QuickThaw™ Plasma Thawing System Service Manual
Contents
1. 0000 cette rn rn rn 26 10 4 Alarm Activation Problems nn nn annan 27 TT Pans we ress eskere eder CBE EE RE NIAE 28 11 1 Frontand Sides 24528 ha de sv ERRARE tebe d pakke esr xU Sands EG Sd eR se 28 12 Top and Real ia saad xr eR er ok ee dae wo AUR Lade sakehenetaamedtae ad gass PESE E 29 11 3 Interlor 2i sd a a ee First a bed 30 11 3 1 Parts Accessible from the Rear 1 eee aaa 30 11 3 2 Parts Accessible from the Bottom aas 31 11 4 BaSk t ER REESE EA QA de ee ANNA dg 31 11 5 sACCESSONES cen wan wea Rad ESPERE TASA NR ET qe RUP 32 12 zusaxeReesRkxE OEEUESNPNUCPRm FK ERE REEXUENE GENERE eres 33 121 2 oes arb oli ue RI PRX a BER mE qvae FSGS CATA RDS 33 122 DE and lec Oen 34 360097 1 l Helmer General Information Section I General Information 1 1 1 2 1 3 2 1 2 2 About this Manual Intended Audience This manual is intended for use by end users of the plasma thawing system and authorized service technicians Model References Generic references are used throughout this manual to group models that contain similar features For example models refers to all models of that type DH2 DH4 DH8 This manual covers all plasm2. 9 AGITATION AGITATION SWITCH SWITCH 9 CAPACITOR CAPACITOR FOR AGITATION M FOR AGITATION amp M MOTOR CAPACITOR FOR MOTOR CAPACITOR FOR LIFT OUT MOTOR K N K N AGITATION LIFT OUT AGITATION LIFT OUT MOTOR MOTOR MOTOR MOTOR LIFT OUT MOTOR END OF MANUAL 360097 1 l 34 HELMER SCIENTIFIC 14400 Bergen Boulevard Noblesville IN 46060 USA PH 1 317 773 9073 FAX 1 317 773 9082 www helmerinc com e Cc E Imer N 1 F
3. Connection between control board and heater triac is faulty or a part is faulty gt Check power to heater triac Replace heater triac or control board if necessary Connection between control board and temperature control sensor is faulty or a part is faulty gt Check connections from control board to temperature controller and from temperature controller to temperature control sensor Secure the connections if necessary Replace temperature control sensor temperature controller or control board if necessary Temperature has reached high alarm setpoint gt Verify chamber has water High Temperature alarm will activate quickly if chamber is empty gt Verify plasma thawer setpoint is set below High Temperature alarm setpoint and the difference is at least 1 0 C E2 lift out system malfunction appears on one or both cycle time indicators Loose connection or faulty part is preventing lift out pulley from winding properly gt Visually compare operation of faulty lift out system with operational lift out system DH8 models only Verify there are no loose parts blocking movement Secure or tighten parts as necessary Replace lift out cable or lift out pulley if necessary Loose connection or faulty part is preventing lift out motor from operating properly gt Check connections from control board to terminal strip and from terminal strip to lift out motor and lift out motor
4. 2 0 eee 11 8 1 Level 1 Parameters and Values 0 0000 eee ete eee 12 8 2 Level 2 Parameters and Values asesinada neugana a ccc tnt tenes 13 8 3 Level 3 Parameters and Values c cece eee 13 8 4 Level 4 Parameters and Values 0 200 tenes 14 8 5 Change the Plasma Thawer 5 rn 14 86 Calibrate the Temperature Controller s 15 8 7 Change the Control Sensor Offset s srrrrcresd erent drte rh 16 360097 1 I Helmer ET 10 ER EE 17 9 1 Test the High Temperature Alarm 0 0 varar kran 17 9 2 Cleanthe Plasma Thawer avauuvvvvvnvvrvv eee eee vann 18 9 2 1 Exter 2 sd ee be eee re eee e eder d bes 18 9 2 2 Chamber and Baskets 0 0 0 0 0c ee eee eee ee eens 18 9 23 F n V0V DAB 2 298 082 er dee odes e da tee ester ane Re eed 19 9 3 Maintaining Water Cleanliness 20 0 19 9 4 Lubricate and Service Internal Pantse no oeann nsara onna eee eee eee ra aan 20 9 5 Supplies dux e EA seder FRE GENE S ARR AR PRI dace ref ka es Ge ea d 21 10 Troubleshooting use em E HR CRDI ere e RD a REC ERR RC EON Rog e hat cade ia 21 10 1 55 5 ues cR Ek p sk LIRE UE E REDE tuos RR Pablo a Rod ru Rs 21 10 2 General Operation Problems 0 0000 rn rv narrer rn 23 10 3 Chamber Temperature Problems
5. POSITIONING 9 ini AGITATION SWITCH o CAPACITOR FOR AGITATION 6 MOTOR M CAPACITOR FOR LIFT OUT MOTOR K N AGITATION LIFT OUT MOTOR MOTOR 360097 1 33 Helmer Service 12 2 DH4 and DH8 MAIN POWER 100 10 V ac 50 Hz 115 10 V ac 50 60 Hz 230 410 V ac 50 60 Hz C CHAMBER HEATER connections to control board vary by voltage POWER 3 CONNECTOR o WITH POWER LINE FILTER F TEMPERATURE CONTROLLER 100 240 Vai SP1 chamber heater SP2 temperature alarm LT 1 B CIRCUIT f 9 jo A BREAKERS V oJ ony D D HEATER TRIAC ry He T G TEMPERATURE SENSOR Buttons on the control panel 51 Main power 2 Mute 53 Cycle time left 54 Lift out left 55 Cycle start left S6 Cycle time right S7 Lift out right 58 Cycle start right ALARM f f fff NOR VT BUZZER Fuses F1 Agitation motor left F2 Lift out motor left F3 Agitation motor right F4 Lift out motor right E CONTROL BOARD I cycle I cycle N INDICATORI IINDIGATORI M RIGHT D DH8 100 V models only 1 I FAN I TERMINAL TERMINAL F5 Heater 0 5 A STRIP STRIP k 3 F6 Main power 2 0 A RIGHT SIDE LEFT SIDE SPARET andiSPAREZ Spare fuses for replacing F1 F4 all 1 0 A L L MICROSWITCHES MICROSWITCHES FOR BASKET FOR BASKET POSITIONING POSITIONING id qj i ad i iMm J
6. baskets Exterior Clean the exterior with soap or mild cleaning agent and water Disinfect using a mild disinfectant solution Clean the vents as needed to maintain airflow and prevent the motors from overheating Chamber and Baskets NOTE gt Various factors can cause staining discoloration and rust spots on the chamber and baskets These factors include the type of water used regularity of cleaning and the usage environment gt Although the chamber and basket are stainless steel corrosive matter can adhere to the surfaces and crevices causing discoloration 1 Confirm the basket s have been lowered into the chamber Lower the basket s if necessary by pressing the LIFT OUT button for each basket 2 Press the AC ON OFF button to power the plasma thawer OFF Disconnect the plasma thawer from AC power 3 Drain the chamber Insert the end of the drain tube into a waste container or sanitary drain b Connect the drain line to the plasma thawer by inserting the drain coupling into the drain port on the side of the plasma thawer 4 Remove the baskets Unscrew the finger knobs securing the basket s to the lift out system b Remove the basket s from the lift out system Basket installed on lift out arm Finger knob circled 5 Remove the 2 V shaped brackets from the rear wall of the chamber optional 6 Using a soft cloth or sponge and a disinfectant cleaner suitable for stainless steel thoroughly clean the chamb
