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Plasma Freezer MP500 Service Manual

1. 6 1 Assembly Number Cross Reference Table 6 2 6 Parts Lists 6 Parts Lists Part Description Cross Reference Table Part Description Look for Assembly Accessories Kit Freezer MP500 7 01 086 Aluminum Bushing Seal Assembly 7 36 007 Chamber Probe Housing 7 46 007 Chassis MP500 7 63 052 Clamp Adjustable 34 134 2 24 009 Contactor Assembly 7 35 054 Control Display Panel Front 7 35 010 Cover Motor Box 7 44 001 Deck Heater Transformer 7 35 057 Heater Harness 7 34 042 Hose Urethane Clear 1 2 4 34 004 Installation Kit MP500 7 01 078 Lid Assembly MP500 6 51 027 Lid MP500 7 42 010 Motor Box Assembly MP500 7 44 003 Motor Cover Box Cover 7 44 038 Motorbox Cover MP500 7 44 001 Panel Sides Lid Assembly MP500 6 52 308 Power Panel 500 0 Tested 7 51 034 Probe Box Assembly MP500 7 65 054 Rack 4 Pocket with Springs 15 75 L 7 48 104 Solenoid Coil MP500 7 35 075 Spare Parts Kit 8 0500 20 Basic 7 01 087 Suction Heat Exchanger Assembly 7 21 039 Temperature Sensor 25 inch 7 32 013 Look up the part description in the table above and cross reference it to the assembly number table show on the next two pages NOTE Orders for certain subassemblies such as screws washers tape etc may be subject to a minimum quantity allowable order Plasma Freezer Integral Refrigeration MP500 Servi
2. 6 2 Plasma Freezer Integral Refrigeration MP500 Service Manual 6 Parts Lists Ass y Part Description 7 42 010 Lid MP500 1 2 11 003 Washer Flat 410 316 SS 18 8 8 2 12 012 Washer Nordlock 10 316 SS 16 2 13 037 Screw SP Button 10 32 x 34 16 2 21 002 Hinge 453018HRS 2 6 51 027 Lid Assembly MP500 1 7 44 001 Motor Box Cover 1 15 001 Pump Motor Cooling Fan 3 2 13 021 Pump Mtr Cool g Fn Screws 10 32 x 16 VY 7 44 003 Motor Box Assembly MP500 2 11 009 Washer Flat 4 inch x 1 inch 2 2 12 042 Washer Lock Spring inch 2 2 13 030 Screw CP 1 4 20 x ve inch 5 2 33 002 Tape Foam White foot 1 4 33 006 Bushing Red 1 SPIG 1 4 35 005 Fitting 1 4 MPT x 1 inch 4S 1 4 61 007 Comp Trap Adapter 1 1 2 inch 1 4 64 006 Nipple Male 1inch x 2 inch PVC 1 7 26 024 Assembly Pump MP500 1 7 45 010 Motor Box MP500 1 7 44 038 Motor Cover Box Cover 1 7 44 001 Cover MP500 Motorbox 1 7 46 007 Chamber Probe Housing 1 7 48 104 Rack 4 Pocket with Springs 15 75 L 1 7 47 128 Pocket 15 75L x 2 19W x 10 50H 4 7 48 082 Deck Prepared 4 pocket 12 1 4 1 7 63 066 Spring Pocket with protective cap 4 7 51 034 Power Panel 500 0 Tested 1 7 63 052 Chassis MP500 7 24 001 Assembly Condensing Unit MP500 1 7 65 054 Probe Box Assembly MP500 1 35 003 Probe Temperature 30 F to 100 F 1 2 32
3. 5 8 Figure 22 Motor Box Top View 5 9 Figure 23 Motor Box Electrical 5 9 Figure 24 Power Panel 5 12 Figure 25 Power Panel Grounding Terminal 5 12 Figure 26 Motor Mounting Bracket Connections 5 14 Figure 27 Probe Box Installation 5 15 Figure 28 Circulating Pump Impeller Assembly 5 20 Figure 29 Condensing Unit Vent Covers 5 30 Figure 30 Condensing Unit Access Covers 5 30 Figure 31 Refrigeration System Piping 5 30 Figure 32 Pressure Switch Location 5 35 Plasma Freezer Integral Refrigeration MP500 Service Manual TOC 3 Chapter 1 Introduction TABLE OF CONTENTS Intended Use mmrmnvvrerrnnnoverrnnnnvnnnnnnvnvnsnnnvnnvnannnenne 1 1 How to use this manual seen 1 1 Text Conventions sse 1 1 Electrical Safety AA 1 2 Safety Precautions ee ee eee eee sse 1 2 Copyright Notice sss eee eee eee 1 3 Trademiarks eite eee dete EES 1 3 Se T ie ttt eod editus 1 3 Help LING eave eee re mes 1 4 Limited Warranty essen 1 4 Warranty issin iai aaa dee dad ee ode 1 4 Sae aT rosari e aa Ae Aa TE AAAA 1 5 Limitation et ai adm GARNET 1 5 1 Preface 1 Preface Intended Use How to use this manual Text Conventions The THERMOGENESIS CORP MP500 Plasma Freezing System is intended for the fast effi
4. Date of Purchase Plasma Freezer Integral Refrigeration MP500 Service Manual 3 1 3 Installation Connecting the Desiccant Filter Before placing the freezer in position it is necessary to connect the desiccant filter tubing The desiccant filter system is located on the back of the freezer To connect the desiccant filter 1 Remove the plastic protective caps from the inlet and outlet of the filter housing 2 Slide the tubing from the lid onto the inlet fitting on the top of the filter housing 3 Slide the tubing from the chassis to the outlet fitting at the bottom of the filter housing Figure 2 Desiccant Filter 3 2 Plasma Freezer Integral Refrigeration MP500 Service Manual 3 Installation Placing the Freezer in Position Figure 3 Clearances The freezer must be located on a level floor in a room where the ambient temperature is in the range of 15 C to 30 C 60 F to 86 F and the humidity is in the range of 10 to 80 RH Under no circumstances is the MP500 freezer to be located in an outside environment Please refer to the freezer Specifications on page 2 2 of this manual DO NOT ADD the InstaCoolant IV to the machine before placing the freezer in its final location For ease of movement and accessibility to the place of location allow 4 15 cm in passageways and doorways There should be at least 6 15 cm clearance from the back and sides of the freezer and any walls or adja
5. 5 Parts Replacements 50 Product Chamber Tools and Supplies Required Removal Installation 10 11 2 Phillips screwdriver 5 16 inch nutdriver or socket wrench 7 16 inch nutdriver or socket wrench 1 2 inch nutdriver or socket wrench ESD protective bags Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove membrane rack per Section SE Membrane Rack Removal and Installation page 5 7 Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation page 5 8 Remove probe box per Section 5 Probe Box Removal and Installation page 5 14 Remove motorbox per Section 5J Motorbox Removal and Installation page 5 17 Remove 9 each Phillips Flathead screws that mount probe box trim to chassis and remove probe box trim Remove T shape motorbox support bracket from chassis mounting clips Remove 4 4 20 hex cap screws and lock washers which mount chamber splash plate using 7 16 nutdriver Remove 4 4 20 hex cap screws and lock washers which mount chamber Remove product chamber by gripping sides and lifting straight up Lower product chamber onto chamber support bracket Align mounting holes and install 4 hex cap screws and lock washers Do not tighten at this time Align splash plate mounting holes with that of chamber and chamber support bracket and inst
6. Electrical Safety Safety Precautions 1 N CAUTION The MP500 Plasma Freezer is designed in accordance with Protection Class IEC The chassis of the system is connected to ground by means of a cable and surfaces on the system that the operator may come in contact with are connected to the chassis by means of screw connections For protection against electrical hazards the system must be directly connected to a properly grounded electrical source approved by a qualified electrician Contact Helmer Technical Service for assistance if you have any questions concerning the electrical connection for the MP500 Plasma Freezer When servicing the MP500 Plasma Freezer make sure the power switch is turned off and the unit is unplugged Safety precautions that are necessary when operating maintaining and troubleshooting the MP500 Plasma Freezer are outlined below It is important that these precautions be carefully read and understood This information should also be made aware to new employees CAUTION For greatest assurance of proper and safe operation keep this manual in a place where it is readily accessible for reference NOTE During disassembly keep parts in order to facilitate re assembly CAUTION Prior to starting any electrical work disconnect all power to the freezer NOTE Check all hose and wiring connectors to make sure they are secure and correct NOTE
7. OL CL WAU 2892 31 HDL Med SIL 3O SCIL OL EL WW Adel NOU Add NY THI OS OL GL Wall FUP ACHT AN MOTIV OLP NEI USO 979 JO 305 IND ni SNOSNIN HOIS e S31OH Q3ddvl Z TRIO Te GLAS WOA IE Ord C 01 INSU 134090 TSN OL MAL ve PORS dN Ive 3O SOS NDE CL 3RRIHOY ONY LZ PDU Ach NEVE OMAR 934 SIN3IOdAICO TBANISSY L 10342345 39WeHHIO SIN UON Plasma Freezer Integral Refrigeration MP500 Service Manual 7 12 7 Schematics 7 65 054 Assembly Probe Box MP500 Sheet 2 of 2 ASSY PROBE BOX MP500 Plasma Freezer Integral Refrigeration MP500 Service Manual 7 13 Index A Adding the InstaCoolant IV to the Freezer Adjusting the Safety Thermostat Adjusting the Safety Thermostat Fig 12 Ambient Operating Temperature Assembly Number Cross Reference Table Basic Troubleshooting C Charging the Refrigeration System Circulating Pump Impeller Assembly Fig 28 Clearances Fig 3 Condensing Unit Condensing Unit Access Covers Fig 30 Condensing Unit Pressure Test Condensing Unit Vacuum Test Condensing Unit Vent Covers Fig 29 Connecting the Desiccant Filter Copyright Notice D Defrost Heater Defrost Heater Temperature Probe Desiccant Filter Fig 2 Disclaimer Display Control Panel Display Panel Removal Fig 8 E Electrical Installation and Specifications Electrical Safety G 4 1 5 35 5 22 5 24 3 2 1 3 5 11 3 6 3 3 1 2 Gasket Plate Sealant Appl
8. System Summary The THERMOGENESIS CoRP MP500 Plasma Freezer is a compact liquid bath freezer that freezes bags containing plasma using a low temperature recirculating liquid coolant passing outside polyurethane pockets containing the plasma bags The MP500 Plasma Freezer consists of the following subsystems e Low temperature refrigeration condensing unit e Coolant circulating pump e Plasma rack with polyurethane pockets e Primary Control Panel e Microprocessor User interface display panel and keypad Figure 1 MP500 Plasma Deck Lid for Freezer Plasma Rack Motor Box Cover Houses Pump Motor Cooling Fans and Control Panel Power Panel hermal Expansion Valve Adjustment User Interface Display Panel with Keypad Motor Box Cooling Fan Refrigeration Coolant Condensing Unit Reservoir Plasma Freezer Integral Refrigeration MP500 Service Manual 2 1 2 Overview Specifications Height Height with lid open Width Depth Electric Defrost Heater Operating Weight Coolant Volume Maximum Plasma Loading Volume Product Minimum Final Core Temperature Refrigerant Compressor Minimum Operating Temperature Line Voltage Amperage Minimum Circuit Breaker Ambient Operating Temperature 2 2 Temperature Relative Humidity 119 4 cm 47 inches 200 7 cm 79 inches 68 6 cm 27 inches 81 3 cm 32 inches 400 Watts 240 Kg 532 Ibs 68 Li
