PLASMA THAWING SYSTEM

MODELS DH4 and DH8

VERSION K

Operation – Service - Maintenance

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

PHONE (317) 773-9073 FAX (317) 773-9082
USA and CANADA
1-800-743-5637

Contents
PAGE
Installation……………………………………………………………….. 2
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D
Controls and Components…………………………………….………... 5

General Operation………………………………………………………. 8

A. Step-by-Step Thawing Procedure

B. Temperature Controller Programs - Descriptions and Input Values
C. Controller Lockout System
D. Accessing the Chamber Set Temperature
E. Accessing the Low and High Alarm Programs
F. Chamber Drain System
G. Plasma Overwraps
H. Chamber Cover
I. Error Codes

Quality Control………………………………………………………….. 18

A. Calibration of the Temperature Controller

B. Alarm System Test

Suggested Cleaning Procedure……………………………….………… 20

Recommended Periodic Maintenance…………………………………. 21

Troubleshooting…………………………………………………………. 22

Parts List………………………………………………………….……... 28

Wiring Schematic……………………………………………………….. 29

Installation

1) Carefully remove your new Helmer Plasma Thawer from the shipping container and remove the
protective stretch wrap from the unit - be careful not to discard the power cord, drain tubing, video
and instruction manual that may be held between the layers of the protective wrap or foam
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 packaging.

2) Remove the metal protective cover over the drain port, located on the lower portion of the left rear
side panel of the unit, by loosening the two screws located on the back of the unit. These screws
do not need to be removed, just loosened. Discard the protective cover, as it is used for shipping
purposes only, and retighten the screws.

3) Select a location for the unit keeping the following points in mind:

a. There must be a grounded outlet with adequate power provisions to meet the electrical
requirements as listed on the specification label on the back of the unit.

b. It is helpful to place the unit near a sink or drain to make draining and filling of the chamber
bath easier. It is preferable to locate a laboratory sink on the drain valve side of the unit - if
not, contact Helmer for a drain tube "U-Fitting Assembly" that will allow for easier
draining to the right side of the unit.

c. Keep the unit away from direct sunlight or high temperature areas.

d. There should be at least 8 inches (20cm) of clearance above the unit for the Basket Assembly
lift-out system to operate.

4) Make sure that the chamber is clean of any packaging debris and fill the chamber bath with
distilled or deionized water until the water reaches the desired "Fill Line." There are two "Fill
Lines" stamped in the center of the chamber back wall. The following describes what the two Fill
Lines represent:

____ ____ ____ - Maximum water level for thawing random bags.

____ ____ ____ - Maximum water level for thawing apheresis bags

Caution:
For safety purposes it is recommended to turn the main power switch to
OFF when the chamber bath is emptied of water. The power switch may be
left ON while the chamber bath is dry. However, the bottom of the chamber
will become hot and the controller temperature will initially exceed the set
temperature and trigger the high alarm system - after a period of time it will
decline back down to the set temperature and stabilize.

5) Insert the Helmer Digital Thermometer, if ordered, or a calibrated glass, digital, or small dial
thermometer into the Thermometer Holder brackets located at the back right corner of the chamber.

6) If a Chamber Cover has been ordered with the unit, the knob on the top of the cover will need to be
unscrewed and turned around so that the knob is on the exterior of the cover. The knob is installed
upside down for protection during shipping.

7) Plug the power cord into a properly selected-grounded outlet.

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8) Read through the following section “Controls & Components” to become better familiar with your
Helmer Plasma Thawed before proceeding to the “General Operation” section.

Caution:
The technical complexities of the basket assembly lift-out system require special handling
and operational guidelines by the user. Failure to follow the operational guidelines as listed
in this manual may result in unit failure.

Installation Check-List:

If Completed
Check:

____ 1. Remove drain port protector cover.

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____ 2. Chamber has been cleaned of any packaging debris

3. Verify power source (refer to specifications on the unit)

____ Grounded power outlet

____ Proper power capacity & voltage

____ 4. Nearby draining capability.

____ 5. At least 8 inches (20mm) of clearance above the unit

6. Chamber temperature calibration:

Temperature Independent
Controller Thermometer

Initial Reading ________ºC ________ºC

Calibrated Reading ________ºC ________ºC

____ 7. High alarm system check.

Signature________________________________Title____________________________

Department___________________________________________Date_______________

Controls and Components

Control Panel - The main control panel is conveniently located on the front of the unit. The power,
agitation, alarm, mute and temperature controller systems are all located on the main control panel.