7. capacitor Secure connections if necessary Replace lift out motor or capacitor if necessary Fuse for lift out motor has opened gt Verify the fuse has not blown on the circuit board Replace fuse if necessary 21 Helmer 360097 1 I Error Message Possible Cause Service Action E2 lift out system malfunction appears on one or both cycle time indicators Loose connection or faulty part is preventing basket position from being sensed correctly gt Check connections from control board to terminal strip and from terminal strip to microswitches Secure connections if necessary gt Visually compare operation of faulty lift out system with operational lift out system DH8 models only Check operation of microswitches Replace one or both microswitches if necessary Control board is faulty gt If lift out system for one basket is operating correctly swap the connections at P4 and P6 on control board DH8 models only Press LIFT OUT button for basket for which the error message appeared gt If error code remains on the same indicator even after connections have been swapped control board is faulty gt If error code appears on indicator for the other basket control board is working properly and problem is with another part in the lift out system Bearing block is faulty Contact Helmer Technical Service Lift out system is malfunctioning Reset e
8. cer Zero sensor error calibration across full scale varies ChE Selection for the control accuracy monitor oFF EHd Read control accuracy monitor results variance UAr l ELH Read autotune tuning cycle data CtA MT Software version select this parameter to access Level 4 utr parameters 392b rSEk Functions reset nonE L EU L Parameter level currently selected 3 360097 1 1 13 Helmer 8 4 Service Level 4 Parameters and Values 8 5 360097 1 I Parameter Description Default Value L a Program security lock nonE d rs Derivative sensitivity 0 4 44 Display sensitivity or direct display of input m na fl Disable SP2 alarm annunciator oFF Pr 17 Program mode auto exit switch returns display to normal Auto FOU mode if no activity for one minute Change the Plasma Thawer Setpoint The default setpoint is 36 5 The temperature controller adjusts chamber temperature around the setpoint When chamber temperature is below setpoint the controller activates the heater to warm the chamber NOTE Do not change the setpoint to a value outside the temperature control range The current chamber temperature is displayed The temperature may be different from the setpoint especially if the chamber temperature has not yet stabilized Temperature controller display 1 Access the setpoint adjustment function a Press and hold the button gt The controller displays current s
9. cord is connected securely to plasma thawer and outlet Tighten connections if necessary gt Verify outlet is operational and meets power requirements for the plasma thawer Repair original outlet or connect to a different outlet if necessary Circuit breaker s have tripped or are not seated correctly gt Confirm circuit breaker s are seated Push circuit breaker to reset if necessary If a reset is not possible or breaker s trip again contact a qualified service technician Component is faulty or internal connections are loose Contact Helmer Technical Service Basket does not agitate even though agitation is enabled for the basket Agitation switch was accidentally turned off gt Confirm appropriate agitation switch on back of plasma thawer is switched ON Basket movement is obstructed by something in the chamber gt Confirm there are no obstructions in chamber Component is faulty or internal connections are loose Contact Helmer Technical Service Chamber is draining more slowly than usual Drain is obstructed gt Confirm there is no debris in chamber gt Backflush drain to clear any debris in the internal tubing between chamber and drain To backflush the drain empty chamber by whatever means necessary Connect drain tube using coupling valve Backflush drain by forcing water through opposite end of drain tube into chamber Drain is leaking
10. is greater than or equal to this value the alarm activates The low temperature alarm setpoint AL Lo specifies the temperature at which the Low Temperature alarm should activate If the temperature detected by the temperature control sensor is less than or equal to this value the alarm activates View or change parameter values NOTE gt Default high alarm setpoint is 37 6 gt Low alarm setpoint is disabled by default setpoint is 0 0 C gt When setting alarm setpoints maintain at least a 1 0 C difference above or below the plasma thawer setpoint gt When there is no interaction for 60 seconds the temperature controller exits program mode 1 Enter Level 1 program mode a Press and hold the UP and DOWN buttons simultaneously for approximately 3 seconds b tunE and oFF flash on the display c The temperature controller is now in Level 1 program mode 2 Select the parameter to be changed a Press and release the UP or DOWN buttons until the desired parameter flashes on the display b For the High Temperature setting select the AL hi parameter c For the Low Temperature setting select the AL Lo parameter 3 Change a parameter value a Press and hold the button b Press the UP or DOWN buttons to change the parameter value 4 Release all buttons to exit the parameter New settings are saved 5 Exit program mode a Press and hold the UP and DOWN arrow buttons simultaneously for approximately 3 seco
11. model shown Label Description Part Number e A Fan guard 220145 100 V DH8 B Drain port valve 220232 C Drain port cover 320520 1 D Control panel touchpad 370099 1 DH2 370067 1 4 and DH8 E Temperature controller 400591 1 F NOTE Replace the drain port valve when the drain line coupling is replaced 360097 1 1 28 Helmer Service 11 2 Top and Rear E A F G H Top and rear of thawer 230 V DH4 model shown with parts from various models Label Description Part Number i ras A Agitation switch 120202 J B Agitation switch cover 320524 1 C Circuit breaker 2 A 120552 230 V DH2 B Circuit breaker 4 A 120279 115 V DH2 and 230 V DH4 Circuit breaker 5 A 120558 100 V DH2 Circuit breaker 6 A 120288 230 V DH8 Circuit breaker 7 A 120272 115 V DH4 Circuit breaker 10 A 120110 100 V DH4 Circuit breaker 15 A 120259 115 V DH8 120281 100 V DH8 D Power connector includes power line 120299 A filter E Finger knob 230193 F Basket arm assembly 400302 1 includes hardware G Lift out rail 320516 1 H Lift out rail gasket 320491 1 360097 1 1 29 Helmer 11 3 Interior 11 3 1 Parts Accessible from the Rear Service Label Description Part Number sem Lift out motor capacitor 120204 110 V and 115 V M 120260 230 V B Agitation motor capacitor Included w