9. De solder s inch liquid line at connection above sight glass See Figure 31 Refrigeration System Piping 14 Using 7 16 open end wrench remove 4 each 1 4 inch nuts from carriage bolts which mount chassis to caster base plate See Figure 31 Refrigeration System Piping 15 Push carriage bolts out and remove 5 30 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements CAUTION The following step s may require assistance from other service personnel 16 17 18 Installation Raise chassis off of condensing unit caster base plate assembly and place to one side Using 2 inch open end wrench where necessary and 2 inch socket wrench remove 4 each bolts and washers that mount condensing unit base plate to caster base plate Lift condensing unit off caster base plate CAUTION Steps 1 4 may require assistance from other service personnel e OG 4 11 12 13 14 15 16 17 18 19 Place condensing unit onto caster base plate and align condenser base plate mounting holes with threaded holes of caster base plate Install 4 each 5 46 inch bolts amp flat washers Tighten using inch open end wrench where necessary and inch Socket wrench Lift chassis up and over condensing unit caster base plate assembly Check alignment of chassis mounting holes to caster base plate mounting holes and adjust as necessary Insert 4 inch car
10. 16 inch nutdriver or socket wrench ESD protective bag Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Place covering on top of lid to protect surface Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation Remove 4 truss head motor support bracket mounting screws including guide holddown and loop clamp See Figure 26 Motor Mounting Bracket Connections this page Remove 2 hex cap head motor support bracket mounting screws See Figure 26 Motor Mounting Bracket Connections this page Disconnect control panel grounding terminal on motor mounting plate See Figure 26 Motor Mounting Bracket Connections this page Remove motor support bracket Remove remaining 4 truss head screws which mount both stainless steel seal plate and probe box to chassis r NOTE Two of the screws also mount cable loop clamps to probe box 10 Remove plastic spiral cable wrap and multi cable loop clamp from 11 5 14 cables and wire Separate wires and cables to their corresponding assemblies This will aid in removal of probe box and motorbox Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 12 Lift out probe box and metal cover plate assembly by levering up flanges to gain a finger hold and then pulling straight up until the assemb
11. 33 5R Condensing Unit Vacuum Test 5 34 5S Charging the Refrigeration System 5 35 5 Parts Replacements 5 Parts Replacements Sr a l l 5A Hinge Tools Required Removal Figure 14 Hinges NOTE During disassembly keep parts in order to facilitate re assembly CAUTION Prior to starting any electrical work disconnect all power to the freezer NOTE Check all hose and wiring connectors to make sure they are secure and correct NOTE Special tools and service material may be required depending on the repair Be sure to use these tools and materials and follow the proper work procedure NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment CAUTION Make sure the InstaCoolant IV is above freezing before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger e T Handle Allen wrench 5 32 inch 1 Remove pull off both upper and lower plastic hinge covers to expose mounting screws See Figure 14 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 1 5 Parts Replacements 2 Using Allen wrench remove 4 screws and washers that secure the upper hinge body to the lid See Figure 15 Figure 15 Hinge Assembly 3 Remove the 2 upper screws a
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13. Sensor Temperature Probe 5 26 Setting the Motorbox Cover Aside Fig 11 Specifications Starting the MP500 Plasma Freezer System Summary T Temperature Pulldown 3 8 Temporarily secure the display panel Fig 10 3 7 Text Conventions 1 1 Timer Display Panel Fig 13 3 8 Trademarks 1 3 Unpacking and Inspection 3 1 Warranty 1 4 IND 2 Plasma Freezer Integral Refrigeration MP500 Service Manual
14. Special tools and service material may be required depending on the repair Be sure to use these tools and materials and follow the proper work procedure NOTE When replacing fuses be sure the new fuse has correct amperage rating NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment Plasma Freezer Integral Refrigeration MP500 Service Manual 1 Preface Copyright Notice Trademarks Disclaimer CAUTION Danger of fire if the vapors from the InstaCoolant IV are allowed to reach 130 F 54 C For operational purposes THERMOGENESIS CORP has set the limit on the MP500 Plasma Freezer safety thermostat at 55 F 13 C When warming the coolant during a defrost operation DO NOT PLACE AN ELECTRIC IMMERSION HEATER IN THE COOLANT CAUTION Make sure the InstaCoolant IV is above freezing before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger CAUTION The user shall be made aware that if the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired March 2001 THERMOGENESIS CORP All Rights Reserved The material in this manual is intended for use by the purchaser of the equipment covered by the manual Permission is granted to the purchaser to make one copy of the manua
15. is not necessary to remove them 10 Pull motor drive shaft coupler and drive shaft out through column pump head assembly 11 Using 1 8 inch Allen wrench loosen the coupler set screw which secures the pump drive shaft Remove the drive shaft 12 Loosen the coupler set screw which secures the motor drive shaft and remove the coupler from the motor 13 Remove the aluminum bushing seal from the motor drive shaft 14 Remove column pump head assembly from motor box by sliding out through nipple Plasma Freezer Integral Refrigeration MP500 Service Manual 5 19 5 Parts Replacements Assembly Inspect aluminum bushing seal for damage or excessive wear and replace if necessary 2 Fill seal trough with High Vacuum Grease and install bushing on motor drive shaft with bushing flange toward motor 3 Install coupler onto motor shaft per P N 7 44 003 drawing SHEET 3 of 3 and tighten coupler set screw 4 Install pump drive shaft in coupler per P N 7 44 003 drawing SHEET 3 of 3 and tighten coupler set screw 5 Inspect bearing of pump head for damage or excessive wear Replace if necessary 6 Slide column pump head assembly through bottom of motorbox 7 Install motor drive shaft assembly down through column ensuring that column end fully seats into hub of motor 8 Orient Motor relative to pump discharge as shown in drawing P N 7 44 003 9 Tighten the three hex head screws that secure the motor to the column 1
16. 0 Inspect impeller for damage or excessive wear and replace if necessary 11 Install impeller on to drive shaft Check clearance between vanes and pump head The tolerance range is 0 003 inches minimum and 0 063 inches maximum See Figure 28 Circulating Pump Impeller Assembly Figure 28 Circulating Pump Impeller Assembly COLUMN a ZZ Lie LLELD DRIVE SHAFT D MOM NWA N NNN NNN SSE AY CLEARANCE TDLERANCE SA A BETWEEN PUMP HEAD Is er lle L ND IMPELLER PUMP BASE IMPELLER 5 20 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 12 Inspect white caulked sealing surface between pump head and pump base Sealing surface should be continuous with no breaks or junctions If breaks exist then clean old caulk from pump head and or base and apply a continuos new bead of caulk NOTE Let caulk cure for 15 min before proceeding to next step 13 Install pump base to pump head 14 Orient pump assembly in motorbox as shown in drawing P N 7 44 003 15 Slide pump assembly through motorbox until hub of motor rests approx V from inner bottom of motorbox 16 Hand tighten compression nut on threaded nipple at motorbox bottom to secure column from movement CAUTION compression nut will break if over tightened 17 Install motorbox per Section 5J Motor Box Cover Hemoval and Installation 18 Install probe box per Section 5 Probe
17. 0 SNITIOIN AE IHI HI JO IX WHO ewe TUZ ONY 1230 X LY 1 Zei 9 3l SAROS 36H 1H TEBII EVO TIE MH JO INTON EHNHOO 3H1 30 3903 HLY ONY 25032 33 JHI 3OINOLIC 3HL HUA HIT 38 OL Plasma Freezer Integral Refrigeration MP500 Service Manual 7 Schematics 7 63 062 Freezer MP500 Basic Sheet 2 of 2 THERMOGENESIS FREEZER MP500 BASIC Plasma Freezer Integral Refrigeration MP500 Service Manual 7 3 7 Schematics t Iter Desiccan F 7 43 005 Assembly Sheet 1 of 1 NOROS Ar Z e se d 0 SKN HONIZ FW Ae e HOM es Geen MRI BI z HINZ ONW c ATO ed INIO nc ZIL OVIH NOWI Suel ui 2 oMeHSh3H cwn usc NOIS INSUUND Oe 204 D iod SS3N3910 N83HL HUN Srl Te 01 L Mnp nora anr JOSS NOOTIE ASD G 3 NN CHS WHM Cal Halv ITAN JO BOV HL OL E MA det NOHA WE 03801 6 30 ONT LHP HS VH JH 30 ON HOM TK TNS 13 Y ONS 6 PDU SAL WNEHSKH TL URS EPAI SHALIH n KASS 12155371 40 CI AHIO O4 G OL Ee SAG NE 9 WABI SHI OLT LL ABI ell ETO ON 2 MEL TRAIAN ss V FM do SOV RHLOL BAAS 391 RUD ads dele L9 ONY JA JOS L HAA Y WAU GO E EE STEI del ONY Kar Vel3HK HOT Cu Mie ZC ie BEIN OUEV Id Ca 3HL 3875 DM SNE 0 93 SIS DO INSIO TEGE 1 1342345 359WeHHIO SINN 31ON Plasma Freezer Integral Refrigeration MP500 Service Manual 7 Schematics 7 47 128 7 48 104 Rack 4 Pocket Sheet 1 of 2 Ber ZE 11335041 ger Uro oe 3 AIOS 38 3465 SEINN S
