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Helmer i.Series Service Manual

Undercounter freezer
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See also: Service Maintenance Manual , Operating Manual
Undercounter Freezer
Service Manual
i.Series™ and Horizon Series™
Plasma Models
•
i.Series: iPF105 (Version B)
•
Horizon Series: HPF105 (Version B)
Laboratory Models
•
i.Series: iLF105 (Version B)
•
Horizon Series: HLF105 (Version B)
Model
S/N
0086
ISO 13485:2003 CERTIFIED
360142-1/E
HELMER, INC.
14395 Bergen Boulevard
Noblesville, IN 46060 USA
Phone +1 (317) 773-9073
USA and Canada (800) 743-5637

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Summary of Contents for Helmer i.Series

  • Page 1 Undercounter Freezer Service Manual i.Series™ and Horizon Series™ Plasma Models • i.Series: iPF105 (Version B) • Horizon Series: HPF105 (Version B) Laboratory Models • i.Series: iLF105 (Version B) • Horizon Series: HLF105 (Version B) Model HELMER, INC. 14395 Bergen Boulevard...

  • Page 3: Table Of Contents

    Section II: i.Series™ Models........
  • Page 4 Undercounter Freezer Service Manual 8 Parts ..............44 Control and monitoring .
  • Page 5 Contents 15 Maintenance ............88 15.1 Recharging refrigerant .
  • Page 6 Undercounter Freezer Service Manual This page left blank intentionally. 360142-1/E...

  • Page 7: Section I: General Information

    Section I: General Information Section I: General Information 360142-1/E...
  • Page 8 Undercounter Freezer Service Manual This page left blank intentionally. 360142-1/E...

  • Page 9: About This Manual

    , i.C³ , Horizon Series™, and Rel.i™ are registered trademarks or trademarks of ™ Helmer, Inc. in the United States of America. Copyright © 2012 Helmer, Inc. All other trademarks and registered trademarks are the property of their respective owners. 360142-1/E...

  • Page 10: Safety

    Decontaminate parts prior to sending for service or repair. Items not decontaminated appropriately will not be accepted. Documentation stating contents are not contaminated and are safe to handle must accompany returns. Contact Helmer or your distributor for decontamination instructions and a Return Authorization Number. 360142-1/E...

  • Page 11: Configuration

    3.2.1 i.C³ control system i.Series freezers are equipped with the i.C³ monitoring and control system. The i.C³ system combines temperature control and monitoring into a single interface, displaying multiple information logs with historical information in full color. The touchscreen monitor, located on the freezer door, displays operational information.

  • Page 12: Preparing The Temperature Probe

    Preparing the temperature probe The temperature probe monitors chamber temperature. In addition to using standard probes installed by Helmer, external probes may be introduced through the existing rear port and immersed in the existing probe bottle. For each probe bottle, obtain: ► Approximately 4 oz (120 ml) of product simulation solution.

  • Page 13: Preparing The Chart Recorder

    General Information: Configuration Preparing the chart recorder If installed, see the Temperature Chart Recorder Operation and Service Manual on CD. Complete these tasks to prepare recorder for use: ► Installing the backup battery. ► Adding paper. ► Calibrating the chart recorder to match the chamber temperature. 3.4.1 Accessing the chart recorder ► Pull the door open.
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  • Page 15: Section Ii: I.series™ Models

    Section II: i.Series™ Models Section II: i.Series™ Models 360142-1/E...
  • Page 16 Undercounter Freezer Service Manual This page left blank intentionally. 360142-1/E...

  • Page 17: Product Configuration

    Product Configuration Installing batteries for backup power The monitoring systems and chart recorder each have a battery backup system, enabling a period of continuous operation if power is lost. NOTE The monitoring systems will start on battery power alone. If the freezer was previously not connected to AC power and the backup battery is connected or switched on, the monitoring system will begin running on battery power.

  • Page 18: Freezer Setpoint Configuration

    Undercounter Freezer Service Manual 4.2 Freezer setpoint configuration The temperature controller adjusts chamber temperature around the freezer setpoint. The controller activates the compressor when the chamber probe registers temperature above the setpoint. The controller also senses unit cooler temperature through a probe in the cooler. The temperature in the unit cooler typically varies from the temperature in the chamber, so an offset value is used in the control system.