12. on the product specification label located on the left side of the plasma thawer REF DH8 QuickThaw Helmer 1000000 t 14400 Bergen Boulevard Noblesville IN 46060 USA Version A www helmerinc com Plasma Thawing System Voltage 115V D Weight 741b 34 kg pe og mps Power 1 15kW Ow Certified UL 61010 1 CSA 61010 1 Made in USA Product specification label Label Description A Model B Serial number SN Version D Power requirements Remove Packing Materials NOTE Keep the packaging materials for future use The plasma thawer is shipped with packing materials to ensure it is not damaged during shipping Remove the packing materials prior to operating the plasma thawer 1 Remove screws holding drain port cover slide cover outward and re secure screws 2 Retain drain port cover and all other accessories 3 Unscrew knob from underside of chamber cover 4 Relocate knob to top of cover Helmer Left Drain port cover Right Chamber cover with knob in proper position DH4 model shown S Helmer General Information 3 3 Lifting and Carrying the Plasma Thawer AN CAUTION gt The plasma thawer may be too heavy for one person to move alone Get assistance as needed gt Never move plasma thawer while connected to power or with water in chamber NOTE Do not lift by holding the basket s as this may damage the basket s When lifting the plasma thawer hold the ends of
13. the base of the plasma thawer and lift If the base is not accessible hold the ends of the storage frame and lift Lifting the plasma thawer 4 References and Compliance 4 1 Alarm Reference If an alarm condition is met an alarm activates The following table indicates if an alarm is audible A or visual V Messages for visual alarms if applicable appear in the table as well Alarm Alarm Type High Temperature A V AL on temperature controller E1 on all cycle time indicators Low Temperature A V AL on temperature controller Lift Out System A V E2 on affected cycle time indicator Malfunction Low temperature alarm is available but not used 4 2 Regulatory Compliance Pollution degree 2 for use in USA and Canada only This product is certified to applicable UL and CSA standards by a NRTL This device complies with the requirements of directive 93 42 EEC concerning Medical Devices as amended by 2007 47 EC Sound level is less than 70 dB A 360097 1 1 6 Helmer General Information 4 3 5 1 5 2 5 3 5 4 360097 1 I WEEE Compliance The WEEE waste electrical and electronic equipment symbol right indicates compliance with European Union Directive WEEE 2002 96 EC and applicable provisions The directive sets requirements for labeling and disposal of certain products in affected countries When disposing of this product in countri
14. Drain is faulty Contact Helmer Technical Service 25 Helmer Chamber Temperature Problems Problem Possible Cause Service Action Chamber temperature does not stabilize at plasma thawer setpoint Temperature controller has improper settings or is faulty gt Verify plasma thawer setpoint is set below High Temperature alarm setpoint and the difference is at least 1 0 C Replace controller if necessary Connection between control board and heater is faulty or a part is faulty gt Check power to the heater Replace heater or control board if necessary Connection between control board and heater triac is faulty or a part is faulty gt Check power to the heater triac Replace heater triac or control board if necessary Connection between control board and temperature control sensor is faulty or a part is faulty gt Check connections from control board to temperature controller and from temperature controller to temperature control sensor Secure connections if necessary Replace temperature control sensor temperature controller or control board if necessary Heater fuse has opened gt On the circuit board verify fuse has not opened Replace fuse if necessary Displayed chamber temperature is higher or lower than actual temperature Connection between control board and temperature control sensor is faulty or a part is faulty gt Check co
15. Helmer I ENT I Plasma Thawing System Service Manual QuickThaw Model Version DH2 A DH4 A DH8 A HELMER SCIENTIFIC 14400 Bergen Boulevard al Noblesville IN 46060 USA C 360097 1 ISO 13485 2003 CERTIFIED PH 1 317 773 9073 FAX 1 317 773 9082 USA and Canada 800 743 5637 Helmer Document History Revision Date CO Supersession Revision Description H 07 MAY 2013 8409 Revised layout for ease of navigation and locating information 16 MAY 2014 9492 supersedes Removed 0086 mark from manual Date submitted for Change Order review Actual release date may vary 360097 1 I Helmer Contents Section 1 General Information rn es 4 About this eve ee 4 1 1 Intended Audiences saree donee beds 4 12 Model References sisi etu do ERR MEER a ROR wee RR ARP g 4 1 3 Copyright and Trademark ee ee a e aa 9 9 XU 3 4 4 24 Product Labels sies a ck EE KE EA ROS ROVRO 4 2 2 AVOIGINGUINUN esaesa Akan seede GU e ORE eae PAR we 4 3 COnnQUraniOn s P Mm 5 3 1 Model and Input Power 0 00 0 5 3 2 Rem
16. NCLUDING WITHOUT LIMITATION DAMAGES RELATED TO LOST REVENUES OR PROFITS OR LOSS OF PRODUCTS This warranty does not cover damages caused in transit during installation by accident misuse fire flood or acts of God Further this warranty will not be valid if Helmer determines that the failure was caused by a lack of performing recommended equipment maintenance per Helmer manual or by using the product in a manner other than for its intended use Installation and calibration are not covered under this warranty agreement Outside of USA and Canada Consult your local distributor for warranty information Helmer Service Section ll Service 6 1 7 1 7 2 360097 1 1 Product Configuration Install External Thermometer Optional Install the external thermometer according to the manufacturer s documentation If using a Helmer DT1 digital thermometer refer to the instructions on the CD shipped with the plasma thawer Alarm Settings Chamber Heater When the chamber heater is providing heat to the chamber a green light illuminates on the temperature controller display The light may flash on and off to indicate that the heater is pulsing on and off to provide a minimal amount of heat to the chamber Temperature controller with chamber heater light circled Active Alarms and Error Messages If the temperature reaches the high temperature alarm setpoint or low temperature alarm setpoint the temperature controller wil