18. 015 Tape Cork Insulation 3 x 2 Inches 4 2 41 002 Stop Rub Temperature Probe 1 2 41 025 Coil Nipple 1 6 16 113 Heater Compression Fitting 1 1 6 16 114 Heater Compression Fitting 2 1 6 26 006 Heater Immersion 25 inch 1 Plasma Freezer Integral Refrigeration MP500 Service Manual 6 3 Chapter D Schematics TABLE OF CONTENTS Schematics LIS tete de 7 1 7 63 062 Freezer MP500 rrnnnnnnnnrannnnnnnornernnrnnnnnernenn 7 2 7 43 005 Assembly Filter Desiccant 7 4 7 48 104 Rack 4 Pocket 7 47 128 nsnsennsseeeneneeenn 7 5 7 42 010 Lids MPB00 see 7 7 7 44 003 Assembly MotorBox MP500 7 9 7 65 054 Assembly Probe Box MP500 7 12 7 Schematics 7 Schematics Schematics List Sheet s Drawing Description 7 63 062 Freezer MP500 Basic Sheets 1 amp 2 of 2 7 43 005 Assembly Filter Desiccant Sheet 1 of 1 7 48 104 Rack 4 Pocket 7 47 128 Sheets 1 amp 2 of 2 7 42 010 Lids MP500 Sheets 1 amp 2 of 2 7 44 003 Assembly MotorBox MP500 Sheets 1 2 amp 3 of 3 7 65 054 Assembly Probe Box MP500 Sheets 1 amp 2 of 2 Plasma Freezer Integral Refrigeration MP500 Service Manual 7 1 7 Schematics 7 63 062 Freezer MP500 Basic Sheet 1 of 2 KP 403 310 H INUN NOIR IN RITD Ov 838TN Lie SEINFDONRFHL HUM Led ei B eg Ale IO OL c ONY FHI li 1321 GE ANH HL 3
19. Back of Motor Box Cover Deck Heater Snap Connector 2 Remove the twelve screws holding the membrane deck in place lift the deck out and place in on the motor box cover or in any other safe place See Figures 5 and 6 next page Figure 5 MP500 Membrane Deck MP500 Membrane Deck Holddown screws Phillips Head Typical of 12 3 Add the coolant to the machine through the chamber until the level is about 12 30 5 cm below the top of the stainless steel top of the freezer See Figure 6 3 4 Plasma Freezer Integral Refrigeration MP500 Service Manual 3 Installation Figure 6 MP500 Membrane Deck Removal Gently remove the rack and store in a safe place The level of the coolant should be about 12 below the stainless steel top of the freezer CAUTION InstaCoolant IV Dow Syltherm XLT should be stored in a room where the temperature does not exceed 85 29 4 Never store InstaCoolant IV in direct sunlight Preparing the Unit for Start up Temporarily adjust the Safety Thermostat for a higher temperature See Safety Precautions on page 1 2 in the Introduction Chapter The thermostat is normally set to 55 F 13 C The coolant is usually at room temperature 75 F to 85 F 24 C to 29 C when it is added to the machine Therefore the thermostat must be set slightly higher than the coolant temperature during the unit pulldown to operating temperature Adjusting th
20. Box Cover Removal and Installation 19 Install motorbox cover per Section 5F Motorbox Cover Removal and Installation 20 Re connect unit to power source 21 Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 21 5 Parts Replacements BL Defrost Heater fF Tools and Supplies Required Removal Installation 5 22 NOTE Reference Chapter 7 Drawing P N 7 65 054 sheet 2 of 2 for this operation 10 e 2 Phillips screwdriver 1 4 inch nutdriver or socket and ratchet 5 16 inch nutdriver or socket and ratchet 7 16 inch nutdriver or socket and ratchet 5 8 inch open end wrench 2 each 4 inch cable ties 2 each ESD protective bags Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation Remove probe box per Section 5l Probe Box Cover Removal and Installation Remove thermal bulb heater bracket from heater Secure bulb out of way Cut cable ties from coil nipples rubber boots and remove from heater terminals Remove nuts washers electrical wires and insulators from heater terminals Note sequence of removal Using 5 8 inch wrench remove compression nuts
21. C 1 General Table of Contents Chapter 4 BASIC TROUBLESHOOTING Precailll ns bs etu ete dde ee ees 4 1 Basic Troubleshooting sss sese eee eee eee eee eee 4 1 Chapter 5 PARTS REPLACEMENTS 5A HINGE iicet crt drag Lcd s 5 1 5B Eid usse ntt ed dies 5 8 5C Bre BET 5 4 5D Lid Gasket Plate AA 5 5 5E Membrane Pack 5 7 5F Motorbox Cover 5 8 5G Display Control Panel 5 11 5H Power Panelo ada VE Ea Tae 5 12 5l Probe Bos deed Rc edes 5 14 5J Motorbox Removal and Installation 5 17 5K Motorbox Disassembly and Assembly 5 19 5L Defrost Heater eee eee eee 5 22 5M Defrost Heater Temperature Probe 5 24 5N Sensor Temperature Probe 5 26 5O Product Chamber 5 27 5P Condensing Un 5 29 5Q Condensing Unit Pressure Test 5 33 5R Condensing Unit Vacuum Test 5 34 5S Charging the Refrigeration System 5 35 Chapter 6 PARTS LISTS Part Description Cross Reference Table 6 1 Assembly Number Cross Reference Table 6 2 Chapter 7 SCHEMATICS Schematics LUIS eee eee 7 1 7 63 062 Freezer MP500 rrrannnnnnrannnnrnnennvrnnnnnrsnernenn 7 2 7 43 005 Assembly Filter Desiccant 7 4 7 48 104 Rack 4 Pocket 7 47 128 ss 7 5 7 42 010 Lids MPB00 see 7 7 7 44 003 Assembly MotorBox M
22. E ILON 335 SALON 7 5 Plasma Freezer Integral Refrigeration MP500 Service Manual 7 Schematics 7 48 104 Rack A Pocket 7 47 128 Sheet 2 of 2 apod ou Guus apod JO LOD poA SION M3IA 3016 NOILO3S t turedo Guds jey2cd 184500 pep jo abpa LICHOQ toua Aq B00 ui pey si Buds ach MIA dOL doodous JENDO Plasma Freezer Integral Refrigeration MP500 Service Manual 7 6 7 Schematics 7 42 010 Lids MP500 Sheet 1 of 2 NOEN 2 INZ NO Av H38FCTN Leod SS3S9OWNEHHI HIM Bie O71 CHHO 348 39NeHHIO SE 7 7 Plasma Freezer Integral Refrigeration MP500 Service Manual 7 Schematics 7 42 010 Lids MP500 Sheet 2 of 2 7 42 010 UDS MP500 7 8 Plasma Freezer Integral Refrigeration MP500 Service Manual 7 Schematics MP500 7 44 003 Assembly MotorBox Sheet 10f3 38 XH Te ea ECH DEEG Asmw CC Oaa apr ASSv 1 INNI OLW MOB 1 SOLL AUSI DEHNI ec UHA OS eil vr XORION ech Odds CT 2X8 NN Ha NIST eo 1 af Hz NOU34SNI ASSY XOSOJON NTL OT FHL D I JASON NG UNIO OW TII C2 1334 AUNTS NOLOA 7 288 MAL 905 NOOTE L OL ZL dd TR OCH LS3L LL V OLNO VALE did LIIOISSUPICO RI HOU aw No NDD DA NO HOME 30D INGIH dd TIVEN b 3H1O1 5 MEL AEH OY MUO Kleid TIDA CEN NOL DNI HOLAN NO ano OL INOVA 9 dd 30 39RITH2SO 3416 M MOIS WN WAU WTE Tei STIOH Hl S310H AROS NONO HCH RAHN 9 PAI ISOON XOG HDM 40 KTO 30S OW Hra aD Ol HHY
23. P500 7 9 7 65 054 Assembly Probe Box MP500 7 12 TOC 2 Plasma Freezer Integral Refrigeration MP500 Service Manual General Table of Contents Table of Figures Figure 1 MP500 Plasma Freezer 2 1 Figure 2 Desiccant Filter esses 3 2 Figure 3 Clearances e eee eee eee 3 3 Figure 4 MP500 Deck Heater Connector at rear of Freezer 3 4 Figure 5 MP500 Membrane Deck 3 4 Figure 6 MP500Membrane Deck Remowval 3 5 Figure 7 Rear View of Motorbox Cover 3 5 Figure 8 Display Panel Remowval 3 6 Figure 9 Removal of Motorbox Front Fastener 3 6 Figure 10 Temporarily secure the display panel 3 7 Figure 11 Setting the Motorbox Cover Aside 3 7 Figure 12 Adjusting the Safety Thermostat 3 7 Figure 13 Timer Display Panel 3 8 Figure R Salle ittis 5 1 Figure 15 Hinge Assembly ee eee ee ee 5 2 Figure 16 Lid Gasket Remowval 5 4 Figure 17 Installing Gasket Plate 5 6 Figure 18 Gasket Plate Sealant Application 5 6 Figure 19 Pocket Pocket Spring Configuration 5 6 Figure 20 Power Panel OFF ON Switch 5 8 Figure 21 Motor Box Assembly
24. Plasma Freezer MP500 A Low Temperature Liquid Bath System for Freezing Plasma Products Integral Refrigeration Service Manual e Aa THERMOGENESIS 0197 6 07 028 A Serviced by Helmer Scientific General Table of Contents General Table of Contents Chapter 1 INTRODUCTION Intended Use niet eet 1 1 How to Use this Manual sees 1 1 Text CGonventions sse 1 1 Electrical Safety esses 1 2 Safety Precautions sss 1 2 Copyright Notice sss eee eee eee 1 3 KI ET GE OS 1 3 Disclaimer ETH 1 3 Help Eire co oe eei 1 4 Limited Warranty essen 1 4 Warrariy etit eta teet ote tees 1 4 ProCed te oi ihe beet 1 5 Bil Le NEE 1 5 Chapter 2 OVERVIEW System Summary sse 2 1 Specifications sese eee eee eee eee 2 2 Ambient Operating Temperature 2 2 Chapter 3 INSTALLATION Unpacking and Inspection sss sees eee eee ee 3 1 Connecting the Desiccant Eiter 3 2 Placing the Freezer in Position 3 3 Electrical Installation and Specifications 3 3 Adding the InstaCoolant IV to the Freezer 3 4 Preparing the Unit for Start Up sss 3 5 Adjusting the Safety Thermostat see eee 3 5 Starting the MP500 Plasma Freezer 3 8 Temperature Pulldown esses 3 8 Plasma Freezer Integral Refrigeration MP500 Service Manual TO
25. Refrigerant weigh scale Refrigerant recovery system AZ 50 4 each 5 gallon containers for coolant Refrigerant AZ 50 Leak Detection fluid Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove membrane rack per Section SE Membrane Rack Removal and Installation page 5 7 Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation page 5 7 Remove probe box per Section 5 Probe Box Removal and Installation page 5 14 Remove motorbox per Section 5J Motorbox Removal and Installation page 5 17 Remove product chamber Section 5K Product Chamber Removal and Installation page 5 19 Transfer coolant from unit to 5 gallon containers using a siphon pump Remove front and rear vent covers using 2 screwdriver See Figure 29 Condensing Unit Vent Covers Plasma Freezer Integral Refrigeration MP500 Service Manual 5 29 5 Parts Replacements 10 Remove left and right access covers See Figure 30 Condensing Unit Access Covers this page Figure 29 Condensing Unit 7 Vent Covers Figure 30 Condensing Unit Access Covers Carriage Bolts 11 Evacuate refrigerant AZ 50 from system 12 Disconnect suction line service valve of compressor by using 12 inch socket wrench See Figure 31 Refrigeration System Piping Figure 31 Refrigeration System Piping 13
26. Service Manual 5 Parts Replacements 5E Membrane Rack Tools Required Removal Installation ech moo mmc 2 Phillips screwdriver Raise lid to its fully opened position Remove 12 each rack mounting screws See Figure 5 Disconnect deck heater circuit at connection terminal located inside metal housing at rear of unit See Figure 4 Remove membrane rack by lifting straight up until the bottom of the pockets clear the stainless steel top of chassis Place membrane rack over chamber opening and lower onto chassis Align mounting holes of rack to corresponding tapped holes of chassis Install the 12 rack mounting screws Check pocket spring installation to ensure they engage under lip of deck opening See Figure 19 Reconnect deck heater circuit at connection terminal and re place inside metal housing Plasma Freezer Integral Refrigeration MP500 Service Manual 5 7 5 Parts Replacements DE Motorbox Cover Tools and Supplies Required Removal Figure 20 Power Panel OFF ON Switch 2 Phillips screwdriver 2 each ESD protective bags Turn unit power off at switch located on power panel See Figure 20 Figure 21 Motor Box Assembly 5 8 Remove electrical plug from power source If hardwired to power source then turn power off at supply panel Place protective covering over top of lid The lid will act as a temporary workbench for this operation Remove control panel per Section 5F Di