Main Power Switch

Main Power Switch - The main power switch is located on the left side of the control panel
and activates power to the unit. When the main power switch is ON, the green LED light
above the power switch is illuminated.
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 Agitation System

Basket Access Button - The basket assembly can be raised or lowered at any time by pressing
this button. If the basket assembly is in a thawing cycle, pressing this button will raise the
Basket Assembly and the Cycle Time Indicator will flash. To continue the thawing cycle press
the Basket Access Button again and the Basket Assembly will lower into the chamber and the
timing cycle will continue from where it was interrupted.

Caution:
Do not operate the Basket Access lift-out systems when the
Basket Assemblies have been removed. The weight of the
Basket Assembly helps to keep the internal lift-out rail and
cable assembly properly positioned during operation.

Cycle Time Indicator - The two digital timers display the agitation cycle time (minutes),
remaining cycle time, and error messages.

Time Set Button - Programmed time settings of 0, 3, 5, 8, 10, 12, 14, 16, 18, 20, and 25
minutes, as well as a hold (“HO”) setting, are preprogrammed into the timing system. Press the
Time Set Button to advance through each preprogrammed time setting. If you wish to extend a
thawing cycle that is in progress, press this button (the digital timer display will read “HL”)
and the thawing cycle will continue indefinitely. Press the Time Set Button again and the cycle
will finish its initial programmed time.

Cycle Start/Stop Button - This button starts or stops the thawing cycle. To start a thawing
cycle after the frozen bags have been loaded and the timing cycle has been selected, press this
button. The basket assembly will automatically lower into the chamber bath, the agitation
system will start, and the timing cycle will begin to count down. To cancel a thawing cycle
after it has been started, press the Cycle Button to raise the basket assembly. This will stop the
agitation system and cancel the timing cycle.

Temperature and Alarm Systems

Digital Temperature Controller - Your Helmer Plasma Thawer incorporates a state-of-the-art PID
digital controller system and RTD sensor to accurately control the temperature of the chamber. The
controller system provides visual readouts of the chamber operating temperature, alarm system, heater
output, and other pertinent functions. All temperature, calibration, and alarm settings are made

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through the controller touch keys.

Set Key - Used to display the set temperature and to display the program function values.

Up Arrow Key - Used to increase the controller digit values in conjunction with the SET key
and to enter into the program functions in conjunction with the DOWN key.

Down Arrow Key - Used to decrease the controller digit values in conjunction with the SET
key and to enter into the program functions in conjunction with the UP key.

Heater On Indicator - This small round light, located next to the digital temperature readout
and labeled "1", will light whenever the controller sends power to the heater. This indicator
will light on and off continuously during normal use.

High Alarm Indicator - When the controller senses that the chamber temperature has
exceeded the high alarm limit, the High Alarm Indicator, located next to the digital temperature
readout and labeled as "2", will light and the audible alarm will sound. In addition, the baskets
will automatically rise out of the water and the Timing Cycle Indicators will flash. The baskets
will not be able to be lowered back into the water until the water temperature falls below the
High Alarm limit. To change the program settings for the High Alarm refer to the section
entitled "Setting the High Alarm".

Alarm Mute Button - If the High Alarm system is activated, the audible alarm can be silenced
by depressing the "MUTE" button located between the two Time Set Buttons on the main
control panel. When the MUTE button is pressed the Cycle Time Indicators will flash on and
off. The High Alarm Indicator light will remain on until the alarm condition ceases.

Basket Assembly - Each coated stainless steel Basket Assembly holds various frozen bags during the
thawing cycle. Metal holding fingers are located at the top of each compartment on the Basket
Assembly to hold the Plasma Overwraps in an upright position. Each Basket Assembly can be
removed by unscrewing the finger knob at the top of the Basket Assembly and carefully lifting the
Basket Assembly out of the chamber. DH8 models have a removable divider that can be taken off of
the Basket Assembly for larger bags requiring more space. Remove the divider by gently squeezing it
and pulling the tabs out of the slots.

Caution:
Raising or lowering the Basket Assemblies by hand can cause mechanical
failure to the internal lift-out system. Only raise or lower the basket assemblies
by use of the control panel touch keys.