  • Page 19: Automatic Defrost Cycle Configuration

    4.2.2 Changing freezer setpoint The default setpoint is either -20.0 °C or -30.0 °C, depending on use. Change the setpoint if: ► Your organization requires a chamber temperature different from the default setting. ► The normal chamber temperature is too high or low, even after completing preventive maintenance and applicable troubleshooting tasks.

  • Page 20: External Monitoring Devices

    Do not connect any monitoring device that exceeds the maximum load capacity for your model. The freezer provides a remote alarm interface to send information to external devices, such as the Helmer Remote Alarm Monitoring System. For more information and availability, contact Helmer or your local distributor.

  • Page 21: Moving Drawers, Shelves, And Baskets

    Moving drawers, shelves, and baskets Storage features (availability of shelves, drawers, and baskets varies by model). NOTE Plasma freezer models (iPF) feature drawers as the standard storage configuration. Laboratory models (iLF) feature shelves as the standard storage configuration. Any combination of drawers, baskets, and shelves may be installed.

  • Page 22: Leveling The Freezer

    After the freezer has been placed, the leveling feet must be adjusted in order to provide proper drainage of condensation from the evaporator coil, inside the unit cooler. NOTE Helmer recommends the use of leveling feet. Level the freezer front-to-back Use a wrench to adjust the leveling feet.

  • Page 23: Door Characteristics

    Door characteristics In general, service information varies depending on the door characteristics. In Helmer undercounter freezers, the single door is solid (standard configuration). The door has a spring-loaded, self-closing hinge set, which may be located on the right or the left side of the door frame.
  • Page 24 Undercounter Freezer Service Manual On the access panel, pull the plug out of the hole on the handle-side of the freezer. Pull the grommet out of the hole on the hinge-side of the freezer. Slide the braided sleeve out of the slot. Pull grommet Pull plug out Slide sleeve...
  • Page 25 Without Access Control option: Remove the two (2) screws holding the door latch plates and spacer bar from the cabinet and set the assembly aside. With Access Control option: Remove the two (2) screws holding the door catch to the cabinet and set the catch aside.
  • Page 26 If a shim is needed for proper door leveling, contact Helmer Technical Service. 11 Lay the door face-down in front of the cabinet. Ensure that there is no strain on the cable(s) passing from the cabinet to the door.
  • Page 27 13 Lift the door to the front of the cabinet, aligning the holes in the hinges with the corresponding holes in the cabinet. Loosely install three (3) screws in each hinge to attach the hinges to the cabinet. Do not allow the weight of the door to rest on the hinges.

  • Page 28: Hinge Reversal (Glass Door And Solid Door)

    Undercounter Freezer Service Manual 4.10 Hinge reversal (glass door and solid door) The undercounter door is comprised of an inner frame and outer frame (A). A gray power cable (B) and black communication cable (C) are connected to the display circuit board on the front of the door (behind the LCD touchscreen).
  • Page 29 Re-route the power cable and communication cables inside the door and along the opposite side of the door frame. The cables should follow the edge of the door frame as closely as possible. Tape the cables to the door frame. The excess slack in the cables should be outside of the door. If the freezer is equipped with the Access Control option, reverse the installation of the Access Control power cable and tape the cable to the door frame.

  • Page 30: Hinge Spring Assembly Reversal

    When stacking a refrigerator and a freezer, always place the freezer on the bottom. Call Helmer or your distributor for more information on the stacking kit, and on optional ways to secure both units to the wall and/or the floor.

  • Page 31: Temperature Controller Programs

    Models: Temperature Controller Programs Temperature Controller Programs NOTE The Lower Temperature calibration setting is not applicable to undercounter freezer models. Left: Temperature Controller Programs screen. Right: Temperature Calibration screen. Settings The i.C³ temperature monitor and controller is programmed at the factory with the settings that are listed in this chapter.