17. a thawing systems which may be identified singly by their size or by their series DH Copyright and Trademark Helmer and Rel i are registered trademarks or trademarks of Helmer Inc in the United States of America Copyright O 2013 Helmer Inc All other trademarks and registered trademarks are the property of their respective owners Helmer Inc doing business as DBA Helmer Scientific and Helmer Safety Includes general safety information for plasma thawing system operation Product Labels Caution Risk of damage Earth ground terminal to equipment or danger to operator Caution Hot surface Protective earth ground terminal Caution Shock electrical hazard Avoiding Injury Review safety instructions before installing using or maintaining the equipment Before moving unit ensure chamber water has been removed Never physically restrict any moving component Avoid removing electrical service panels and access panels unless so instructed Use supplied power cords only v v v v v AN CAUTION Decontaminate parts prior to sending for service or repair Contact Helmer or your 360097 1 1 distributor for decontamination instructions and a Return Authorization Number Helmer General Information 3 3 1 3 2 360097 1 Configuration Model and Input Power NOTE Service information varies depending on the model and power requirements This information appears
18. alue NOTE When there is no interaction for 60 seconds the temperature controller exits program mode 16 Helmer Service 9 1 360097 1 1 1 Enter Level 1 program mode a Press and hold the UP and DOWN buttons simultaneously for approximately 3 seconds b tunE and oFF flash on the display c temperature controller is now in Level 1 program mode 2 Switch to Level program mode a Press and release the UP or DOWN buttons until LEVL flashes on the display b Press and hold the button c Press the UP or DOWN buttons to change the parameter value to 3 d Release the button 3 Enter the offset adjustment value a Press and release the UP or DOWN buttons until ZEro flashes on the display b Press and hold the button c Press the UP or DOWN buttons to change the value to the calculated offset adjustment value d Release the button 4 Release all buttons to exit the parameter New settings are saved gt Ifthe LEVL parameter value is changed the temperature controller returns to the selected program level 5 Exit program mode a Press and hold the UP and DOWN arrow buttons simultaneously for approximately seconds b current chamber temperature is displayed Maintenance Test the High Temperature Alarm Regularly test the High Temperature alarm to ensure it is working correctly Test the alarm NOTE Testing the alarm requires temporary change to the plasma thawer setpoint P
19. e Service Action Basket does not agitate during thawing process even though agitation is enabled for the basket Loose connection or a faulty part is preventing agitation motor from operating properly gt Check connections from control board to terminal strip and from terminal strip to agitation motor Secure connections if necessary Replace agitation motor or capacitor if necessary Replace agitation switch if necessary Loose connection or a faulty part is preventing basket from agitating properly gt Visually compare operation of the faulty agitation system with operational agitation system DH8 models only Verify there are no loose parts blocking movement Secure or tighten parts as necessary Replace agitation motor and gearbox if necessary Replace agitation cam if necessary Control board is faulty gt On the circuit board verify fuse has not opened Replace fuse if necessary gt If agitation system for one basket is operating correctly swap the connections at P4 and P6 on the control board DH8 models only Verify both agitation switches are switched ON then press CYCLE START button for the basket exhibiting the agitation problem gt If basket exhibiting the agitation problem is now agitating control board is faulty gt If basket is still not agitating control board is working properly and problem is with another part in agitation system Baske
20. ecessary High Temperature alarm setpoint and plasma thawer setpoint are too close together gt Verify plasma thawer setpoint is set below High Temperature alarm setpoint and the difference is at least 1 0 C Replace controller if necessary Component is faulty or internal connections are loose gt Contact a qualified service technician Plasma thawer meets high alarm condition but the alarm is not audible The alarm buzzer is faulty gt Replace alarm buzzer Temperature controller has improper settings or is faulty gt Confirm temperature controller parameters are set correctly Change parameter values or replace controller if necessary Control board is faulty gt Replace control board Audible alarms have been muted gt Verify audible alarms are not muted Component is faulty or internal connections are loose gt Contact a qualified service technician High Temperature alarm activates quickly after plasma thawer has been turned on Chamber is empty gt Verify chamber has water High Temperature alarm will activate quickly if chamber is empty 27 Helmer Service 11 Parts NOTE gt Before replacing parts protect items in plasma thawer from extended exposure to adverse temperature gt Allow plasma thawer temperature to stabilize at setpoint after replacing parts 11 1 Front and Sides Front and left side features 115 V DH4
21. emperature range 5 From the range calculate the average temperature Remove the thermometer from the chamber 7 Determine the change in value to reach desired setpoint o EXAMPLE gt Current setpoint is 36 5 C gt Average temperature is 35 0 C Offset adjustment value is 1 5 C Enter the new offset value NOTE When there is no interaction for 60 seconds the temperature controller exits program mode 1 Enter Level 1 program mode a Press and hold the UP and DOWN buttons simultaneously for approximately 3 seconds b tunE and oFF flash on the display c The temperature controller is now in Level 1 program mode 15 Helmer Service 8 7 360097 1 I 2 Switch to Level program mode a Press and release the UP or DOWN buttons until LEVL flashes on the display b Press and hold the button c Press the UP or DOWN buttons to change the parameter value to 3 d Release the button 3 Enter the offset adjustment value Press and release the UP or DOWN buttons until ZEro flashes on the display b Press and hold the button c Press the UP or DOWN buttons to change the value to the calculated offset adjustment value d Release the button 4 Release all buttons to exit the parameter New settings are saved gt If the LEVL parameter value is changed the temperature controller returns to the selected program level 5 Exit program mode Press and hold the UP and DOWN arrow but