Plasma Overwraps - A box of 250 disposable Plasma Overwraps is included with each new Helmer
Plasma Thawer. The Plasma Overwraps protect frozen plasma against contaminants and help to
isolate a broken plasma bag. A plastic Overwrap Holder is located on the side of the unit to
conveniently hold the Plasma Overwraps for easy access (the Overwrap Holder can be placed on either
side of the DH8 units). Large plasma Overwraps, part number 400303, are also available from
Helmer for use on DH8 units.

Heating System - The temperature of the water in the chamber is controlled by a thermostatically-

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protected heater. The temperature controller activates power to the heater that is located on the
underside of the bath chamber.

Thermometer Holder - Located at the back right corner of the chamber is a set of holes for holding a
thermometer. The Helmer Digital Thermometer, or a thermometer of your choice (glass, digital, dial),
may be placed through the top hole in the bracket that has the rubber grommet, making sure that the
thermometer extends down through the hole of the bracket within the chamber bath to keep the
thermometer in a safe position.

Circuit Breaker - The unit is protected by circuit breaker(s) that are located at the back of the unit.

Chamber Drain Connection - Located on the left side of the exterior, towards the back of the unit, is
the drain valve plug. To empty the chamber bath, simply push the one end of the drain tube that has
the drain fitting (included with the unit) into the drain valve plug until it locks into position. This will
automatically open the valve system and allow the water to flow out of the chamber. After the
chamber is empty, disconnect the drain tube fitting from the drain valve plug by pushing down on the
button located at top of the drain valve plug. If you are draining the chamber water to the right side of
the unit, contact Helmer and request a "U-Fitting Assembly." The U-Fitting Assembly will allow for
the drain tubing to run behind the unit and towards the right without kinking the drain tubing.

Specification:
Weight DH4 = 58 lbs. DH8 = 74 lbs.
115 volt amps = 6 amps = 10
watts = 690 watts = 1150
230 volt amps = 3 amps = 5
watts = 690 watts = 1150

General Operation
A. Step-by-Step Thawing Procedure

1) Start: Turn the power switch to ON and allow the chamber temperature to stabilize to the factory
preset controller value of 36.5ºC.

2) Verify Temperature Calibration: After the chamber temperature has stabilized, verify that the
chamber temperature displayed on the digital controller matches the temperature that is displayed
on a calibrated thermometer. If the controller temperature does not match with the calibrated
thermometer, refer to the section entitled "Calibration of the Digital Controller."

3) Load the Plasma Bag(s): Press the Basket Access Button to raise the basket assembly if it is still
lowered into the chamber bath. Insert a frozen plasma bag into a Helmer Plasma Overwrap and
place it into the basket assembly. Make sure that the metal finger tab on the top of the basket
assembly is inserted through the slot in the top of the Plasma Overwrap.

*When loading two bags into each side of a DH8 basket assembly, place
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 the bag with the widest profile in the basket assembly compartment that
is towards the front of the unit. If the wider bag is placed in the back
compartment the front door will not close against the thinner bag.

*The metal basket assembly dividers located between each compartment

on the DH8 units may be removed to allow for large size bags to be held
in the basket assembly. Large size Overwraps are available from
Helmer to protect larger bags from water contamination.

4) Set the Cycle Time: Press the Time Set Button to advance through the pre-programmed times
until the desired cycle time is selected. The following are some general timing guidelines to work
from:
(minutes)
Bag Size Manner Frozen Timing Range
250ml random Fully Flat 8-12
300ml random Fully Flat 12-16
250ml random-thick plastic Fully Flat 14-18
250ml random Folded 14-20
Apheresis or "Jumbo" bag Flat 16-20

The above are common time ranges that have been experienced by other users. As a result of the
many various factors that effect the thawing time of frozen plasma, your thawing times may differ
from the above listed time ranges.

5) Start the Thawing Cycle: Press the Start/Stop Button to begin the thawing cycle. The basket
assembly will automatically lower into the chamber bath and begin agitating. The Cycle Time
Indicator(s) will begin to count down the minutes remaining in the thawing cycle for the
corresponding basket assembly.

6) Interrupting the Thawing Cycle: You can raise and lower the basket assembly at any time
throughout the thawing cycle by two means:

1) Pressing the Basket Access Button will raise the basket assembly and the digital Cycle Time
Indicator will hold and flash. Press the Basket Access Button again and the basket assembly
will lower back into the chamber and continue the thawing cycle from where it was interrupted.

2) Pressing the Start/Stop Button will raise the basket assembly, stop the thawing cycle, and reset
the digital Cycle Time Indicator.