  • Page 32: Temperature Setpoint Settings

    CAUTION The hysteresis setpoint is factory-preset and should not be changed unless directed by Helmer Technical Service. Touch i.C³ APPS, i.C³ Settings. Enter the Settings password then touch Temperature Setpoints. Touch plus (+) or minus (-) on the Temperature Setpoint spin box.

  • Page 33: Temperature Calibration Settings

    The Control Sensor and Control Sensor Offset, Evaporator Defrost and CAUTION Evaporator Defrost Offset, and Compressor Probe Temperature settings are factory-preset and should not be changed unless directed by Helmer Technical Service. Touch Home, i.C³ APPS, Settings. Enter the Settings password.
  • Page 34 Undercounter Freezer Service Manual The Evaporator Defrost Offset value is set at the factory and should not be changed unless directed by Helmer Technical Service. Setting Setting description Default value Control Sensor Calibrated temperature of the Varies (set at the factory to match...

  • Page 35: Maintenance

    Models: Maintenance Maintenance CAUTION See Operation Manual for the preventive maintenance (PM) schedule. Recharging refrigerant CAUTION The procedures in this chapter should only be completed by trained refrigeration technicians who are familiar with the terminology and processes described here, as well as with local and organizational regulations regarding refrigerant leaks.

  • Page 36: Checking The Monitoring System Backup Battery

    Undercounter Freezer Service Manual Checking the monitoring system backup battery CAUTION Checking the monitoring system rechargeable backup battery requires that power be disconnected from the freezer, which may affect the chamber temperature. Before testing the alarm, take precautions to protect items in the freezer from extended exposure to adverse temperatures.

  • Page 37: Defrosting The Freezer

    Models: Maintenance Interior Clean painted surfaces with mild detergent. Clean stainless steel surfaces with a general-purpose laboratory cleaner suitable for stainless steel. Door gaskets Clean door gaskets with a soft cloth and mild soap and water solution. Clean and refill probe bottles NOTE A replacement kit that includes a probe bottle and glycerin is also available from Helmer.

  • Page 38: Removing And Installing The Unit Cooler Cover

    Undercounter Freezer Service Manual Removing and installing the unit cooler cover The unit cooler cover has a port to drain condensation generated in the cooling process. If the unit cooler cover is not removed correctly, the drain port may be damaged. Improper drainage may result in excessive icing in the freezer and the freezer’s inability to maintain the temperature setpoint.
  • Page 39 Models: Maintenance While holding the unit cooler cover in place to prevent it from dropping, use the socket wrench to remove the four screws securing the cover to the unit cooler. Gently lower the cover to avoid damaging the unit cooler fan wiring.

  • Page 40: Removing And Replacing The Access Control Cartridge

    Pull the electrical wiring out of the door handle to expose the spade connectors. Separate the two pairs of spade connectors. Remove the three screws securing the handle and cartridge to the door. NOTE To obtain a #10 spanner driver (part number 220559), Contact Helmer Technical Service. Remove NOTE Nylon spacers are installed over the middle and lower screws, between the handle and the door.
  • Page 41 Models: Maintenance To install the replacement Access Control cartridge Place the cartridge inside the handle, aligning the holes in the cartridge with the holes in the handle. While holding the cartridge in the handle, insert a screw through the upper hole in the handle, then through the door latch, latch bushings, and the cartridge body.

  • Page 42: Supplies

    Undercounter Freezer Service Manual Supplies Refrigerant: non-CFC R-404A Chart paper: 220419 (52 sheets) Glycerin solution: 400922-1 Monitoring system backup battery One 12 V, 7 Ah rechargeable sealed lead acid battery: 120628 Chart recorder backup battery One 9 V non-rechargeable alkaline (or equivalent) battery: 120218 360142-1/E...

  • Page 43: Troubleshooting

    Models: Troubleshooting Troubleshooting CAUTION Review all safety instructions prior to completing troubleshooting recommendations. See chapter 2 (Safety). General operation problems Problem Possible Cause Action ► Pull the drawer or basket out and confirm the A drawer or basket does There is debris in the not slide easily.