22. ents Labor For a period of one 1 year Helmer will cover repair labor costs provided that the product is returned to Helmer for warranty service Alternatively your facility s staff may work with a Helmer technician to make repairs on site Labor costs for repairs performed at a location other than Helmer or for repairs made without the assistance of a Helmer technician will be the responsibility of the end user Additional Warranty Information The time periods set forth above begin two weeks after the original date of shipment from Helmer Warranty procedures set forth above must be followed in all events THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE SHALL APPLY Helmer General Information 5 5 360097 1 I THE LIABILITY IF ANY OF HELMER FOR DIRECT DAMAGES WHETHER ARISING FROMA BREACH OF ANY SALES AGREEMENT BREACH OF WARRANTY NEGLIGENCE OR INDEMNITY STRICT LIABILITY OR OTHER TORT OR OTHERWISE WITH RESPECT TO THE GOODS OR ANY SERVICES IS LIMITED TO AN AMOUNT NOT TO EXCEED THE PRICE OF THE PARTICULAR GOODS OR SERVICES GIVING RISE TO THE LIABILITY INNO EVENT SHALL HELMER BE LIABLE FOR ANY INDIRECT INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES I
23. er walls and basket s If stains or discoloration remain after general cleaning use a stain scale or rust remover suitable for stainless steel 18 Helmer Service 9 2 3 9 3 360097 1 7 Reinstall the V shaped brackets 8 Reinstall the basket s 9 Reinstall the finger knobs to attach the basket s to the lift out system 10 Reconnect the plasma thawer to AC power Press the AC ON OFF button to power the plasma thawer ON Fan 100 V DH8 NOTE Cleaning the fan is applicable to 100 V DH8 models only The fan must be kept clean to maintain airflow and prevent the agitation motors from overheating In environments where the plasma thawer is exposed to excessive lint or dust the fan may need to be cleaned more frequently than stated in the maintenance schedule Clean the fan 1 Press the AC ON OFF button to power the plasma thawer and the fan OFF 2 Clean the fan using a soft brush and a vacuum cleaner 3 Press the AC ON OFF button to power the plasma thawer Maintaining Water Cleanliness When the plasma thawer is not being used place the chamber cover over the chamber to reduce contamination of the water NOTE Do not use the chamber cover while a thaw cycle is in progress When the thaw cycle is completed the lift out system raises the basket s and pushes on the cover This may push the cover off the plasma thawer and strain the lift out motor Helmer Chamber cover in place DH4 mode
24. es affected by this directive gt Do not dispose of this product as unsorted municipal waste gt Collect this product separately gt Use collection and return systems available locally For more information on the return recovery or recycling of this product contact your local distributor Warranty For technical service needs please contact Helmer at 800 743 5637 or www helmerinc com Be sure to have the model and serial number available Rapid Resolution When a warranty issue arises it is our desire to respond quickly and appropriately The service department at Helmer is there for you Helmer will oversee the handling of your warranty service from start to finish Therefore Helmer must give advance authorization for all service calls and or parts needs relating to a warranty issue Any repeat service calls must also be authorized as well This allows for proper diagnosis and action Helmer will not be responsible for charges incurred for service calls made by third parties prior to authorization from Helmer Helmer retains the right to replace any product in lieu of servicing it in the field Parts For a period of two 2 years Helmer will supply at no charge including freight any part that fails due to defects in material or workmanship under normal use with the exception of expendable items Inspection of defective parts by Helmer will be final in determining warranty status Warranty procedures must be followed in all ev
25. etpoint value Change the setpoint a Press and hold the button b Press the UP or DOWN buttons to increase or decrease setpoint in increments of 0 1 Release all buttons to exit the setpoint parameter New settings are saved 14 Helmer Service 8 6 360097 1 I Calibrate the Temperature Controller Display The temperature controller senses chamber temperature through a probe in the chamber The chamber setpoint typically varies from the measured temperature so an offset value is used by the control system to compensate for the difference P Value is factory preset and varies for each unit gt Offset value can be changed from 10 0 C to 10 0 C EL v A Temperature controller display NOTE gt Do not change the control sensor offset unless instructed in product documentation or by Helmer Technical Service gt Ifthe variance is within acceptable limits for your organization changing the offset value is optional Obtain gt Independent thermometer calibrated and traceable per national standards Determine the new offset value 1 Fill the chamber and press the AC ON OFF switch to switch the plasma thawer 2 Place the independent thermometer in the chamber Do not allow the thermometer to touch the sides or bottom of the chamber 3 Allow the chamber to stabilize for 30 minutes 4 Observe the temperature displayed on the independent thermometer temperature for 10 minutes and determine t