7) Completion of the Thawing Cycle: After the thawing cycle is completed the agitation will stop,
the basket assembly will automatically lift out of the chamber, a tone will sound five times, and the
cycle Time Indicator will reset itself in preparation for the next thawing cycle.

For maximum performance, the Helmer Plasma Thawing Systems are designed
to be used for one thawing cycle and then set idle until the bath water returns to
the set temperature. Running consecutive cycles will in no way damage the unit
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but will result in progressively slower thawing cycles if the bath water is not
allowed to return to the set operating temperature.

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 B. Temperature Controller Programs

The PID digital controller contains internal programs that effect the operation and accuracy of the
controller and alarm system. A few of the internal programs may be altered by the operator for
specific requirements and are noted below by an asterisk (*). The remaining program functions
must not be altered without consulting Helmer - doing so could effect the operation of the unit
and the manufacturer's warranty. The following is a summary of the controller's internal programs
with their description and proper value settings:

Main Program Program Program Program

Titles and Access Description Display Value

1. Operating Set Temp.

Press SET key Chamber Set Temperature *36.5

2. Operations Menu
Press UP and DOWN Auto-tune Aut no
keys together for 3 Low Alarm Deviation ALO *OFF
seconds High Alarm Deviation Ah1 *37.6
PID Menu Pid no
Configuration Menu CnFg no

3. PID Menu
Change the "PId" Proportional Band Pb h 2.0
Menu setting to "yes" Cycle Time Ct h 0.5
Integral Function It 30.00
Derivative Function dE 0.40
Calibration Offset CAL *varies

4. Configuration Menu
Change the "CnFg" Input Type In rt.d
Menu to "yes" Celsius C_F ºC
Temperature Low Limit rL 20.0
Temperature High Limit rh 45.0
Output 1 Function Ot1 hEAt
Output 2 Function Ot2 ALr7
Display Default dISP Ac
Alarm Type ALty Prno
Alarm Hysteresis AhyS 0.1
Alarm Latch LAt no
Alarm Silencing SIL no
Failure Mode FAIL bPLS
Set Point Lockout SLOC *no
Controller Lockout Tag tAg _C_A

C. Controller Lockout System

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A) Factory Lockout Mode: tag = (_C_A)
The digital Temperature Controller has been set in a “factory lockout” mode. This means
that the user can access the Set Temperature, Low and High Alarms, Calibration Offset and
the Controller Lockout program values.

B) Full Lockout Mode: tag = (PCOA)

If the Controller Lockout is set to “PCOA” then all controller programs will be
inaccessible, except the Set Temperature.

C) Unlocked Mode: tag = (_ _ _ _)

If the Controller Lockout Tag is set to “_ _ _ _”, then all controller programs will be
accessible to the user.

D) Set Point Lockout: (SLOC) = “yes” or “no”

If the Set Point Lockout is set to “no”, the operating set temperature can be changed by the
user. If the Set Point Lockout is set to “yes”, the operating set temperature is locked and
can not be changed.

1) Accessing the Controller Program Lockout:

1) Press and hold the Up and Down arrows until a controller program is displayed. If the
lockout is in the factory lockout setting, the first controller program to appear will be
“ALO”. If the "Aut" prompt appears, the controller programs are fully unlocked. If the
"CnFg" prompt appears, the controller programs are fully lockout.

2) Press the up or down arrow until the "CnFg" prompt appears.

3) While pressing the SET key in (the digital readout will display "no”) press the Up or Down
key to display "YES", and then release the SET key. If the "IN" prompt appears, proceed to
step 4. If the "tAg" prompt appears, you are at the program display for the Controller
Lockout Tag, proceed to step 5.

CAUTION
Do not change the “In” or “°C” program values. Doing so automatically changes
many of the controller program values causing uneven temperature controlling of the
chamber bath.

4) Press the Up arrow once to display the "tAg" prompt. You are now at the program display
for the Controller Lockout Tag.

5) Press and hold the SET key to display the current input value of the "tAg" program.

6) To change the lockout program value, hold the SET key in and press the Up or Down
arrows to change the program value.

7) To exit back to the main operating mode, release the SET key and press both the UP and
Down arrows until the operating temperature appears on the digital display.

2) Accessing the Set Point Lockout (SLOC):

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1) With the controller fully unlocked, (refer to steps 1-6 in the Accessing the Controller
Program Lockout), press and hold the Up and Down arrows until a controller program is
displayed.