  • Page 44: Chamber Temperature Problems

    Undercounter Freezer Service Manual Chamber temperature problems Problem Possible Cause Action ► Test the chamber probe connections. Secure The chamber The connections for the temperature displayed is chamber temperature the connections if necessary. higher or lower than the probe are loose. ► Check the continuity of the probe wiring.

  • Page 45: Alarm Activation Problems

    A component is faulty or internal connections are loose. ► Verify that audible alarms are not muted. Audible alarms are muted. For i.Series, if time remaining is greater than 5 minutes, change MUTE timer value to 5 minutes and wait until timer resets. 360142-1/E...
  • Page 46 ► Check the current setpoints for the alarms. The alarm setpoint was changed. ► Contact Helmer Technical Service. A component is faulty or internal connections are loose. ► Test the chamber temperature probe The High Temperature...
  • Page 47 ► Replace control parts with those included in The monitor/control board is faulty. the control and display board kit, or replace the monitor/control board. ► Contact Helmer Technical Service. A component is faulty or internal connections are loose. ► Check the current setpoint for the Door Ajar...

  • Page 48: Testing Problems

    ► Test the temperature alarms manually. than the default value, or the Low Alarm setpoint is set significantly lower than the default value. ► Contact Helmer Technical Service. A component is faulty or internal connections are loose. 360142-1/E...

  • Page 49: Condensation And Icing Problems

    ► Confirm the drain line heater is warm to the The drain line heater is faulty. touch. Contact Helmer Technical Service to resolve issues as necessary. ► Check for ice buildup on the evaporator by The defrost heater on the looking through the fan grill with a flashlight.

  • Page 50: Parts

    Undercounter Freezer Service Manual Parts This chapter lists most replaceable parts and part numbers. It also references parts to schematics. See chapter 9 (Schematics). Before replacing parts that affect chamber temperature, take precautions to CAUTION protect items in the freezer from extended exposure to adverse temperatures. Control and monitoring The temperature chart recorder can be placed 15 feet from the freezer.
  • Page 51 Interface cable 800010-1 Power cable 800010-1 Display assembly (includes touchscreen, display 800041-1 board, interface cable, speaker) NOTE Although the touchscreen and display board may be replaced independently of the i.C³ display assembly, Helmer recommends replacing the complete assembly. 360142-1/E...

  • Page 52: Front

    Undercounter Freezer Service Manual Front A B C D Lower panel features. Label Description Replacement part Label on number schematic Battery backup switch 120202 Battery access door Monitoring system backup battery 120628 shown Circuit breakers (230 V models only) 120288 ON/OFF AC power switch 120478 8.2.1...

  • Page 53: Rear And Under

    Models: Parts Rear and under 8.3.1 Parts on the rear of the freezer ILF105 000000 Version A www.helmerinc.com Rear features. Label Description Replacement part Label on number schematic Nut flanges for brace bars used in stacking undercounter units Rear access port...
  • Page 54 Undercounter Freezer Service Manual Label Description Replacement part Label on number schematic Compressor 115 V: 800012-1 230 V 50 Hz: 800104-1 230 V 60 Hz: 800105-1 Condenser fan motor 115 V: 120608 230 V 50 Hz: 120660 230 V 60 Hz: 120661 Caster (optional, swivel with brake) 220467 shown...
  • Page 55 Models: Parts 8.3.3 Electrical tray parts Label Description Replacement part Label on number schematic Power supply board 800035-1 Compressor relay 115 V: 120426 230 V 50 Hz: 120669 230 V 60 Hz: 120671 i.C³ control board 800034-1 Power line filter...

  • Page 56: Side Access Panel

    Undercounter Freezer Service Manual Side access panel Undercounter freezers feature easy access for servicing, removal, and replacement of the compressors and condensers and their respective parts. Access is available from the rear and side. This chapter demonstrates the side access panel. Using a screwdriver, remove the screws holding the side access cover (below left), and the cover itself.
  • Page 57 Models: Parts 8.5.2 Unit cooler parts Unit cooler interior features. Label Description Replacement part Label on number schematic Unit cooler assembly 115 V: 120592 230 V: 120657 Fan guard Unit cooler fan motor 115 V: 120540 230 V: 120658...
  • Page 58 Drawer slide kit for drawer or roll out basket 400753-2 Roll-out basket 400815-1 Standard for shelf, drawer, or roll out basket 321173-1 Shelf 400814-1 Optional adapter kit for medication dispensing Call Helmer or your distributor for shown lock information 360142-1/E...

