
Description
Part Number
Schematic
Label
Flow meter
B1
Pump
E2096
M2
Braking resistor
R1
F3
Motor relay
E2193
K1
Isolation transformer
E2195
T1
Motor hood
E2191
E2690
48
Service
J
K
L
I
Parts on the right side,
under the bowl.
Label
360113-1/H
Motor mount.
Schematic
Label
Description
Part Number
Varistor board
E1463
F1
Speed sensor
E730
B2
Motor
E823
M1
Imbalance microswitch
E2528
S1
Motor mount
E2915
49
Service
11.8 Accessories
B
Cell washer accessories.
Label
360113-1/H
Description
Part Number
Saline adapter
Bypass tool
E2287-01
E613
Transport bolt removal tool
(NOTE This tool is also used to
remove the rotor shaft/motor hub)
Not
Power cord
shown
115 V: 6083
230 V: 120156
Not
Pump tubing assembly
shown
450005-1
Included in the tubing kit (450003-1), which includes
the drain/fill tubing assembly
Not
Drain/fill tubing assembly
shown
450006-1
Included in the tubing kit (450003-1), which includes
the pump tubing assembly
Not
Tubing kit
shown
50
Service
12 Schematic
MAIN POWER
100-120 V 50/60 Hz
200-240 V 50/60 Hz
X5
-+
X7
X4 1
X3
X1
1
(X1)
POWER
CONNECTOR
X1 X9
X2
X3 1
X6
X4 1
X8
4 3 2 1
(A3) LIQUID
HANDLING BOARD
A3
A1
X4
A1
(C3)
RIBBON
CABLE
250/10p
X1
A2
A2
(A4) CONTROL/DISPLAY
BOARD
115 V
230 V
70
130C
S501
A1
1 2 3 4 5 6
X4
1 2 3 4
A1
X3
1 2 3 4
43
13
44
14
(A2) FREQUENCY
CONVERTER
N
U1
PE
S501
(R1) BRAKING
RESISTOR
P10
S102
X3
S2
(K1) MOTOR
RELAY
115 V
A3
140C
X100
(T1)
TRANSFORMER
1.7 at
cold motor
2 1
X1
X101
1
A4
X101
(C2)
RIBBON
CABLE
130/10p
(M1)
DRIVE MOTOR
(C1)
RIBBON
CABLE
140/16p
A4
SERVICE
JUMPER
0
X2
S2
1
(Q1)
MAIN
POWER
SWITCH
X9
S101
W2
V2
U2
(F1)
VARISTOR
BOARD
P1
A1
X5
1 2 3 4 5 6
A3
X1
1 2 3 4 5 6
U
130C
M
1~
5.9
(B1)
FLOW
METER
(B2)
SPEED
SENSOR
(S1)
IMBALANCE
SWITCH
(Y1)
LID
LOCK
(M2)
PUMP
END OF MANUAL
360113-1/H
51
HELMER SCIENTIFIC
14400 Bergen Boulevard
Noblesville, IN 46060 USA
PH +1.317.773.9073
FAX +1.317.773.9082
www.helmerinc.com