2) Press the Up or down arrow until the "CnFg" prompt appears.

3) While pressing the SET key in (the digital readout will display "no"), press the Up or Down
key to display "YES", and then release the SET key. The "In" prompt will appear.

4) Press the Up arrow twice to display the "SLOC" prompt. You are now at the program
display for the Set Point Lockout.

5) Press and hold the SET key to display the current input value of the Set Point program -
either "YES" or "no" will be displayed. The "YES" prompt means that the Set Point
Lockout is in the Lockout mode. The "no" prompt means that Set Point Lockout is
Unlocked.

6) To exit back to the main operating mode, release the SET key and press both the UP and
Down arrows until the operating temperature appears on the digital display. If you want to
reset the lockout function, do so before returning to the main operating mode.

7) To change the program value simply hold the SET key in while pressing either the Up or
Down key once.

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14 1-360008/G
 D. Accessing the Chamber Set Temperature

To alter the chamber temperature setting:

1) Press and hold the SET key to display the current set temperature input value.

2) Press either the Up or Down keys to alter the set point as desired. If the set point
temperature will not change, the Set Point Lockout is in the lockout mode - refer to
"Accessing the Set Point Lockout" to unlock this program value.

3) Release the SET key to complete the chamber temperature setting change.

E. Accessing the Low and High Alarm Programs.

To alter the Low and/or High Alarm settings:

1) Press and hold the Up and Down arrow keys until a controller program is displayed. If the
"CnFg” prompt appears, the Controller Program Lockout will need to be unlocked - refer to
"Accessing the Controller Program Lockout" to unlock this program value.

2) Press the Up or Down arrow key until the “ALO” program appears for the Low Alarm, or
“Ahl” for the High Alarm program.

3) While holding the SET key down, press the Up or Down arrow keys to alter the set point
value as desired.

4) To exit back out to the main operating mode, release the SET key and press both the UP and
Down arrows until the operating temperature appears on the digital display.

F. Chamber Drain System

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The Helmer Plasma Thawers are equipped with a unique disconnect drain valve system to empty the
chamber bath quickly and easily. The built-in quick drain system provides for frequent and fast
draining of the chamber - it can even be done daily - which will greatly help in maintaining a clean
chamber. The procedure for draining the chamber bath is as follows:

Caution:
For safety purposes turn the power switch OFF
before draining the chamber bath.

1) Place the open end of the drain hose securely into a sink or drain.

2) Push the other end of the drain hose with the coupling valve into the drain plug that is
located on the left side of the unit towards the back, until it "clicks" securely in place. The
chamber water will immediately begin to flow out of the chamber until it is empty. Squeeze
the tubing just after the coupling and release to remove any air pockets, improving the speed
of draining.

3) After the chamber bath has fully drained, press down on the button located on the top of the
drain plug to disconnect the drain hose.

If draining to the right side of the unit, contact Helmer and request a drain tube "U-Fitting Assembly."
This will allow the drain tubing to be easily run to the right side of the unit.

G. Plasma Overwraps

Included with the unit is a dispenser box of 250 Helmer Plasma Overwraps. The disposable Plasma
Overwraps protect frozen random and apheresis plasma against contaminants, as required by AABB
standards, and isolate a broken FFP bag. To access the Plasma Overwraps carefully remove the
perforated section at the one end of the dispenser box and place the dispenser box into the plastic
holder on the side of the unit. Individual Plasma Overwraps can now be easily removed from the
dispenser box as needed.

Carefully fit a frozen plasma bag into a Plasma Overwrap and place it into one of the compartments in
the Basket Assembly. Make sure that the metal finger tab on the top of the Basket Assembly is
inserted through the slot at the top of the Plasma Overwrap - this will prevent the Overwrap from
falling down into the chamber.

To order more Helmer Plasma Overwraps - part number 400273 -

contact Helmer (USA and Canada) at 1-800-743-5637 or your local
Helmer distributor. Helmer also has available large size Overwraps for
use with DH8 units.

H. Chamber Cover

The chamber cover is designed to aid in the reduction of airborne contaminates, bacterial growth, and
water evaporation. The chamber cover is intended to be used only during those times that the
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Plasma Thawer is not being used to thaw frozen plasma - if the chamber cover is placed on the unit
during a thawing cycle it will be pushed off when the basket assembly automatically lifts out of the
chamber at the end of the thawing cycle. Chamber covers are an optional accessory on units sold in
the USA and Canada.