  • Page 59: Door And Hinge Parts

    Models: Parts Door and hinge parts Hinge, hinge spring and pin assembly, and door handle with key lock. NOTE Spring tension is controlled at the point where the pin is stopped by the side plate (C, D). Label Description...

  • Page 60: Schematics

    Undercounter Freezer Service Manual Schematics 9.1 iPF and iLF models; 105 configuration i.Series Freezer MAIN POWER iPF and iLF 115V~ (±10%) 60 Hz 230V~ (±10%) 50 Hz 105 models 230V~ (±10%) 60 Hz Page 1 of 2 UNIT COOLER POWER CORD L1 IN L2 IN GND...

  • Page 61: I.series Freezer Ipf And Ilf

    Models: Schematics i.Series Freezer Bezel Mount (iQ) Components iPF and iLF Reset 105 models Page 2 of 2 Speaker (iM) USB Host i.C3 Display PCBA SD Memory Card i.C3 LCD w/ Touch Screen LCD Back Light USB Port Reset...

  • Page 62: Settings

    Undercounter Freezer Service Manual Settings NOTE Information regarding descriptions and default values for general settings, alarm settings, and display settings is available in the i.C³ User Guide. 10.1 Navigating the Home screen The Home screen displays current information and is the starting screen for all interaction with the monitoring system.

  • Page 63: Viewing And Changing Settings

    Models: Settings 10.2 Viewing and changing settings Through the i.C³ monitoring system, the current settings may be viewed and changed. To view settings, touch Home, i.C³ APPS, Settings. Details for each setting are displayed. Use a touch-drag motion to scroll up or down to display additional settings.
  • Page 64 To ensure the freezer maintains the correct temperature, the compressor and evaporator temperature probes have been calibrated at the factory. Changing the calibration settings for the compressor or evaporator probe is not typically necessary, and should not be performed unless directed to do so by Helmer Technical Service.
  • Page 65 Through the i.C³ monitoring system, the current settings may be viewed and changed. The factory settings can be changed through the same screen that they are viewed in. Contact Helmer Technical Service to verify if changing factory settings is necessary, and for instructions in accessing the factory settings page.

  • Page 66: Testing Alarms

    Undercounter Freezer Service Manual 10.3 Testing alarms Test the alarms to ensure they are working correctly. The freezer has alarms that indicate if the chamber temperature becomes too high or too low. Test these alarms using the built-in Peltier device. The Peltier device physically heats or cools the temperature probe;...
  • Page 67 Models: Settings Observe the temperature at the time of the low temperature alarm event. Compare this value to the alarm setpoint. If the values do not match, refer to chapter 7 (Troubleshooting), for information on how to proceed. NOTE If the temperature alarm test does not automatically complete within two minutes, restart the i.C³...
  • Page 68 Undercounter Freezer Service Manual Tape the temperature probe to the thermometer, and immerse them in the glass of chilled water so their ends are toward the bottom of the glass. Activate the Low Temperature Alarm with this method: While constantly stirring the thermometer and probe in the chilled water and watching the temperature on the monitor, slowly add ice so the temperature decreases 0.5 °C per minute.

  • Page 69: Upgrading The System Firmware

    Change the Door Open Time setting back to the original value. 10.4 Upgrading the system firmware Helmer may occasionally issue updates for the i.C³ firmware. In the case of updated firmware, follow the upgrade instructions included with the firmware update. 10.5 Calibrating the touchscreen The i.C³...

  • Page 70: Warranty

    11.1.3 Parts For a period of two (2) years, Helmer will supply at no charge, including freight, any part that fails due to defects in material or workmanship under normal use, with the exception of expendable items. Expendable items such as glass, filters, light bulbs, and door gaskets are excluded from this warranty coverage.

  • Page 71: Outside Of Usa And Canada

    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.