26. ith agitation motor C Bearing block Contact Helmer for repair options D Basket position microswitch 120266 L E Lift out motor 400504 2 all 230 V models N 400504 3 all 115 V models and 100 V DH4 400504 4 100 V DH8 F Agitation motor includes 120449 110 V and 115 V K capacitor 120307 230 V G Agitation motor gearbox 220231 H Agitation motor cam 320508 1 Pulley includes lift out cable 400295 1 J Lift out cable 400289 1 K Lift out rail 320516 1 L Bearing block assembly 400304 1 M Elbow hose 220238 Not Fan 120150 100 V DH8 shown 360097 1 30 Helmer 11 3 2 Parts Accessible from the Bottom Service Plasma thawer with bottom panel removed DH4 model shown Label Description Part Number Control board 400716 1 DH2 E 400272 2 DH4 and DH8 B Heater triac 120269 DH4 and DH8 D C Chamber heater 120551 100 V DH2 120550 115 V DH2 and 230 V DH2 120294 100 V DH4 120263 115 V DH4 and 230 V DH4 120295 100 V DH8 120264 115 V DH8 and 230 V DH8 D Alarm buzzer 120160 H E Temperature controller 400591 1 F F Temperature control 120280 G sensor 11 4 Basket Basket and lift out system parts Label Description Part Number Basket assembly 2 compartment includes bearing assemblies 400299 1 DH2 and DH4 B Basket bearing assembly includes hardware 400625 1 360097 1 31 Helmer Service Part Number Label Descri
27. l alternately display AL and the chamber temperature The red light on the temperature controller display also flashes E1 also flashes on the cycle time indicator s Temperature controller with a high temperature alarm Alarm light is circled gt If E2 appears on the cycle time indicator the basket lift out system is malfunctioning gt If FAIL alternately flashes on the temperature controller there is an operational problem with the plasma thawer Helmer Service 7 3 360097 1 I View or Change Temperature Alarm Setpoints NOTE gt Changing parameter values affects plasma thawer operation Do not change parameter values unless instructed in product documentation or by Helmer Technical Service gt The low temperature alarm is not enabled by default If the low temperature alarm is enabled follow your organization s regulations to determine the temperature setting Ensure the low temperature alarm setpoint is no greater than 30 C The monitoring and control system has alarms which activate if the chamber temperature is too high or too low if the low temperature alarm is enabled The setpoints for these alarms may be viewed and or changed using the temperature controller Temperature controller display The high temperature alarm setpoint AL hi specifies the temperature at which the High Temperature alarm should activate If the temperature detected by the temperature control sensor
28. l shown Helmer CleanBath 400348 1 may be added to the water in the chamber to inhibit bacterial growth 19 Helmer Service 9 4 360097 1 Lubricate and Service Internal Parts NOTE gt Do not press the LIFT OUT button if the basket is not attached to the lift out system The weight of the basket is required for proper positioning of the rail and cabling gt Lubricate the rails with lightweight oil Do not use grease The bearings on the baskets should be checked regularly for wear Signs of worn bearings include noisy or rough agitation and markings on the chamber walls where the bearings make contact with the chamber Lubricate the rails and bearings according to the maintenance schedule for optimal performance Bearing on the basket DH4 model shown Lubricate components 1 Confirm the basket s have been raise from the chamber Raise the basket s if necessary by pressing the LIFT OUT button for each basket 2 Press the AC ON OFF button to power the plasma thawer OFF Disconnect the plasma thawer from AC power 3 Drain the chamber a Insert the end of the drain tube into a waste container or sanitary drain b Connect the drain line to the plasma thawer by inserting the drain coupling into the drain port on the side of the plasma thawer 4 Remove the baskets a Unscrew the finger knobs securing the basket s to the lift out system b Remove the basket s from the lift out system Basket installed on
29. lectronics by turning power OFF Wait 10 seconds then switch power ON Press the LIFT OUT button If error message reappears contact a qualified service technician and FAIL alternately flashing on the temperature controller Connection between temperature controller and temperature control sensor is faulty or a part is faulty gt Check connections between temperature controller and temperature control sensor Secure connections if necessary Replace temperature control sensor or temperature controller if necessary dAtA and FAIL alternately flashing on the temperature controller Memory error with the control system gt Reset electronics by turning power OFF Wait 10 seconds then switch power ON If problem persists contact a qualified service technician 22 Helmer 10 2 360097 1 1 General Operation Problems Problem Possible Cause Service Action Main power switch is on but nothing is working Outlet connection is faulty gt Verify power at the outlet Repair original outlet or connect to a different outlet if necessary Power cord is faulty gt gt Check condition of the power cord Replace if in poor condition Verify voltage through cord is appropriate If not replace power cord Power connector is faulty Verify connections between power cord and power connector are secure Verify voltage through
30. lift out arm Finger knob circled 5 Lubricate the lift out rail a Place a maximum of 3 drops of lightweight oil on your finger b Spread the oil along the length of all 4 sides of each lift out rail gt Lubricating all 4 sides ensures the bearing is properly lubricated 6 Reinstall the basket s 7 Reinstall the finger knobs to attach the basket s to the lift out system 20 Helmer 8 Press the AC ON OFF button to power the plasma thawer ON Reconnect the plasma thawer to AC 9 5 10 10 1 360097 1 I power Service 9 Press the LIFT OUT button s to lower the basket s into the chamber Supplies Overwrap bags standard size 4 boxes of 250 bags per box 400273 1 Overwrap bags large size 1 box of 250 bags 400303 1 CleanBath bacterial growth inhibitor 8 oz 237 mL bottle 400348 1 Troubleshooting CAUTION Review all safety instructions prior to troubleshooting Refer to chapter 2 Safety Error Messages Error Message Possible Cause Action E1 high temperature alarm appears on both cycle time indicators Temperature controller has improper settings or is faulty gt Verify plasma thawer setpoint is set below High Temperature alarm setpoint and the difference is at least 1 0 C Replace controller if necessary Connection between control board and heater is faulty or a part is faulty gt Check power to heater Replace heater or control board if necessary