I. Error Codes

The system software can diagnose certain problems with the unit and communicates the diagnosis
through error messages on the Cycle Time Indicator. Following is a summary of the error codes and
their respective problems. Refer to the "Troubleshooting" section of the manual for further
information on resolving problems that occur.

Control Panel
Error Code Problem

E1 The water temperature has exceeded the high alarm setting.

E2 Liftout mechanism malfunction. Turn the main power switch

OFF and refer to the "Basket Assembly and Agitation System"
section in "Troubleshooting".

Temperature
Controller
Error Code Problem

Er 1 Reversed sensor wires.

Er 2 Incorrect input value (“In”) in the configuration menu or open RTD.

Er 3 Sensor type mismatch.

Er 4 Open RTD sensor, bad connection, broken wire.

Quality Control
A. Calibration of the Temperature Controller

To verify that the digital temperature controller is calibrated correctly allow the chamber temperature
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to stabilize and then take a temperature reading from a calibrated thermometer inside the chamber
bath. If the thermometer reads the same as the controller display, the temperature controller is
calibrated correctly. If there is a temperature variance, the temperature controller needs to be
calibrated.

As an example, if a calibrated thermometer reads 35.5ºC and the Temperature Controller reads 36.5ºC,
then the controller display ("CAL" function) needs to be reduced by 1.0ºC. If the thermometer reads
37.5ºC and the Temperature Controller reads 36.5ºC, then the controller display ("CAL" function)
needs to be increased by 1.0ºC.

To recalibrate the Temperature Controller:

1) Press and hold the Up and Down arrow keys until a controller program is displayed. (If the
"CnFg" prompt appears first, the Controller will need to be unlocked - refer to "Accessing the
Program Lockout").

2) Press the Down arrow key until the "PId" Menu prompt appears.

3) While pressing the SET key in (the digital readout will display "no"), press the Down arrow
key to display "yes", and then release the SET key.

4) Press the Up arrow once to display the "CAL" prompt.

5) While holding the SET key down, press either the Up or Down arrow keys to alter the
calibration program value.

6) To exit back to the main operating mode, release the set key and press the Up and Down
arrow keys simultaneously until the operating temperature appears on the digital display.

After making any calibration changes to the Temperature Controller allow the chamber temperature to
stabilize and make a new reading to verify that the controller is properly calibrated. Make any
additional adjustments as needed until the controller readout is properly calibrated.

B -Alarm System Test

To test that the High Alarm System is working properly, it is recommended to follow methods that
may be recommended by the AABB or other governing organizations for such alarm system checks.
A suggested method to activate an actual high alarm test condition is as follows:

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1) Remove any plasma or other such critical products from the unit.

2) Increase the Set Temperature value at least 0.5ºC above the High Alarm set point (refer to
Accessing the Chamber Set Temperature). As an example, if the High Alarm is set at
37.6ºC, then change the Set Temperature value to 38.1ºC.

3) Watch the chamber temperature digital readout until it reaches the High Alarm setting,
whereupon, the visual and audible alarms should activate, the basket assemblies should lift
out of the chamber, and the digital agitation timers should blink "E1."

4) After conducting this high alarm system test, reset the chamber Set Temperature to the
desired value and allow the chamber temperature to stabilize before using.

Suggested Cleaning Procedure

Water Type: Use DISTILLED or DEIONIZED water – the use of

“hard” non-purified waters can result in stains and Deposits within
the chamber bath and on the basket assemblies.

Bath Cleaner/ Inhibitor: Use a sanitizing / algaecide agent such as:

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 Professional Lysol No Rinse Sanitizer®
Roccal II®
Clear Bath®

The active ingredient for the above products is

Alkyl Dimethyl Ammonium Chloride.

On a weekly basis, or as is determined to be needed for your conditions, clean your Helmer
Plasma Thawer as follows:

1. Turn the power switch Off.

2. Fully drain the existing water from the chamber bath – refer to “Chamber Drain System” section.

3. Remove the basket assemblies from the unit. The two V-shaped stainless steel brackets located on
the back wall of the chamber bath are held in place by two screws and may also be removed for
cleaning when necessary.

4. Using a soft cloth or sponge and a solution of distilled or deionized water with bath
cleaner/inhibitor, thoroughly clean the chamber bath walls and basket assemblies. If water stains
or deposits remain, use a general-purpose stain or scale remover that is compatible with stainless
steel.