27. all 4 hex cap screws and lock washers Tighten all 8 mounting screws Install T shape motorbox support bracket onto chassis mounting clips Mount probe box trim to chassis and secure with mounting screws Install motorbox per Section 5J Motorbox Removal and Installation page 5 17 Install probe box per Section 51 Probe Box Removal and Installation page 5 14 Install motorbox cover per Motorbox Cover Removal and Installation page 5 17 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 27 5 Parts Replacements 10 Install membrane rack per Section 5E Membrane Rack Removal and Installation page 5 7 11 Re connect unit to power source 12 Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 5 28 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5P Condensing Unit Tools and Supplies Required Removal CAUTION Only a licensed refrigeration service person should perform this procedure 2 Phillips screwdriver 5 8 inch flare nut wrench 13 16 inch flare nut wrench 15 16 inch flare nut wrench 1 4 inch nut driver and socket wrench 5 16 inch nut driver and socket wrench 7 16 inch socket wrench 1 2 inch socket wrench 7 16 inch open end wrench 1 2 inch open end wrench Vacuum pump Vacuum gauge 50 1000 micron Refrigeration gauges and hoses Refrigeration service wrench
28. all one mounting screw NOTE If installing a new gasket installer should use gasket plate as a template and transfer holes onto gasket using awl before proceeding with this step 4 Continue around the lid by lifting gasket aligning mounting holes and installing mounting screws until all screws are secure 5 Re check each mounting screw to ensure tightness 6 Re install lid per Section 5B Lid Removal and Installation 5 4 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5D Lid Gasket Plate Tools and Supplies Required 2 Phillips screwdriver Bostik 1100FS ThermoGenesis P N 5 13 004 4 cable tie Removal 1 Remove lid gasket per Section 5C Lid Gasket Removal and Installation 2 Separate gasket plate from lid by pulling up and away from lid K NOTE Gasket plate is factory bonded to lid with a flexible sealant Some La force maybe required in breaking this bond In some rare cases older freezers for instance the old gasket plate may be needed for a mounting hole template to transfer holes to new gasket plate Therefore it is recommended that care be taken to keep old gasket plate in tact during removal 3 Disconnect desiccant tube from barbed elbow located on backside of plate by cutting cable tie that secures tube to elbow See Figure 17 4 Remove threaded barbed elbow from plate and retain for installing on new gasket plate See Figure 17 Install
29. apter 3 5 18 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5K Motorbox Disassembly and Assembly NOTE Reference Chapter 7 Drawing P N 7 44 003 sheet 3 of 3 for this A operation Tools and Supplies Required e 2 Phillips screwdriver e 1 4 inch nutdriver or socket and ratchet e 5 16 inch nutdriver or socket and ratchet e 7 16 inch nutdriver or socket and ratchet e 1 8 inch Allen wrench e 1 tube High Vacuum Grease e 1 each caulking tube of Bostik 1100FS e 2 each ESD protective bags Disassembly 1 Turn unit power off at switch located on power panel See Figure 24 Power Panel 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation 4 Remove probe box per Section 5 Probe Box Cover Removal and Installation 5 Remove motorbox per Section 5J Motor Box Cover Removal and Installation and place it on its side 6 Using 5 16 inch nut driver remove the 8 hex head screws that secure the pump base to the pump head 7 Remove pump impeller from end of drive shaft 8 Loosen 1 7 compression nut located at base of motorbox Column of pump assembly should now slide freely through gray PVC nipple 9 Slide column up through motorbox enough to provide access to Hex head bolts that secure motor to column Loosen the three bolts It
30. arts Replacements 9 Position single loop clamp attached to temperature control capillary tube and install truss head screw See Figure 27 Probe Box Installation this page 10 Install guide holddown at location shown in Figure 27 Probe Box Installation this page NOTE Fender washer should be up against head of screw with brass spacer between fender washer and motor support bracket 11 Install remaining 2 motor support bracket mounting screws 12 Tighten all 8 truss head mounting screws 13 Install motorbox cover per Section 5F Motorbox Cover Removal and Installation 5 16 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5J Motorbox Removal amp Installation Tools and Supplies Required Removal Installation 10 2 Phillips screwdriver 1 4 inch nutdriver or socket wrench 5 16 inch nutdriver or socket wrench 7 16 inch nutdriver or socket wrench 2 each ESD protective bags Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Place covering on top of lid to protect surface Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation Remove probe box per Section 5I Probe Box Cover Removal and Installation Lift out motorbox assembly by levering up flanges to gain a finger hold and then
31. ation 1 If new gasket plate does not have pre drilled mounting holes use old gasket as a template and transfer holes to new plate 2 Cut away any loose or raised portions of old bonding sealant from lid surface 3 Apply a continuous 5 32 bead of Bostik sealant all along the inside edge of the foam to plastic joint See Figure 18 4 Install threaded barbed elbow removed from old gasket plate on backside of new plate until it is flush with textured surface 5 Install desiccant tube onto barbed elbow NOTE Some slight adjustment tightening loosening of elbow may be necessary to align it with tube Secure tube to elbow with new cable tie See Figure 17 Locate gasket onto new gasket plate and install plate to lid Section 5C Lid Gasket Removal and Installation Re install lid per Section 5B Lid Removal and Installation Plasma Freezer Integral Refrigeration MP500 Service Manual 5 5 5 Parts Replacements Figure 17 Installing Gasket Plate REMOVING amp INSTALLING LID GASKET PLATE Figure 18 Gasket Plate LID FLANGE Sealant Application a SEALANT BEAD GASKET LID REAR Fen TEXTURED o SIDE OF iL FOAM GASKET PLATE LID FRONT GASKET PLATE SEALANT APPLICATION Figure 19 Pocket Pocket Spring Configuration SECTION SIDE VIEW 5 6 Plasma Freezer Integral Refrigeration MP500
32. ce Manual 6 1 6 Parts Lists Assembly Number Cross Reference Table H 0 A H Ha Le eji e e 2 24 009 Clamp Adjustable 1 2 4 34 004 Hose Urethane Clear 1 2 foot 2 6 51 027 Lid Assembly MP500 2 42 049 Gasket Magnetic 11 5 x 2312 1 5 16 004 Adhesive Bostick 1100 FS ounces 1 6 52 304 Gasket Plate 11 x 234 1 6 52 308 Panel Sides Lid Assembly MP500 2 7 01 078 Installation Kit MP500 5 32 003 InstaCoolant IV Gallons 18 7 01 086 Accessories Kit Freezer MP500 2 72 026 Pump Hand Siphon Water Removal 1 4 41 022 Tubing Vincon Zus x Wtr Rmvl Feet 25 5 34 001 Food Color Dye Blue Bottle 1 7 01 002 Kit Membrane Repair 1 7 02 007 Manual Operator and Maintenance 1 7 01 087 Spare Parts Kit 8 0500 20 Basic 1 7 01 035 Kit Fuse 500 550 750 1 7 01 038 Dessicant Package Replacement 1 7 01 084 Kit Screw Freezer MP500 1 7 47 128 Pocket 15 75L x 2 19W x 10 50 H 1 7 21 039 Suction Heat Exchanger Assembly 4 36 001 Valve Thermal Expansion TEY 2 1 4 36 014 Orifice 402 for part number 4 36 014 1 7 32 013 Temperature Sensor 25 inch 1 7 34 042 Heater Harness 1 7 35 010 Control Display Panel Front 1 7 35 054 Contactor Assembly 1 7 35 057 Deck Heater Transformer 1 7 35 075 Solenoid Coil MP500 1 7 36 007 Aluminum Bushing Seal Assembly 2 42 017 O Ring 123 Buna N 1 5 41 005 Grease High Vacuum Silicone 1
33. cent equipment to allow adequate ventilation Make sure the Power Switch is in the off position before plugging the power cord into the wall Once the freezer is in position lower the leveling feet IMPORTANT Level the freezer both side to side and front to back Electrical Installation and Specifications The power source of the freezer should be wired by a qualified electrician The unit may be wired directly to a supply circuit or a locally approved plug and socket may be used Electrical supply lines with the freezer s power cord are colored as follows e USA o L lt Blue Hot o L2 Brown Hot o L3 Yellow Green Ground e Europe o L1 Brown Hot o L2 Blue Neutral L3 Yellow Green Ground Plasma Freezer Integral Refrigeration MP500 Service Manual 3 3 3 Installation The MP500 freezer requires a 20 ampere dedicated circuit See Specifications page 2 2 It is important that a qualified electrician survey the existing power availability at your facility to verify your facility s actual capabilities Adding the InstaCoolant IV to the Freezer The MP 500 takes 18 gallons of InstaCoolant IV Dow Syltherm XLT silicone based coolant The coolant is added to the machine in 4 1 2 gallon 17 Liters containers using the following method 1 Unplug the white snap connector for the deck heater on the back of the machine See Figure 4 Figure 4 MP500 Deck Heater Connector at rear of Freezer