31. lue access Level 2 parameters change the value for the LEVL parameter to 2 d access Level 3 parameters change the value for the LEVL parameter to 3 4 Release all buttons to exit the parameter New settings are saved gt Ifthe LEVL parameter value is changed the temperature controller returns to the selected program level 5 Repeat steps 2 through 4 to access another program level or to view or change parameter values in the selected level 6 Access Level 4 parameters a Navigate to Level 3 program mode b Select the UEr parameter c Press and hold the UP and DOWN buttons simultaneously for approximately 10 seconds d The parameter flashes on the display 11 Helmer Service 7 Exit program mode a Press and hold the UP and DOWN arrow buttons simultaneously for approximately 3 seconds or b the current chamber temperature is displayed 8 1 Level 1 Parameters and Values NOTE gt Parameters are listed in order of appearance gt SP1 refers to the chamber heater gt SP2 refers to the temperature alarm gt Temperature controller is programmed at the factory with a setpoint of 36 5 C Parameter Description Default Value L LUT Autotune selection oFF bHnd SP1 proportional band gain or hysteresis in C 22 SP1 integral time reset in minutes 2 0 at rk SP1 derivative time rate 10 p SP1 derivative approach control 0 5 EYEE SP1 pr
32. nds or b the current chamber temperature is displayed 10 Helmer Service 8 360097 1 I Temperature Controller Setpoints Temperature controller setpoints are programmed at the factory Setpoints can be viewed and changed through the temperature controller Parameter values reside in 4 program levels Temperature controller display Values that are frequently changed during operation are listed below Parameter Program Function ZEro 3 Calibrate the temperature controller readout AL hi 1 Set high temperature alarm value AL Lo 1 Set low temperature alarm value View or change parameter values NOTE gt Changing parameter values affects plasma thawer operation Do not change parameter values unless instructed in product documentation or by Helmer Technical Service gt When there is no interaction for 60 seconds the temperature controller exits program mode 1 Enter Level 1 program mode a Press and hold the UP and DOWN buttons simultaneously for approximately 3 seconds b tunE and oFF flash on the display c temperature controller is now in Level 1 program mode 2 Select the parameter to be changed a Press and release the UP or DOWN buttons until the desired parameter flashes on the display b access Level 2 or Level 3 parameters select the LEVL parameter 3 Change a parameter value a Press and hold the button b Press the UP or DOWN buttons to change the parameter va
33. nnections from control board to temperature controller and from temperature controller to temperature control sensor Secure connections if necessary Replace temperature control sensor temperature controller or control board if necessary Connection between control board and heater is faulty or a part is faulty gt Check power to the heater Replace heater or control board if necessary Connection between control board and heater triac is faulty or a part is faulty gt Check power to the heater triac Replace heater triac or control board if necessary Temperature controller is not calibrated gt Confirm temperature control sensor is reading correctly Calibrate temperature controller readout if necessary 26 Helmer 10 4 360097 1 I Alarm Activation Problems Problem Possible Cause Service Action Chamber temperature meets high alarm condition but High Temperature alarm is not active visual or audible Temperature controller has improper settings or is faulty gt Verify plasma thawer setpoint is set lower than High Temperature alarm setpoint and the difference is at least 1 0 C Confirm parameters are set correctly Change parameter values or replace controller if necessary Control board is faulty gt Replace control board High Temperature alarm setpoint was changed gt Check setpoint for High Temperature alarm Change setpoint if n
34. oportional cycle time 0 5 ESE SP1 offset manual reset 0 5 SPL H Lock main setpoint oFF GP r Ramp rate if ramp is on 0 GP Ramp selection OFF SoA Soak time selection Na SP2 low alarm setpoint in C 0 0 SP2 high alarm setpoint in 37 6 hnde SP2 hysteresis or proportional band in 0 1 ryre SP2 mode selection ON OFF or proportional cycle time on oF L EUL Parameter level currently selected 1 360097 1 l 12 P Helmer Service 8 2 Level 2 Parameters and Values Parameter Description Default Value Ip Display of SP1 output power percentage read only read only h Aad Selection for manual control of power for SP1 oFF PL SP1 power limit percentage 100 2 SP2 power limit percentage cooling 0 SPER Main SP2 operating mode alarm strategy bAnd SP2h Subsidiary SP2 mode nonE di Display resolution 0 17 hi or Full scale 45 0 L ost Minimum scale 20 0 pm PL Input sensor type rtd E Units C F C L EL L Parameter level currently selected 2 8 3 Level 3 Parameters and Values Parameter Description Default Value SP ld SP1 output device type SSd1 SPed SP2 output device type read only SSd2 burn Sensor burn out protection type upscale or downscale uP SC rEuld Output mode reverse or direct 1r 2r rE LED indicator modes for SP1 and SP2 normal or inverted 1n 2n SPAR Sensor span adjust 0 0
35. ove Packing ppp E qeu ree YR SPEER Re SEGA RR 5 3 3 Lifting and Carrying the Plasma Thawer auauunuannnnaernve ee 6 4 References and Compliance 2 55 ERE eee see 6 441 Alarm Referentes scana cada des sad get KIMS RU AN Pas SYNG AS GT sc RR BUS OR Raia Bee nee dis 6 42 Regulatory Compliance cx ea i eh Se eed gas Seas aes Po eee ERR Peas EAR P ERE A RR ES 6 4 3 WEEE Compliance cs y hx eee EON Re OR AC SAR ala Sane eee LER 7 5 WaITOnly EE REESE REG RE EE 7 5 1 Rapid Resolutions oc Ee RE x eR Geta pc a ea ade AN en OR DAR ae RC RIA 7 52 PS 7 SC ED NN 7 5 4 Additional Warranty Information iisiileee RR RR Hu 7 55 Outside of USA and Canada isasi end dosale dea Pee ae eens Pad 8 Section li Service colour exams EE ERA ER ER ERRARE ERE aq Rx s 9 6 Product Configuration aucuns aija su i e aa eee rane I xn RT aya Ea a a pa ae aaa Fase 9 6 1 Install External Thermometer Optional sisse RR HH 3 9 7 Alarm SCUINGS ss exa Rr RE RREKGa RANA EET ES 9 7 1 Chamber Heater 2 0 0 0 00 0 raner rn nn hr rn 9 7 2 Active Alarms and Error Messages csi ee ke a kn Pas eed 9 7 3 View or Change Temperature Alarm Setpoints 00 000 cee es 10 8 Temperature Controller Setpoints