5. Install the V-brackets if removed.

6. Refill the chamber with distilled or deionized water and add the proper amount of bath
cleaner/inibitor.

7. Install the basket assemblies.

Recommended Maintenance

1. Routine cleaning of the chamber bath, basket assemblies, and unit exterior will help to increase the
units operating life.

2. A high alarm test and temperature controller calibration test should be conducted on a regularly
scheduled basis.

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3. On a quarterly basis lightly lubricate the basket assembly lift-out rail. This is done by placing no
more than 2 or 3 drops of a light duty oil (not grease) on your finger and rubbing the oil up and
down the rail. Apply the thin coat of lubrication to each of the 4 sides on both lift-out rails.

Troubleshooting

Main Power

Problem Possible Cause Action to be taken

Unit does not turn on - Circuit breaker activated - Reset circuit breaker

- Faulty outlet connection - Verify power outlet is good

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 - Verify power cord is plugged in unit

- Faulty power cord - Verify proper cord connections

- Change power cord

- Faulty power switch - Replace switch on circuit board

Chamber Temperature

Chamber bath getting too - Controller not calibrated -Verify calibration with thermometer.
cold or getting too warm Refer to “Calibration of Temperature
Controller

- Faulty controller -Verify controller is giving DC power

output to heater circuit

- Replace controller as needed

- Faulty heater - Verify voltage to heater

- Replace heater as needed

- Faulty circuit board - Verify voltage to heater

- Replace circuit board as needed

- Faulty RTD sensor - Verify sensor is adhered to chamber

- Verify connections to the controller

- Replace as needed

Chamber temperature - Calibrate Controller - Refer to "Calibration of the

not calibrated to Temperature Controller"
controller

Temperature Controller and High Alarm Systems

Controller does not turn - Faulty connections - Verify connections from circuit
on board to controller

- Faulty controller - Verify voltage to controller Change

controller

Controller not calibrated - Calibrate controller - Refer to "Calibration of Temperature

Controller”
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Cannot change controller - Controller is locked out - Refer to "Setting the Lockout
values Function"

Audible alarm not - Faulty connections - Verify proper line connections

sounding

- Faulty controller - Verify that High Alarm Indicator

light is operating

- Verify voltage from the alarm

outputs on the controller to circuit
board

- Replace controller as needed

- Faulty circuit board - Verify voltage from the alarm

outputs on the controller to circuit
board

- Verify DC voltage to the alarm

- Replace circuit board as needed

- Faulty alarm - Replace alarm as needed

Alarm not activating at - Incorrect alarm function - Verify that the desired high alarm
high alarm setting value temperature value is correctly
inputted into the controller Refer to
“Setting the High Alarm”

- Calibrate controller - Refer to "Calibration of Temperature

Controller"

- Temperature & Alarm - Adjust the settings so that there is a

settings are too close to each minimum 0.5 to 1.0ºC range
other. between the Temperature & alarm
setting.

Alarm sounding after - Adjust controller ramping - Increase the "dE" controller program
thawing of plasma speed value by “0.20” increments until the
temperature over-shooting stops.

Displays “Er 1” - Reversed sensor connections - Change the sensor leads on terminals
1 & 2.

Displays “Er 2” or “Er 3” - Sensor type mismatch - Verify the “In” value reads “rt.d”

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 - Open RTD sensor - Replace RTD sensor.

Displays “ Er 4” - Faulty sensor or sensor - Check the sensor and sensor

connection connection. Replace as necessary.

Basket Assembly and Agitation Systems

The Basket Assembly does - Blown fuse on circuit board - Check fuse on circuit board. (See
not raise and lower schematic for location.)

- Faulty lift-out motor - Verify power to the lift-out motor

- Replace lift-out motor as needed

- Faulty motor capacitor - Verify power to the motor capacitor

- Replace motor capacitor as needed

- Lift-out roller wheel is loose - Verify that the roller wheel is tight to
the shaft of the lift-out motor.