34. chnical Service on the next business day after a request for emergency repairs may result in denial of coverage for that service call When calling for service have available 1 detailed information about the problem 2 the serial number of the unit 3 the service record for the unit 4 the date and place of purchase of the unit Limitations EQUIPMENT OR SPARE PART MALFUNCTIONS OTHER THAN THOSE CAUSED BY DEFECTS IN MATERIALS OR WORKMANSHIP INCLUDING MALFUNCTIONS CAUSED BY MISUSE ACCIDENT OR FAILURE TO PERFORM SCHEDULED MAINTENANCE ARE EXCLUDED FROM COVERAGE ANY ALTERATIONS OR MODIFICATIONS MADE TO THE UNIT OTHER THAN MODIFICATIONS OR ALTERNATIONS MADE BY THERMO RENDER THE WARRANTY NULL AND VOID THERMO WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES RESULTING FROM EQUIPMENT MALFUNCTION OR LOSS OF USE OF THE EQUIPMENT THERMO MAY AUTHORIZE INDEPENDENT CONTRACTORS TO PERFORM SERVICE SERVICE PROVIDERS ARE INDEPENDENT CONTRACTORS NOT THERMO EMPLOYEES CONSEQUENTLY THERMO IS NOT RESPONSIBLE FOR THE ACTS OR OMISSIONS OF THE SERVICE PROVIDERS INCLUDING WITHOUT LIMITATION FAILURE BY A SERVICE PROVIDER TO RESPOND TO CALLS FOR EMERGENCY SERVICE IN A TIMELY FASHION Plasma Freezer Integral Refrigeration MP500 Service Manual 1 5 Chapter 2 Overview TABLE OF CONTENTS System Summary sss 2 1 Specifications s eee eee eee 2 2 Ambient Operating Temperature 2 2 2 Overview 2 Overview
35. cient freezing of Fresh Frozen Plasma and Plasmapheresis This Service manual is organized to provide easy access to service and repair issues on the MP500 Plasma freezer Please read this manual in its entirety The Pointing Hand icon in the sidebar indicates to pay close attention to the indicated text The Exclamation icon in the sidebar indicates a Caution or Warning about a potential hazard such as injury to the operator or others or about potential damage to the equipment To convey information readily and consistently certain text conventions are used throughout this manual These conventions are as follows Text Convention Used For Numbered Lists Numbered lists should be carried out in the order listed for example 1 Remove the screws from the rear of the motor box 2 Remove the screws from the Display Panel Bulleted Lists Bulleted Lists indicate items to be carried out but not necessarily in sequence for example e Check the fuses e Make sure all snap connectors are tight Bold Typeface Uppercase Calls attention to a CAUTION WARNING or DANGER Bold Typeface lowercase Emphasizes any term or component that is being described or referred to Italics Used in designating another section in this Operator and Maintenance Manual that should be consulted for example Refer to the troubleshooting section Plasma Freezer Integral Refrigeration MP500 Service Manual 1 1 1 Preface
36. ctrician Plasma Freezer Integral Refrigeration MP500 Service Manual 4 1 4 Basic Troubleshooting Problem Freezer display is lit but pump does not work Probable Cause Blown Fuse Pump is iced up Loss of control voltage Solution Remove the motor box cover and replace the fuse s See Section 5H Power Panel Removal and Installation page 5 12 Defrost the freezer Refer to the Operator and Maintenance Manual Remove the motor box cover and check power to the 5 Volt Power Supply See Section 5H Power Panel Removal and Installation page 5 12 Coolant Chamber fills initially but during the cycle the coolant level drops off Freezer has accumulated ice that is clogging the pump inlet Defrost the freezer Refer to the Operator and Maintenance Manual Product is not completely frozen The product chamber is not completely filling with fluid Freezer has accumulated ice that is clogging the pump inlet The coolant pump is not running The coolant level is low in the machine The pump coolant transfer hoses are loose on the connections or have broken The freeze cycle is out of adjustment Defrost the freezer Refer to the Operator and Maintenance Manual See Freezer display is lit but pump does not work above Verify the level of coolant in the machine and fill if necessary Please see the procedure for Check the Coolant Level and Adding Coolant R
37. e Safety Thermostat The safety thermostat is located under the motorbox cover at the right rear corner of the machine Follow the instructions below to perform the adjustment 1 Remove the 4 Philips head screws attaching the motorbox cover to the freezer chassis See Figure 7 Figure 7 Rear View of Motorbox Cover 4 Philips head Screws Plasma Freezer Integral Refrigeration MP500 Service Manual 3 5 3 Installation Figure 8 Display Panel Removal E Figure 9 Hemoval of Motorbox Front Fastener 3 6 2 Remove the 4 Philips head screws attaching the display panel to the motor box cover See Figure 8 4 Philips head Screws 3 Gently place the display panel upside down on the chamber lid of the freezer Remove the Philips head screw that secures the front of the motor box cover to the freezer chassis NOTE DO NOT disconnect the panel wiring Panel wiring Display panel Philips head screw 4 After removing the screw that secures the front of the motor box cover replace the display panel and temporarily secure it to the cover with two screws See Figure 10 Plasma Freezer Integral Refrigeration MP500 Service Manual 3 Installation Figure 10 Temporarily Secure the Display Panel Display panel and two screws 5 Carefully set the motorbox cover on its side on the chamber lid You will notice that the safety thermostat is in the right rear of the motorbox
38. e with the maintenance schedule included with the operating instructions for the unit is excluded from Warranty coverage This Warranty covers only the cost of parts needed to make Warranty repairs Labor charges and shipping charges for replacement parts will be billed to the purchaser THERMO reserves the right to replace any malfunctioning unit or part with a new or refurbished unit in lieu of repairing such unit This warranty and THERMO s obligation to repair or replace defective parts is the sole and exclusive remedy of purchaser Under no circumstances shall THERMO be liable for consequential or economic damages that might arise from a defective part THERMO WARRANTIES AS SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF AND PURCHASER HEREBY WAIVES ALL OTHER Plasma Freezer Integral Refrigeration MP500 Service Manual 1 Preface WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR WARRANTY OF NON INFRINGEMENT Procedure If Warranty repairs are needed contact Helmer Technical Service 14400 Bergen Boulevard Noblesville IN 46060 Telephone 1 317 773 9092 or 800 743 5637 in the US Fax 1 317 773 9082 For emergency repairs at night or on weekends or holidays contact your THERMO Authorized Service Provider Service Provider directly and notify Helmer Technical Service on the next business day Failure to notify Helmer Te
39. econnect the coolant hose to the fitting and tighten the clamps or replace the coolant hose See Section 5J Motorbox Removal and Installation page 5 17 Adjust the timer for a longer freeze cycle The coolant temperature is too high The amount of product loaded has exceeded the capacity of the machine The condensing coil is clogged with dirt The compressor is not running Load only that amount of plasma as set forth in the Operation and Maintenance Manual Specifications Shut off the unit and clean the condensing unit grilles and coil Refer to a Qualified Refrigeration Technician to check the refrigeration System Plasma Freezer Integral Refrigeration MP500 Service Manual Chapter 5 Parts Replacements TABLE OF CONTENTS 5A Hihge iem meet 5 1 5B Lic toten Cet o dette Arte fetta 5 8 5C Lid Gasket AA 5 4 5D Lid Gasket Plate sss 5 5 5E Membrane Pack 5 7 5F Motorbox Cover 5 8 5G Display Control Panel 5 11 5H Power Panel esee 5 12 5l Probe B9x ae tan eti 5 14 5J Motorbox Removal amp Installation 5 17 5K Motorbox Disassembly and Assembly 5 19 5L Defrost Heater sss 5 22 5M Defrost Heater Temperature Probe 5 24 5N Sensor Temperature Probe 5 26 50 Product Chamber 5 27 5P Condensing Un 5 29 5Q Condensing Unit Pressure Test 5
40. from heater Slide heater up to reveal ferrules compression bushings Loosen ferrules and remove from heater Slide heater down through compression fittings to remove Slide new heater up through compression fittings until approx 3 inches of heater including terminals protrudes above fittings Install new ferrules onto heater and lower heater into compression fittings until approx 1 4 inch of heater remains above fitting not including terminals Install compression nuts and tighten Be sure to keep heater stationary in order to maintain inch location indicated in step 2 Install insulators onto heater terminals Install in sequence nut washer terminal washer nut Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements K NOTE Be sure to connect BROWN and BLUE wires to heater terminals VL according to P N 7 65 054 drawing SHEET 2 of 2 6 Install coil nipples over heater terminals and secure with cable ties 7 Install thermal bulb heater bracket with bulb oriented vertically 8 Install probe box per Section 5I Probe Box Cover Removal and Installation 9 Install motorbox cover per Section 5F Motorbox Cover Removal and Installation 10 Re connect unit to power source 11 Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 23 5 Par
41. gs 2 feet cork insulation tape Turn unit power off at switch located on power panel See Figure 24 Power Panel Unplug unit from power source If hardwired to power source then turn power off at supply panel Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation Remove probe box per Section 5I Probe Box Cover Removal and Installation Remove cork insulation tape from around both Defrost Heater Temperature Probe and Sensor Temperature Probe Remove foam insulation tube from Sensor Temperature Probe Loosen compression nut from fitting Slide probe and compression nut up through fitting Remove compression nut and plastic ferrule compression bushing from old Sensor Temperature Probe and install on new probe at approximately the same location Slide new Sensor Temperature Probe through compression fitting until ferrule seats into compression fitting Tighten compression nut approximately 3 4 turn beyond snug Wrap both Defrost Heater Temperature Probe and Sensor Temperature Probe with cork insulation tape include fittings Install probe box per Section 5F Probe Box Cover Removal and Installation Install motorbox cover per Section 5F Motorbox Cover Removal and Installation Re connect unit to power source Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 Plasma Freezer Integral Refrigeration MP500 Service Manual