36. power connector is appropriate If not replace power connector Circuit breaker is tripped Verify all circuit breakers are seated Push circuit breaker to reset Fuse for main power has opened On the circuit board verify fuse has not opened Replace fuse if necessary Power switch on control board is faulty Verify control board is supplying power to other components Replace control board if necessary Main power switch is on but temperature controller is not working Connection between control board and temperature controller is loose or a part is faulty Check connections between control board and temperature controller Secure connections if necessary Confirm control board is supplying power to temperature controller Replace temperature controller or control board if necessary Main power switch Fan is faulty gt Check fan connections Verify correct voltage is is on but fan is not being received Replace fan if necessary running 100 V DH8 Basket does not lift Connection in lift out gt Review possible causes for error message E2 out or lower when system is loose or a and take recommended actions LIFT OUT button is part is faulty pressed Basket lifts out when Lift out motor is faulty gt Replace lift out motor LIFT OUT button is pressed then lowers slightly and activates an E2 alarm 23 Helmer 360097 1 I Problem Possible Caus
37. ption C Basket assembly 4 compartment includes bearing assemblies 400301 1 8 11 5 Accessories F G Accessories Label Description Part Number A Chamber cover 400769 1 DH2 400275 1 DH4 400276 1 DH8 B Security snap 320532 1 C Overwrap bags standard size 4 400273 1 boxes of 250 bags each D Coupling tube 1 75 45 mm 212041 1 E 90 fitting 220267 F Drain tube 6 1830 mm 320515 1 G Coupling valve 220233 Not Overwrap bags large size 250 bags 400303 1 DH8 shown Not Power cord 120155 110 V and 115 V DH2 and DH4 shown 120271 100 V and 115 V DH8 I SO Not CleanBath bacterial inhibitor 400348 1 shown 8 237 mL bottle 360097 1 1 32 Helmer sere 12 Schematics 12 1 DH2 MAIN POWER 100 10 V ac 50 Hz 115 10 V ac 50 60 Hz 230 10 V ac 50 60 Hz C CHAMBER HEATER connections to control board vary by voltage POWER CONNECTOR fo i o WITH POWER LINE FILTER B CIRCUIT f iy BREAKERS V TEMPERATURE CONTROLLER 100 240 Buttons on the control panel 51 Main power E CONTROL BOARD cycle 1 F6 SP1 chamber heater 55 ae 9 SP2 temperature alarm 53 Cycle time at 54 Lift out ES S5 Cycle start TEMPERATURE SENSOR F1 Agitation motor 1 0 A F2 Lift out motor 1 0 A F5 Heater 0 5 A F6 Main power 2 0 A TERMINAL STRIP L MICROSWITCHES FOR BASKET
38. rotect items in the plasma thawer from extended exposure to adverse temperatures 1 Verify the temperature controller display has been calibrated 2 Identify the current settings for the plasma thawer setpoint and the High Temperature alarm setpoint 3 Test the high temperature alarm a Change the plasma thawer setpoint to a value at least 0 5 C above the high temperature alarm setpoint b Observe the chamber temperature reading on the temperature controller The displayed temperature will increase slowly c When the displayed temperature reaches the high alarm setpoint the High Temperature alarm will activate gt An audible alarm will sound and AL hi will flash on the temperature controller d The baskets should also lift out of the chamber and E1 should flash on both cycle time indicators 4 Change the plasma thawer setpoint back to the original value Allow the temperature to stabilize at the setpoint before use 17 Helmer Service 9 2 9 2 1 9 2 2 360097 1 I Clean the Plasma Thawer The following table describes the advantages and disadvantages of each type of water used in an open water bath system Water Type Advantages Disadvantages Tap water gt Availability gt Varying levels of purity gt Accessibility gt iron and sediment content Distilled water gt Cleanliness gt Availability gt Purity gt Accessibility NOTE Do not use deionized water as it may be corrosive to the chamber and
39. t does not lift Basket movement gt Confirm there are no obstructions in chamber out or lower when the is obstructed by LIFT OUT button is something in the pressed chamber Basket movement gt Check for debris on lift out rail Remove debris is obstructed by and lubricate rail if necessary something in the lift out system Cannot change values Temperature controller Contact Helmer Technical Service on the temperature has been locked out controller Agitation is noisy or Rails and bearings on gt Confirm lift out rails and bearings have been rough lift out system are not lubricated according to the maintenance schedule lubricated Lubricate if necessary Bearing on the basket gt Check for marks where bearing contacts chamber is worn Replace basket bearing assembly if necessary Loose connection gt Visually compare operation of faulty agitation or a faulty part is system with operational lift out system DH8 preventing basket models only Verify there are no loose parts from agitating blocking movement Secure or tighten parts as properly necessary Replace agitation motor and gearbox if necessary Replace agitation cam if necessary Replace lift out rail if necessary Bearing block is faulty gt Contact Helmer Technical Service 24 Helmer 360097 1 I Problem Possible Cause Service Action Plasma thawer is connected to power but will not turn on Power cord is loose gt Verify power
40. tons simultaneously for approximately 3 seconds b current chamber temperature is displayed Change the Control Sensor Offset The temperature controller senses chamber temperature through probe in the chamber The chamber setpoint typically varies from the measured temperature so an offset value is used by the control system to compensate for the difference P Value is factory preset and varies for each unit gt Offset value can be changed from 10 0 C to 10 0 C NOTE gt Do not change the control sensor offset unless instructed in product documentation or by Helmer Technical Service gt Ifthe variance is within acceptable limits for your organization changing the offset value is optional Obtain gt Independent thermometer calibrated and traceable per national standards P Zip tie to attach thermometer to chamber temperature probe Determine the new offset value Use the zip tie to attach the independent thermometer to control probe Close door and allow chamber temperature to stabilize for 30 minutes Observe independent thermometer temperature for 10 minutes and determine temperature range From the range calculate the average temperature Remove the thermometer from the control probe Determine the change in value to reach desired setpoint aoa hwWhN EXAMPLE gt Current setpoint is 22 0 C gt Average temperature is 23 C Offset adjustment value is 1 0 C Enter the new offset v
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