Helmer UltraCW Manuale utente

360113-1/A

UltraCW™ Version B

Model UltraCW™

S/N

HELMER, INC. 15425 HERRIMAN BLVD., NOBLESVILLE, IN 46060 USA

PHONE (317) 773-9073 FAX (317) 773-9082

USA and CANADA (800) 743-5637

www.helmerinc.com

Automatic Cell Washing System

Service Manual

360113-1

Aboutthismanual...........................................................ii

1 Workingsafely...........................................................1

1.1 Generalsafety....................................................................1

1.2 Electricalsafety...................................................................1

1.3 Chemicalandbiologicalsafety .......................................................1

2 Reviewing information about your cell washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2.1 Findingmodelandinputpowerinformation..............................................2

2.2 Finding software and part version information ............................................2

3 Troubleshooting..........................................................3

3.1 Troubleshootinggeneraloperationproblems.............................................3

3.2 Addressingerrormessages..........................................................4

4 Servicingthecellwasher .................................................15

4.1 Testing whether the rotor speed is within the design tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.2 Testing whether the imbalance value is in the permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.3 Adjusting the imbalance microswitch ..................................................17

4.4 Removing and installing the front panel................................................18

4.5 Adjustingthedisplaycontrast .......................................................19

4.6 Viewingandchangingthellspeed...................................................20

4.7 Replacingthefrequencyconverter ...................................................21

4.7.1 Settingjumpers.........................................................22

4.7.2 Initializing the cell washer.................................................22

4.8 Removing and installing the bowl assembly ............................................23

4.9 Performingpost-repairchecks.......................................................25

5 Parts ..................................................................26

5.1 Partsonthefrontandlid ...........................................................26

5.2 Partsontherearandbottom........................................................27

5.3 Partsontheside .................................................................27

5.4 Partsonthebowlandrotor.........................................................28

5.5 Partsbehindthefrontpanel.........................................................29

5.6 Partsbehindtherearpanel.........................................................30

5.7 Partsunderthebowl ..............................................................31

5.8 Accessories.....................................................................33

6 Schematic..............................................................34

Contents

360113-1

UltraCW™ Automatic Cell Washing System Service Manual

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 qualied 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.

Warnings

A Warning is used to call attention to a condition or possible situation that could cause injury to the operator.

Warnings are identied as follows:

WARNING: This is a sample of a warning: Follow all chemical handling and disposal

requirements and procedures that are specied by your organization.

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.

Cautions are identied as follows:

CAUTION: This is a sample of a caution: Be sure that the tubing is free of obstructions.

Blocked tubing can cause uid 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.

Notes are identied as follows:

NOTE: This is a sample of a note: Tubing kits are available for purchase through

Helmer.

UltraCW™ is a registered trademark of Helmer, Inc. in the United States of America.

All other trademarks and registered trademarks are the property of their respective owners.

360113-1

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.

1.1 General safety

To avoid injury to yourself and the cell washer, follow these safety instructions:

► 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 specic safety instructions for them.

► Before using tools, materials, and equipment to perform procedures in this manual, review the

manufacturer’s safety instructions for them.

► Perform only the maintenance described in this manual. Maintenance other than that specied in this

manual should only be performed by technical service representatives authorized by Helmer.

1.2 Electrical safety

WARNING: 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:

► Before removing covers from the cell washer, disconnect the power to the cell washer.

► Use appropriate grounding precautions when replacing circuit boards and other electrical parts.

► Use power cords and other electrical parts that are designed for use with the cell washer.

1.3 Chemical and biological safety

Review the safety instructions in the Operation Manual before using, cleaning, or servicing the cell washer.

WARNING: In addition to the instructions included in this manual and the Operation Manual,

follow all chemical handling and disposal requirements and procedures specied

by your organization.

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 for decontamination instructions and a return

authorization number.

360113-1

UltraCW™ Automatic Cell Washing System Service Manual

2 Reviewing information about

your cell washer

This section explains how to nd identication information about your cell washer.

2.1 Finding model and input power information

The Product Specication label is located on the right side of the cell washer next to the power connector.

Type: UltraCW

Serial Number 0000000

Volts Freq Amps Power

110-127Vac 60 Hz 2.5 200 Watts

Kinetic Energy Max. Density RPM

250Nm 1.2Kg/dm 3500R/min

3Made in Switzerland

2005

www.helmerinc.com

Noblesville, IN USA

ProductSpecicationlabel(sample)

Label Description

AType (Model)

B Serial number (S/N)

CPower requirements

2.2 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:

Parameter Meaning

CONTROL: XXX h Number of operating hours

VERS XX °C/* 00 XX is the software version

FU/CCI - 1001 Frequency converter type

FU/CCI - S. XX.XX Frequency converter software version

To view version information in the Global menu

1 On the control panel, press and hold the parameter selection button () for about eight seconds until

VOLUME ADJUST XX appears on the message screen.

2 Press and release the parameter selection button () to cycle through the global parameters.

3 Exit the Global menu by pressing the STOP button 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

Troubleshooting

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.

WARNING: Review all safety instructions prior to completing troubleshooting

recommendations. For more information, see Section 1, “Working safely.”

3.1 Troubleshooting general operation problems

Problem Possible Cause Action

The cell washer is

turned on, but nothing

is displayed on the

message screen.