42. ical 44 Safety Over temperature Switch Cable Connector Spiral Wrapped Cables ms Plasma Freezer Integral Refrigeration MP500 Service Manual 5 9 5 Parts Replacements Installation 5 10 15 Using screwdriver remove loop clamp from motorbox cover See Figure 23 this page 16 Remove loop clamp from cable and remount back inside motorbox cover 17 Motorbox is now disconnected Place motorbox cover on its left side on top of lid Remove loop clamp from motorbox cover and install over loose Over Temperature Safety Switch Cable 3 Rerinstall loop clamp Re connect Over Temperature Safety Switch Cable at connector 5 Re connect 4 ground wires to motor bracket and motor mounting plate See Figure 23 this page 6 Remove power panel from ESD bag and install per Steps 2 4 of Section 5G Power Panel Hemoval and Installation 7 Lower motorbox cover over motor assembly until tie brackets contact top of freezer chassis Make sure spiral wrapped cables are routed over the left side of motor mounting plate See Figure 23 this page 8 Slide motorbox cover toward front of unit approximately 2 inches While lifting front align slot in motorbox cover flange with chassis mounting guide holddown 9 Lower front of motorbox cover and slide it toward rear allowing tie brackets to drop down into place at back of unit 10 Lift up on the front of motorbox cover to make sure slotted flange engaged chassis mo
43. ication Fig 18 5 6 Index H Help Line 1 4 Hinge 5 1 Hinges Fig 14 5 1 Hinge Assembly Fig 15 5 2 How to Use this Manual 1 1 Installing Gasket Plate Fig 17 5 6 Intended Use 1 1 L Lid 5 3 Lid Gasket 5 4 Lid Gasket Plate 5 5 Lid Gasket Removal Fig 16 5 4 Limitations 1 5 Limited Warranty 1 4 Membrane Rack 5 Motor Box Assembly Fig 21 5 Motorbox Cover 5 Motorbox Disassembly and Assembly 5 19 Co ON Motor Box Electrical Fig 23 5 9 Motorbox Removal and Installation 5 17 Motor Box Top View Fig 22 5 9 Motor Mounting Bracket Connections Fig 26 5 14 MP500 Deck Heater Connector at rear of Freezer Fig 4 3 4 MP500 Membrane Deck Fig 5 3 4 MP500Membrane Deck Removal Fig 6 3 5 MP500 Plasma Freezer Fig 1 2 1 P Part Description Cross Reference Table 6 1 Placing the Freezer in Position 3 3 Pocket Pocket Spring Configuration Fig 19 5 6 Power Panel 5 12 Power Panel Fig 24 5 12 Plasma Freezer Integral Refrigeration MP500 Service Manual IND 1 Index Power Panel Grounding Terminal Fig 25 5 12 Power Panel OFF ON Switch Fig 20 5 8 Precautions 4 1 Preparing the Unit for Start Up 3 5 Pressure Switch Location Fig 32 5 35 Probe Box 5 14 Probe Box Installation Fig 27 5 15 Procedure 1 5 Product Chamber 5 27 R Rear View of Motorbox Cover Fig 7 3 5 Refrigeration System Piping Fig 31 5 30 Removal of Motorbox Front Fastener Fig 93 6 S Safety Precautions 1 2
44. icrons If vacuum test fails repeat Section 5M Condensing Unit Pressure Test page 5 24 pressure test to locate leak Disconnect yellow line from vacuum pump and disconnect the vacuum gauge Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5S Charging the Refrigeration System CAUTION Only a licensed refrigeration service person should perform this procedure 1 Obtain AZ 50 R 507 or HP62 R 404a refrigerant and refrigerant weigh scale charging meter 2 Connect yellow line of RTC manifold to outlet port of scale charging meter 3 At RTC manifold crack open the yellow line to allow the line to be fully purged before entering the condensing unit 4 Check pressure switch setting adjust as necessary Cut in 12 psig with a differential of 10 psig Figure 32 Pressure Switch Location 5 Turn power onto unit 6 Slowly open blue valve on RTC manifold until gauge reads 10 1 psig Allow unit to sit in this state until unit is adequately charged Unit requires 2 lbs 5 oz 7 Close both discharge service valve and suction valve Disconnect the yellow line from the outlet side of scale weigh scale 8 Close both red and blue valves of the RTC manifold and disconnect the lines from the condensing unit Plasma Freezer Integral Refrigeration MP500 Service Manual 5 35 Chapter 6 Parts Lists TABLE OF CONTENTS Part Description Cross Reference Table
45. l for record retention and internal personal use This does not create a license to the purchaser under any copyright trademark patent or other intellectual property right THERMOGENESIS CORP For additional copies of this manual contact Helmer Technical Service or the equipment supplier THERMOGENESIS CORP proprietary trademarks identify products and services of THERMOGENESIS CORP are the property of THERMOGENESIS CORP and are protected under State and Federal trademark laws and under international treaties Those proprietary trademarks and service marks may not be used except as provided by law without the prior written consent of THERMOGENESIS CORP trademarks and service marks THERMOGENESIS CORP Companies own other brand trademarks and tradenames mentioned in this manual THERMOGENESIS CORP has thoroughly reviewed the contents of this manual to make it an informative and easy to use guide for the operation of the equipment and devices described herein All statements technical information and recommendations contained in this manual or related documentation are current and believed to be reliable as this document goes to press For this reason the contents of this manual are not intended to be and should not be understood as representations or warranties concerning the equipment and devices described herein Plasma Freezer Integral Refrigeration MP500 Service Manual 1 3 1 Preface Help Line Limited Warranty War
46. ly clears top of freezer chassis CAUTION If storing probe box assembly for later installation lay in flat position and support the heater and probes to keep weight of assembly off these components Installation 1 Lower the probe box and metal cover assembly into the reservoir through opening at right side of unit 2 Position motor support bracket over motor mounting plate and install 2 4 20 hex cap head screws and fender washers Do not tighten screws at this time See Figure 26 Motor Mounting Bracket Connections 3 Bundle together chassis and pump motor cables and defrost heater terminal wires and install spiral wrap See Figure 27 Probe Box Installation this page C NOTE Do not include temperature control cable in the bundle Figure 27 Probe Box Installation 4 Bundle together temp control and chassis cables and install multi cable loop clamp See Figure 27 Probe Box Installation this page 5 Install control panel grounding wire at terminal on motor mounting plate See Figure 27 Probe Box Installation 6 Position multi cable loop clamp over mounting hole and install truss head screw See Figure 27 Probe Box Installation this page 7 Repeat for single loop clamp attached to temperature control cable See Figure 27 Probe Box Installation this page 8 Install remaining 2 probe box mounting screw Plasma Freezer Integral Refrigeration MP500 Service Manual 5 15 5 P
47. n top of deck and align lid mounting holes with hinge mounting holes Install 8 each hinge mounting screws and washers Check lid gasket to deck seal per Maintenance Section in Operator and Maintenance Manual Install upper plastic hinge covers Remove cap from desiccant filter fitting and connect desiccant tube extending from rear of lid to filter assembly Plasma Freezer Integral Refrigeration MP500 Service Manual 5 3 5 Parts Replacements 5C Lid Gasket Tools Required e 2 Phillips screwdriver e Awl for new gasket installation Removal 1 Remove lid per Section 5B Lid Removal and Installation and place on flat work area with gasket side up 2 Starting on one side lift inner flange of lid gasket toward outside edge of lid to expose mounting screws See Figure 16 Figure 16 Lid Gasket Removal le 3 Using the screwdriver remove the exposed mounting screws 4 Continue around the lid by lifting the gasket and removing exposed screws until all screws are removed 5 Remove gasket by stretching flange over edge of mounting plate Installation 1 Position gasket on gasket plate and stretch over edge all around perimeter until gasket flange is fully seated between gasket plate and lid 2 Starting on one side lift inner flange of lid gasket toward outside edge of lid to expose gasket plate mounting holes 3 Align one gasket plate mounting hole with corresponding gasket and lid mounting holes and inst
48. nd washers that secure the lower hinge body to the chassis See Figure 15 4 Loosen the 2 lower screws that secure the lower hinge body to the chassis See Figure 15 5 Remove the hinge by pulling upward Plasma Freezer Integral Refrigeration MP500 Service Manual 5 2 5 Parts Replacements Installation 1 5B Lid Tools and Supply Required Removal Installation Position lower mounting slots of lower hinge body such that they engage between the freezer chassis and flat washers of the 2 loosened lower mounting screws Align upper mounting slots of lower hinge body with chassis mounting holes and install the 2 upper hinge mounting screws and washers Align lid mounting holes with upper hinge mounting holes and install the 4 remaining mounting screws and washers Check lid gasket to deck seal per Maintenance Section in Operator and Maintenance Manual Install both upper and lower plastic hinge covers T Handle Allen wrench 5 32 inch 3 8 rubber cap or duct tape Remove pull off upper plastic hinge covers to expose hinge to lid mounting screws Using Allen wrench remove the 8 screws 4 per hinge and washers that secure upper hinge body to lid See Figure 15 Disconnect desiccant tube extending from rear of lid to filter assembly mounted on rear of freezer chassis See Figure 14 Cap off desiccant filter fitting duct tape works well in place of a rubber cap Remove lid from deck Place lid o