  • Page 72: References And Compliance

    Undercounter Freezer Service Manual References and Compliance 12.1 Alarm reference If an alarm condition is met, an alarm activates. Some alarms are visual only, while others are visual and audible. Some alarms are sent through the remote alarm interface. The table below indicates if an alarm for a particular model is audible (A), visual (V), or sent through the remote alarm interface (R).

  • Page 73: Section Iii: Horizon Series™ Models

    Section III: Horizon Series™ Models Section III: Horizon Series™ Models 360142-1/E...
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  • Page 75: Product Configuration

    Horizon Series™ Models: Product Configuration Product Configuration 13.1 Installing batteries for backup power The monitoring systems and chart recorder each have a battery backup system, enabling a period of continuous operation if power is lost. NOTE The monitoring systems will start on battery power alone. If the freezer was previously not connected to AC power and the backup battery is connected or switched on, the monitoring system will begin running on battery power.

  • Page 76: Freezer Setpoint Configuration

    Undercounter Freezer Service Manual 13.2 Freezer setpoint configuration The temperature controller adjusts chamber temperature around the freezer setpoint. The controller activates the compressor when the chamber probe registers temperature above the setpoint. The controller also senses unit cooler temperature through a probe in the cooler. The temperature in the unit cooler typically varies from the temperature in the chamber, so an offset value is used in the control system.

  • Page 77: Automatic Defrost Cycle Configuration

    Horizon Series™ Models: Product Configuration 13.2.2 Changing freezer setpoint The default setpoint is either -20.0 °C or -30.0 °C, depending on use. Change the setpoint if: ► Your organization requires a chamber temperature different from the default setting. ► The normal chamber temperature is too high or low, even after completing preventive maintenance and applicable troubleshooting tasks.
  • Page 78 Undercounter Freezer Service Manual 13.3.1 Accessing the defrost controller Access to the defrost controller, for adjustment or servicing, is available from the front of the freezer, in the pull-out components tray. Using a screwdriver, remove the front kick plate (located just below the lower front panel, and just above the leveling feet or optional casters).
  • Page 79 Horizon Series™ Models: Product Configuration Label Description PM indicator Current time indicator (includes AM/PM and shows nearest 15-minute interval) Current time indicator (hour and minutes only) AM indicator Time adjustment ring View and change current time Switch the AC ON/OFF switch OFF. Use a screwdriver to remove the kick plate. Pull out the slide tray to expose the defrost controller. On the timer dial, turn the time adjustment ring clockwise until the current time indicators show the correct (current) time.

  • Page 80: External Monitoring Devices

    Do not connect any monitoring device that exceeds the maximum load capacity for your model. The freezer provides a remote alarm interface to send information to external devices, such as the Helmer Remote Alarm Monitoring System. For more information and availability, contact Helmer or your local distributor.

  • Page 81: Moving Drawers, Shelves, And Baskets

    Horizon Series™ Models: Product Configuration 13.5 Moving drawers, shelves, and baskets Storage features (availability of shelves, drawers, and baskets varies by model). NOTE Plasma freezer models (HPF) feature drawers as the standard storage configuration. Pharmacy / laboratory models (HLF) feature shelves as the standard storage configuration. Any combination of drawers, baskets, and shelves may be installed.

  • Page 82: Leveling The Freezer

    After the freezer has been placed, the leveling feet must be adjusted in order to provide proper drainage of condensation from the evaporator coil, inside the unit cooler. NOTE Helmer recommends the use of leveling feet. Level the freezer front-to-back Use a wrench to adjust the leveling feet.