There is no power to the

cell washer.

1 Verify that the outlet is operational.

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 lter.

The display contrast is

set too low.

► Adjust the display contrast. For instructions,

see Section 4.5, “Adjusting the display

contrast.”

A part in the LCD circuit

is faulty.

► Try the following tasks in order, testing after

each to determine if it solved the problem:

1 Replace the control panel.

2 Replace the power supply board.

During a saline check,

the pump is not making

any sound and saline is

not being dispensed.

A part in the pump

system is faulty.

► Remove the pump tubing from the pump. With

the pump tubing removed, perform a saline

check.

► If the pump does not operate, replace the

pump.

► If the pump does operate, replace the

pump tubing, which may have hardened

over time.

During a saline check,

the pump is operating,

but saline is not being

dispensed correctly.

A part in the liquid

handling system circuit

is faulty.

► Try the following tasks in order, testing after

each to determine if it solved the problem:

1 Replace the ow meter.

2 Replace the liquid handling board.

The tubes were not

decanted when they

were programmed to

do so.

The rotor is faulty. ► 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

circuit is faulty.

► Try the following tasks in order, testing after

each to 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.”

3 Replace the power supply board.

360113-1

UltraCW™ Automatic Cell Washing System Service Manual

Problem Possible Cause Action

The rotor speed seems to

be too high or too low.

A part in the speed

sensor circuit is faulty.

1 Measure the rotor speed. For instructions, see

Section 4.1, “Testing whether the rotor speed is

within the design tolerance.”

2 Try the following tasks in order, testing after

each to determine if it solved the problem:

a Replace the speed sensor.

b Replace the motor.

c Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

Tubes are breaking

during processes with a

Decant step.

Tube holder inserts were

not installed correctly

before processing

10 mm x 75 mm tubes.

► Install the tube holder inserts, and repeat

the process to determine if the problem was

solved.

The top of the tube does

not move freely around

the ll port.

► Ensure that the height of the tubes is within the

acceptable tolerance of 75 mm ± 1.5 mm.

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

message

number

Possible cause Action

04,

06 to 09

Continued

The lid lock 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 Check if the lid can be opened while the cell

washer is turned off. If it can, replace the lid

lock.

A connection in the lid lock circuit is

loose.

1 Clear the error message: Open the lid, then

turn off the power. After about 10 seconds, turn

the power back on.

2 Check the contact connection between the lid

lock and the control/display board.

3 Check that the ribbon cable between the

control/display board and the power supply

board is securely connected.

360113-1

Troubleshooting

Error

message

number

Possible cause Action

Continued

04,

06 to 09

A part in the lid lock circuit 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 Try the following tasks in order, testing after

each to determine if it solved the problem:

a Replace the ribbon cable between the

control/display board and the power

supply board.

b Replace the power supply board.

c Replace the control panel.

21 to 26 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

message

number

Possible cause Action

60 A part in the frequency converter

circuit is faulty, resulting in a false lid

lock release signal.

► Try the following tasks in order, testing after

each to determine if it solved the problem:

1 Replace the ribbon cable between the

control/display board and the power

supply board.

2 Replace the ribbon cable between the

frequency converter and the power supply

board.

3 Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

4 Replace the power supply board.

5 Replace the control panel.

61 A part in the frequency converter

circuit is faulty, resulting in a

processing error.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 Try the following tasks in order, testing after

each to determine if it solved the problem:

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. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

e Replace the control panel.

360113-1

UltraCW™ Automatic Cell Washing System Service Manual

Error

message

number

Possible cause Action

62 The main supply voltage is too low,

resulting in an undervoltage condition

to the frequency converter.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 Verify that the outlet in the facility is

operational and supplying adequate voltage to

the cell washer.

3 Try the following tasks in order, testing after

each to determine if it solved the problem:

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. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

e Replace the control panel.

63 A part in the frequency converter

circuit is faulty, resulting in an

overcurrent condition in the motor.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 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.

c Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

64 A part in the frequency converter

circuit is faulty, resulting in an

overvoltage condition in the braking

resistor.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 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 the

frequency converter and the power supply

board.

c Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

360113-1

Troubleshooting

Error

message

number

Possible cause Action

67 A part in the frequency converter

circuit is faulty, resulting in an

overtemperature condition in the

motor.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 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 ribbon cable between the

frequency converter and the power supply

board.

c Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

68 A part in the frequency converter

circuit is faulty, resulting in an

overvoltage condition in the

frequency converter.

1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 Conrm that the ambient temperature during

operation does not exceed 45 °C.

3 Try the following tasks in order, testing after

each to determine if it solved the problem:

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. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

d Replace the power supply board.

69 The frequency converter is faulty. 1 Clear the error message: Open the lid, then

turn off the power. After about 1 minute, turn

the power back on.

2 Replace the frequency converter. For

instructions, see Section 4.7, “Replacing the

frequency converter.”

84 A part in the frequency converter

circuit is faulty, resulting the

frequency converter detecting excess

rotor speed.

► Try the following tasks in order, testing after

each to determine if it solved the problem:

1 Replace the ribbon cable between the

frequency converter and the power supply

board.

2 Replace the frequency converter. For

instructions, see Section 4.7, “Replacing

the frequency converter.”

3 Replace the power supply board.

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