49. ntegral Refrigeration MP500 Service Manual 3 Installation b Begin a freeze cycle by pressing START again By running a freeze cycle during the temperature pulldown the coolant is continuously circulated resulting in faster pulldown to operating temperature If necessary run a second freeze cycle until the unit has reached operating temperature 3 When the unit has reached the operating temperature it is necessary to reset the Safety Thermostat back to 55 F by repeating the steps on Adjusting the Safety Thermostat starting on page 3 5 Upon completion secure the motor box cover to the freezer chassis 4 The MP500 is now ready for validation and operation Plasma Freezer Integral Refrigeration MP500 Service Manual 3 9 Chapter 4 Basic Troubleshooting TABLE OF CONTENTS Precau let 4 1 B Troubleshooting sss sees eee eee eee 4 1 4 Basic Troubleshooting 4 Basic Troubleshooting Precautions NOTE When replacing fuses be sure the new fuse has correct amperage rating NOTE General ESD Control Practices should be utilized when servicing or repairing this equipment CAUTION Make sure the InstaCoolant IV is above freezing before performing any service inside the machine Placing your hands in the coolant when it is below freezing creates an extreme frostbite danger Basic Troubleshooting The following chart outlines common problems that could occur and possible solutions to those p
50. nting holes of probe box bracket and install 2 each 6 32x3 8 screws 3 Reinstall cover and set thermostat to 55 F 13 C 4 Slide bulb of probe through compression fitting 5 Install thermal bulb heater bracket onto defrost heater with bulb oriented vertically Reference Drawing 7 65 054 SHEET 2 of 2 6 Feed probe wire through side of rubber stopper and snuggly insert into top of compression nut 5 24 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 7 Wrap both defrost heater temperature probe and sensor temperature probe with cork insulation tape include fittings 8 Install probe box per Section 5F Probe Box Cover Removal and Installation 9 Install motorbox cover per Section 5F Motorbox Cover Removal and Installation 10 Re connect unit to power source 11 Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 25 5 Parts Replacements 5N Sensor Temperature Probe R NOTE Reference Chapter 7 Drawing P N 7 65 054 sheet 2 of 2 for this operation Tools and Supplies Required Removal Installation 5 26 Razor Blade 2 Phillips screwdriver 1 4 inch nutdriver or socket and ratchet 5 16 inch nutdriver or socket and ratchet 7 16 inch nutdriver or socket and ratchet 5 8 inch open end wrench 2 each ESD protective ba
51. pull straight up Once motorbox assembly has cleared chassis top place cattycorner on chassis top This will allow access to pump hose connection Loosen pump discharge hose clamp with 5 16 nutdriver and remove hose from pump Remove hose clamp from hose and store with motorbox assembly Remove motorbox assembly enough so that it just clears the coolant Tip assembly to discharge side and allow remaining coolant in pump to drain back into reservoir Remove motorbox assembly completely from reservoir and place on its side CAUTION Motor box assembly is top heavy and will easily fall over if allowed to stand upright on pump housing Place motorbox assembly cattycorner on chassis top Position assembly such that motor will be toward the back once in place Install hose and hose clamp on pump discharge fitting and tighten with 5 16 nutdriver Lower motorbox assembly down into position Install probe box per Section 5F Probe Box Cover Removal and Installation Install motorbox cover per Section 5F Motorbox Cover Removal and Installation Plasma Freezer Integral Refrigeration MP500 Service Manual 5 17 5 Parts Replacements 6 Re connect unit to power source 7 Turn power onto unit and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 8 If during the repair process the temperature of the InstaCoolant has risen significantly refer to Section Temperature Pulldown Ch
52. ranty 1 4 All THERMOGENESIS CORP products including the products described in this manual are covered by specific and limited warranties as described in the back of this manual If you have questions on equipment or device warranties call Helmer Technical Service at 800 743 5637 in the US or Canada or 1 317 773 9092 in other locations weekdays except US Holidays from 8 00 a m to 5 00 p m Eastern Standard Time Helmer Scientific 14400 Bergen Boulevard Noblesville IN 46060 Tel 800 743 5637 U S Canada Direct 1 317 773 9092 non U S Canada Fax 1 317 773 9082 Web www helmerinc com THERMOGENESIS CORP THERMO products are designed and manufactured to provide reliable trouble free performance when properly maintained and used in accordance with the operating instructions provided with each unit Each unit is carefully inspected tested and found to be in good working order prior to shipping THERMO warrants to the original purchaser that the unit will be free from defects in materials or workmanship for one year from the date of shipment THERMO also warrants that spare parts will be free from defects in material workmanship for a period of ninety 90 days or the maximum time required by applicable local law from the date of shipment of the spare part Equipment failure due to reasons other than manufacturing defects such as accident misuse or failure to timely perform scheduled maintenance in accordanc
53. riage bolts from outside through mounting holes Install inch nuts and tighten using ue open end wrench Re solder is liquid line at connection point above sight glass Re connect suction line service valve of compressor using 5 inch Socket wrench Pressure and leak test unit per 5M Condensing Unit Pressure Test page 35 Vacuum Leak test unit per 5N Condensing Unit Vacuum Test page 36 Do not proceed further until steps 10 and 11 are complete Pour coolant back into reservoir Re install product chamber per Section 5K Product Chamber Hemoval and Installation page 5 19 Re install motorbox per Section 5J Motorbox Removal and Installation page 5 17 Re install probe box per Section 51 Probe Box Removal and Installation page 5 14 Re install motorbox cover per Motorbox Cover Removal and Installation page 5 17 Re install membrane rack per 5E Membrane Hack Removal and Installation page 5 7 Re connect unit to power source Turn power on to the unit and charge unit per 5O Charging the Refrigeration System page 5 35 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 31 5 Parts Replacements 20 Verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 21 If during the repair process the temperature of the InstaCoolant has risen significantly refer to section Temperature Pulldown Chapter 3 5 32 Plasma Freezer Integral Refrigeration MP500 Service Man
54. roblems The chart is layed out to indicate repair and or replacement procedures to accommodate the solutions indicated For further technical help refer to Helmer Technical Service weekdays except holidays between 8 00am and 5 00pm Eastern Standard Time In the US and Canada dial 800 743 5637 In other locations dial 1 317 773 9092 Problem Probable Cause Solution No Power to Unit Nothing Runs Display Coolant temperature is above the safety limit Panel is Blank Red Light Safety Thermostat has shut off power to the at side of unit is on machine See Section 3 Adjusting the Safety Thermostat page 3 5 Plug is not secured into Secure the plug into the wall receptacle In the the wall receptacle case of a twist lock plug insert into receptacle and twist clockwise into position Power switch has Turn the power switch to the on position accidentally been turned off Blown Fuse s Remove the motor box cover and replace the fuse s See Section 5H Power Panel Removal and Installation page 5 12 Loose wires or snap Remove the motor box cover and check all wire connectors connections and snap connectors to verify that they are secure See Section 5H Power Panel Removal and Installation page 5 12 No power to the wall Check the breaker at the electrical distribution receptacle panel If the breaker is tripped reset the breaker and monitor the operation of the machine If the breaker trips again please refer to a qualified ele
55. see arrow on Figure 11 Figure 11 Setting the Motorbox Cover Aside f 6 Remove the Safety Thermostat Cover Using a flathead screwdriver adjust the Safety Thermostat to read about 80 F 27 C then replace the Safety Thermostat cover see Figure 12 Figure 12 Adjusting the Safety Thermostat Safety Thermostat Cover Plasma Freezer Integral Refrigeration MP500 Service Manual 3 7 3 Installation Starting the MP500 Plasma Freezer 1 Replace the motorbox cover over the motorbox but do not secure the cover to the MP500 Chassis 2 Make sure the unit is properly plugged into the wall then turn on the power switch 3 The MP500 Freezer will begin to chill the InstaCoolant to the operating temperature Temperature Pulldown At the start of the temperature it is a good idea to do the following 1 Record the temperature on the display at the beginning of the pulldown NOTE It is wise to record the temperature as the unit drops in temperature 2 When the coolant temperature display indicates 5 C 41 F initiate a freeze cycle by doing the following a Seta90 minute freeze cycle see Figure 13 e On the timer keypad press RESET s Then enter 9000 e Press START within 10 seconds to confirm the selection Figure 13 Timer Display Panel TIME FUNCTION OPERATING TEMPERATURE DISPLAY ERROR MESSAGE OPERATING TEMPERATURE ERROR MESSAGE 3 8 Plasma Freezer I
56. splay Control Panel Removal and Installation Place panel in an ESD bag and seal it Keep sealed in bag until ready to re install Remove 4 screws that mount power panel to motorbox cover See Figure 20 Power Panel OFF On Switch this page Remove 4 screws that mount motorbox cover stainless steel tie brackets to freezer chassis located at rear of unit See Figure 7 Rear View of Motor Box Cover Disconnect deck heater circuit at connection terminal located inside metal housing at rear of unit See Figure 4 MP500 Deck Heater Connector at Rear of Freezer Carefully lift back of motorbox cover until brackets clear top of chassis Slide cover toward front of unit until inner flange of cover clears chassis mounting guide holddown See Figure 21 Motor Box Assembly this page D Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 10 Rotate motorbox to its left side and place on top of lid 11 Remove power panel per Steps 6 8 of Section 5G Power Panel Installation and Removal 12 Place panel in an ESD bag and seal it Keep sealed in bag until ready to re install 13 Disconnect the 4 ground wires terminating at motor bracket and motor mounting plate See Figure 22 this page Figure 22 Motor Box Top View 14 Disconnect Over Temperature Safety Switch Cable at connector located just after loop clamp inside motorbox cover See Figure 23 this page Figure 23 Motor Box Electr