- Tighten the roller wheel set screw

- Faulty connection - Verify wiring connections from the

circuit board to the lift-out motor
assembly

- Faulty positioning switches - Verify that the two positioning

micro-switches at the roller wheel
are operating properly

- Faulty lift-out cable - Verify that the lift-out cable is

assembly properly secured to the lift-out roller
wheel and to the roller block
attached to the rail
- Replace cable as needed

- Faulty circuit board - Verify voltage out of the main circuit

board to the lift-out motor assembly

- Verify that circuit board push-button

switch is operating correctly

- Replace circuit board as needed

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 - Debris in lift-out assembly - Verify that the roller bearing block is
not jammed and has free movement

- Verify that the screw attaching the

cable to the roller wheel is tightened

- Basket assembly - Verify that the basket assembly is

not catching on something in the
chamber

- Verify that the finger screw is secure

and that the basket assembly is
properly attached

The basket assembly does - Blown fuse on circuit board - Check fuse on circuit board.(See
not agitate schematic for location.)

- Agitation Power Switches - Switch to ON position

not in ON position

- Faulty connections - Verify that connections from the

circuit board to the agitator motor
assembly

- Loose cam wheel - Verify that the cam wheel is securely

attached to the agitation motor shaft

- Faulty motor capacitor - Verify that the motor capacitor is

operating correctly

- Replace as needed

- Faulty agitation motor - Verify that the agitation motor is

operating correctly

- Replace as needed

- Debris in bearing system - Verify that the rail slides freely up

and down in the bearing block

- Basket assembly - Verify that the basket assembly is

not catching on something in the
chamber

- Verify that the finger screw is secure

and that the basket assembly is
properly attached.

25 1-360008/G
It is very noisy when the - Faulty lift-out motor - Verify that the lift-out motor is
basket assembly raises operating properly
and lowers and/or when
agitating

- Replace as needed

- Faulty roller bearing block - Verify that the rail moves freely up
and down in the roller bearing block

- Verify that there is no debris in the

roller bearing block or on the rail

- Faulty agitation motor - Verify that the agitation motor is

operating properly

- Replace as needed

- Basket assembly - Verify that the finger screw on the

top of the basket assembly is tight

- Basket assembly bearing - Verify that the plastic roller bearings

at the bottom of the basket assembly
are operating properly

- Replace as needed

Thawing Cycle

Thawing cycle will not - Faulty push button - Verify Start/Stop button is activating
start the timing cycle; replace as needed

- Faulty circuit board - Verify wiring connections from

circuit board to motor assemblies

- Verify that the circuit board is

securely mounted to the chassis
studs

- Replace circuit board as needed

- Faulty positioning switches - Verify that the two positioning

micro- switches at the roller wheel
are operating properly

26 1-360008/G
Cycle Time Indicator - Circuit board - Verify wiring connections on circuit
does not count down board
correctly

- Verify Start/Stop button is activating

the timing cycle

- Verify that the circuit board is

securely mounted to the chassis
studs

- Replace circuit board as needed

Digital timer does not - Faulty digit light - Replace the digit light or circuit
display board

Preprogrammed time - Push button not activating - Verify Time Set Button activates
settings do not advance when pressed; replace as needed
when the Time Set Button
is pressed

- Verify that the circuit board is

securely mounted to the chassis
studs

- Faulty circuit board - Replace as needed

DH4 and DH8 Parts List

Description Part Number

Digital Temperature Controller 400330

Main Controller Board 400272
Heater Triac 120269
RTD sensor 120280
Power inlet 120282
Alarm 120160
Heater (DH4) 120263 – 115v 120263 – 230v 120294 – 100v
Heater (DH8) 120264 – 115v 120264 – 230v 120295 – 100v
Circuit breaker (DH4) 120272 – 115v 120279 – 230v 120110 – 100v
Circuit breaker (DH8) 120281 – 115v 120288 – 230v 120281 – 100v
Fan (DH8) 120150 – 100v

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Lift-out motor (DH4) 120274 – 115v 120277 – 230v 120276 – 100v
Lift-out motor (DH8) 120274 – 115v 120277 – 230v 120278 – 100v
Lift-out capacitor 120204 – 115v 120260 – 230v 120204 – 100v
Lift-out wheel assembly 400295
Lift-out cable 400289
Microswitch 120266

Agitation motor 400257 – 115v 400258 – 230v 400257 – 100v

Agitation motor gearbox 220231
Agitation motor capacitor 120047 – 115v 120301 – 230v 120047 – 100v
Agitation cam wheel 1-320508
Agitation roller bearing block 400304
assembly

Basket Assembly (DH4) 400299

Basket Assembly (DH8) 400301
Basket Thumb Screw 230193
Basket Arm Assembly 400302
Thermometer Grommet 220038

Overwrap bags (1000/case) 400273

Large Overwrap Bags (250/case) 400303
Overwrap plastic holder 1-320513

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