  • Page 83: Door Characteristics

    Solid Laboratory (HLF) 13.8 Optional adapter kits for medication dispensing locks Call Helmer or your distributor for specific system information. 13.9 Door hinge and handle reversal, all models CAUTION Reversing the door hinges and handle requires the freezer to be disconnected from outlet power.
  • Page 84 Undercounter Freezer Service Manual Remove the six (6) screws holding the access panel and cover to the cabinet. Lay the panel in front of the cabinet, ensuring that there is no strain on the power switch wires. Remove Remove Access Access panel panel cover...
  • Page 85 Horizon Series™ Models: Product Configuration Without Access Control option: Remove the four (4) screws holding the door handle assembly to the door and set the assembly aside. With Access Control option: Remove the three (3) screws holding the door handle assembly to the door. Separate the spade connectors for the Access Control lock and set the assembly aside. Remove Remove Left: Door handle assembly without Access Control option.
  • Page 86 If a shim is needed for proper door leveling, contact Helmer Technical Service. 11 Lay the door face-down in front of the cabinet. Ensure that there is no strain on the cable(s) passing from the cabinet to the door.
  • Page 87 Horizon Series™ Models: Product Configuration 13 Lift the door to the front of the cabinet, aligning the holes in the hinges with the corresponding holes in the cabinet. Loosely install three (3) screws in each hinge to attach the hinges to the cabinet. Do not allow the weight of the door to rest on the hinges.

  • Page 88: Hinge Reversal (Solid Door With Access Control Option)

    Undercounter Freezer Service Manual 24 Reinstall the inner door frame inside the outer door frame. Install screws in the unused holes on the door where the hinges had previously been installed. Return to chapter 13.9, step 12, and complete the hinge reversal procedure. 13.10 Hinge reversal (solid door with Access Control option) The undercounter door is comprised of an inner frame and outer frame (A).
  • Page 89 Horizon Series™ Models: Product Configuration Pull the grommet out of the hole in the door and slide the data and Access Control cables out of the slot. Slide sleeve out of slot Pull plug out Pull grommet Left: Remove the inner door with a J-hook tool. Center: Remove the plug on the handle-side of the door.

  • Page 90: Hinge Reversal (Solid Door Without Access Control Option)

    Undercounter Freezer Service Manual 13.11 Hinge reversal (solid door without Access Control option) The undercounter door is comprised of an inner frame and outer frame (A). A gray data cable (B) is connected to the display circuit board. The cable exits the door at the corner (C). The length of the cable inside the door is approximately 3 feet, and it follows a channel along the top and side of the outer door frame.
  • Page 91 Horizon Series™ Models: Product Configuration Gently pull enough data cable out of the door through the channel running along the bottom of the door in order to route it to the opposite side. Route the cable back into the channel along the bottom of the door, toward the new hinge location.

  • Page 92: Hinge Spring Assembly Reversal

    When stacking a refrigerator and a freezer, always place the freezer on the bottom. Call Helmer or your distributor for more information on the stacking kit, and on optional ways to secure both units to the wall and/or the floor.

  • Page 93: Temperature Controller Programs

    Horizon Series™ Models: Temperature Controller Programs Temperature Controller Programs The freezer is shipped from the factory with preset temperature setpoints. These setpoints are specific to the freezer’s intended use. These setpoints may be changed depending on organizational requirements. The Control Offset and Control Hysteresis are factory preset and should not be NOTE changed.

  • Page 94: Maintenance

    Undercounter Freezer Service Manual Maintenance CAUTION See Operation Manual for the preventive maintenance (PM) schedule. 15.1 Recharging refrigerant CAUTION The procedures in this chapter should only be completed by trained refrigeration technicians who are familiar with the terminology and processes described here, as well as with local and organizational regulations regarding refrigerant leaks.

  • Page 95: Checking The Monitoring System Backup Battery

    Horizon Series™ Models: Maintenance 15.2 Checking the monitoring system backup battery CAUTION Checking the monitoring system backup battery requires that power be disconnected from the freezer, which may affect the chamber temperature. Before testing the alarm, take precautions to protect items in the freezer from extended exposure to adverse temperatures.

  • Page 96: Defrosting The Freezer

    Undercounter Freezer Service Manual Clean and refill probe bottles NOTE A replacement kit that includes a probe bottle and glycerin is also available from Helmer. ► Removing the temperature probe from the bottle may cause the chamber CAUTION temperature to fluctuate. ► Protect stored items from extended exposure to adverse temperatures.