57. ters 18 US Gallons 3 0 Liters 25 13 F R 507 AlliedSignal AZ 50 40 40 F Saturated Suction Temp 200 220 Volts 1 Ph 50 Hz 15 FLA 208 230 Volts 1 Ph 60 Hz 15 FLA 20 amps 15C to 30 C 60 F to 86 F 10 to 80 RH Plasma Freezer Integral Refrigeration MP500 Service Manual Chapter 3 Installation TABLE OF CONTENTS Unpacking and Inspection sese eee eee eee 3 1 Connecting the Desiccant Eier 3 2 Placing the Freezer in Position 3 3 Electrical Installation and Specifications 3 3 Adding the InstaCoolant IV to the Freezer 3 4 Preparing the Unit for Start Ups ee ee ee ee ee 3 5 Adjusting the Safety Thermostat sse eee eee eee 3 5 Starting the MP500 Plasma Freezer 3 8 Temperature Pulldown esse eee eee eee eee eee 3 8 3 Installation 3 Installation Unpacking and Inspection Check for any shipping damage upon receiving the freezer If there is any apparent damage notify the shipping company immediately Contact Helmer Technical Service if there are any problems The following items should be included with the freezer e Operator and Maintenance Manual e Freezer Solenoid Valve Body and Coil Factory Installed e Spare Membrane Pocket e Membrane Pocket Repair Kit e Defrost Drain Hand Pump Please record the following information from the back of the freezer in the spaces marked below Model Number Serial Number
58. tion 5F Motorbox Cover Removal and Installation 6 Disconnect all wires and cables from back of power panel 7 Using nutdriver remove grounding wire from grounding terminal See Figure 25 Power Panel Grounding Terminal this page Figure 25 Power Panel Grounding Terminal 5 12 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 8 Remove panel by lifting out of motorbox cover opening 9 Place in ESD bag and seal it Keep sealed in bag until ready to re install Installation 1 Remove panel from ESD bag 2 Place panel through opening in right side of motorbox cover NOTE Motorbox cover should be on edge with panel opening up to provide en easiest access to cable connections 3 Re install ground wire onto grounding stud Sequence of installation from panel on out is as follows star washer nut starwasher ground ring terminal starwasher nut 4 Re connect wires and cables ensuring full engagement of connections 5 Re install motorbox cover per Steps 7 10 of Section 5F Motorbox Cover Removal and Installation 6 Re install the 4 panel mounting screws CAUTION DO NOT OVER TIGHTEN Plasma Freezer Integral Refrigeration MP500 Service Manual 5 13 5 Parts Replacements 5I Probe Box Tools and Supplies Required Removal Figure 26 Motor Mounting Bracket Connections 2 Phillips screwdriver 1 4 inch nutdriver or socket wrench 7
59. torbox cover opening Turn panel over and disconnect ribbon cables at back of panel 3 total See Figure 9 Removal of Motorbox Front Fastener Using nutdriver unscrew grounding nut and remove ground wire from grounding stud on back of panel See Figure 9 Removal of Motorbox Front Fastener Place panel in an ESD bag and seal it Keep sealed in bag until ready to re install Remove panel from ESD bag Re install ground wire onto grounding stud Sequence of installation from panel on out is as follows star washer nut starwasher ground ring terminal starwasher nut Re connect ribbon cables ensuring full engagement of connections Place panel on flange of motorbox cover opening Re install the 4 panel mounting screws CAUTION DO NOT OVER TIGHTEN Plasma Freezer Integral Refrigeration MP500 Service Manual 5 11 5 Parts Replacements 5H Power Panel Tools and Supplies Required e 2 Phillips screwdriver e 1 4 inch nutdriver or socket wrench e ESD protective bag Removal 1 Turn unit power off at switch located on power panel See Figure 24 Power Panel this page Figure 24 Power Panel sum 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Place covering on top of lid to protect surface 4 Remove 4 screws that mount power panel to motorbox cover See Figure 24 Power Panel this page 5 Remove motorbox cover per Steps 7 9 of Sec
60. ts Replacements 5M Defrost Heater Temperature Probe NOTE Reference Chapter 7 Drawing P N 7 65 054 sheet 2 of 2 for this operation m Tools and Supplies Required e Razor Blade e 2 Phillips screwdriver e 1 4 inch nutdriver or socket and ratchet e 5 16 inch nutdriver or socket and ratchet e 7 16 inch nutdriver or socket and ratchet e 5 8 inch open end wrench e 2each ESD protective bags e 2 feet cork insulation tape Removal 1 Turn unit power off at switch located on power panel See Figure 24 Power Panel 2 Unplug unit from power source If hardwired to power source then turn power off at supply panel 3 Remove motorbox cover per Section 5F Motorbox Cover Removal and Installation 4 Remove probe box per Section 5I Probe Box Cover Removal and Installation 5 Remove cork insulation tape from around both defrost heater temperature probe and sensor temperature probe 6 Remove rubber stopper from compression fitting of defrost heater temperature probe Remove thermal bulb wire of probe from side of rubber stopper Remove thermal bulb heater bracket from defrost heater Slide probe up through fitting 0 Loosen securing screw of temperature probe thermostat cover 1 Remove 2 each thermostat mounting screws and remove thermostat eee OL OD el Installation 1 Loosen cover securing screw and remove cover from new temperature probe thermostat 2 Locate thermostat over mou
61. ttle Slowly open red valve of RTC manifold and allow pressure to bleed off Disconnect red line from suction valve 7 Unplug power cords to solenoid valves Plasma Freezer Integral Refrigeration MP500 Service Manual 5 33 5 Parts Replacements 5R 5 34 Condensing Unit Vacuum Test CAUTION Only a licensed refrigeration service person should perform this procedure 1 Close both valves of RTC manifold 2 Attach blue line of RTC manifold to suction valve Verify that the suction NO 10 11 valve is open on condensing unit Close red line valve of RTC manifold as it is not needed for this procedure Attach the yellow line of RTC manifold to the vacuum pump inlet Open the vacuum pump valve and blue valve of the RTC manifold Attach vacuum gauge to secondary inlet of yellow line of the RTC manifold Attach solenoid coil power cord to liquid line solenoid amp energize coil Turn on vacuum pump and run for 3 hours minimum After vacuum gauge reads 500 microns u or less close the vacuum pump valve Allow the vacuum to stabilize for 5 minutes minimum Record the vacuum level and time Allow system to sit in above state for 2 hours minimum Record final vacuum level and time PASS FAIL criteria for system Unit considered pass if change of vacuum reading from initial to final is less than 300 microns Unit considered fail if change of vacuum reading from initial to final is greater than 300 m
62. ual 5 Parts Replacements BO Condensing Unit Pressure Test SAL H CAUTION Only a licensed refrigeration service person should perform this procedure NOTE Following text refers to refrigeration hoses and hand valves on a color basis In accordance with standard refrigeration nomenclature Red indicates the high side and blue indicates the low side of the refrigeration system Yellow refers to the purging charging line 1 Obtain standard refrigeration and test charging manifold RTC manifold CAUTION Ensure both valves are closed on RTC manifold 2 Attach red hose of RTC manifold to the suction valve located near the oil separator of the condensing unit Backseat then open the suction valve 3 Obtain solenoid power cord energize liquid line solenoid CAUTION Ensure voltage applied to valve is equivalent to condenser voltage rating 4 Attach yellow hose of RTC manifold to dry nitrogen bottle with regulator and open valve Slowly open red valve on RTC manifold until pressure reads 250 10 psig Close red manifold valve and allow pressure to stabilize 2 minutes minimum Close nitrogen bottle valve 5 Apply leak detection fluid on each manifold fitting check for any signs of bubbles Allow unit to remain pressurized for 30 minutes minimum Confirm that no bubbles have formed and pressure has not decayed greater that 1 psig 6 Disconnect yellow line from nitrogen bo
63. unting guide holddown If it does not repeat steps 8 10 taking care to ensure engagement of slot and guide holddown 11 Install 4 power panel mounting screws N A CAUTION DO NOT OVER TIGHTEN 12 Install 4 screws that mount tie brackets to chassis 13 Reconnect deck heater circuit at connection terminal and re place inside metal housing 14 Install control panel per Section 5E Control Display Panel Removal and Installation CAUTION DO NOT OVER TIGHTEN 15 Re connect to power source 16 Turn power to unit ON and verify operation per startup process Section Starting the MP500 Plasma Freezer Chapter 3 17 If during the repair process the temperature of the InstaCoolant has risen significantly refer to Section Temperature Pulldown Chapter 3 Plasma Freezer Integral Refrigeration MP500 Service Manual 5 Parts Replacements 5G Display Control Panel Tools and Supplies Required Removal Installation hp gt A 2 Phillips screwdriver 1 4 inch nutdriver or socket wrench ESD protective bag Turn unit power off at switch located on power panel See Figure 20 Power Panel OFF ON Switch Unplug unit from power source If hardwired to power source then turn power off at supply panel Using screwdriver remove the 4 panel mounting screws See Figure 8 Display Panel Removal Lever up one edge of panel to get a finger grip then lift panel up to remove it from mo

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