  • Page 97: Removing And Installing The Unit Cooler Cover

    Horizon Series™ Models: Maintenance 15.5 Removing and installing the unit cooler cover The unit cooler cover has a port to drain condensation generated in the cooling process. If the unit cooler cover is not removed correctly, the drain port may be damaged. Improper drainage may result in excessive icing in the freezer and the freezer’s inability to maintain the temperature setpoint.
  • Page 98 Undercounter Freezer Service Manual In the chamber, below the unit cooler, push the putty back from the drain port to expose the copper tubing. The putty may be hardened from exposure to cold chamber temperature; allow enough time for the putty to soften. On the rear, remove the angled copper tube by firmly grasping it and pulling it downward and away from the freezer.

  • Page 99: Removing And Replacing The Access Control Cartridge

    Pull the electrical wiring out of the door handle to expose the spade connectors. Separate the two pairs of spade connectors. Remove the three screws securing the handle and cartridge to the door. NOTE To obtain a #10 spanner driver (part number 220559), Contact Helmer Technical Service. Remove NOTE Nylon spacers are installed over the middle and lower screws, between the handle and the door.
  • Page 100 Undercounter Freezer Service Manual To install the replacement Access Control cartridge Place the cartridge inside the handle, aligning the holes in the cartridge with the holes in the handle. While holding the cartridge in the handle, insert a screw through the upper hole in the handle, then through the door latch, latch bushings, and the cartridge body.

  • Page 101: Supplies

    Horizon Series™ Models: Maintenance 15.7 Supplies Refrigerant: non-CFC R-404A Chart paper: 220419 (52 sheets) Glycerin solution: 400922-1 Monitoring system backup battery One 9 V non-rechargeable lithium (or equivalent) battery: 120399 Chart recorder backup battery One 9 V non-rechargeable alkaline (or equivalent) battery: 120218 360142-1/E...

  • Page 102: Troubleshooting

    Undercounter Freezer Service Manual Troubleshooting CAUTION Review all safety instructions prior to completing troubleshooting recommendations. See chapter 2 (Safety). 16.1 General operation problems Problem Possible Cause Action ► Pull the drawer or basket out and confirm the A drawer or basket does There is debris in the not slide easily.

  • Page 103: Chamber Temperature Problems

    Secure the wiring is an open circuit. connections or replace the probe if necessary. ► Contact Helmer Technical Service. An error code displays A component is faulty or on the monitor. internal connections are loose.

  • Page 104: Alarm Activation Problems

    Alarm Disable key is in the OFF position position. ► Verify that audible alarms are not muted. Audible alarms are muted. For i.Series, if time remaining is greater than 5 minutes, change MUTE timer value to 5 minutes and wait until timer resets. 360142-1/E...
  • Page 105 ► Check the current setpoints for the alarms. The alarm setpoint was changed. ► Contact Helmer Technical Service. A component is faulty or internal connections are loose. ► Test the chamber temperature probe The High Temperature...
  • Page 106 ► Replace control parts with those included in The monitor/control board is faulty. the control and display board kit, or replace the monitor/control board. ► Contact Helmer Technical Service. A component is faulty or internal connections are loose. ► Confirm the circuit board and line connections...

  • Page 107: Condensation And Icing Problems

    ► Confirm the drain line heater is warm to the The drain line heater is faulty. touch. Contact Helmer Technical Service to resolve issues as necessary. ► Check for ice buildup on the evaporator by The defrost heater on the looking through the fan grill with a flashlight.

  • Page 108: Parts

    Undercounter Freezer Service Manual Parts This chapter lists most replaceable parts and part numbers. It also references parts to schematics. See chapter 18 (Schematics). Before replacing parts that affect chamber temperature, take precautions to CAUTION protect items in the freezer from extended exposure to adverse temperatures. 17.1 Control and monitoring The temperature chart recorder can be placed 15 feet from the freezer.

  • Page 109: Front

    Horizon Series™ Models: Parts 17.1.1 Control system display parts Top: Display with touchpad. Bottom: Display board. Label Description Replacement part number Label on schematic Touchpad / display board assembly 400838-1 Interface cable Without Access Control: 800032-1 shown 17.2 Front Lower panel features. Label Description Replacement part...

  • Page 110: Rear And Under

    Undercounter Freezer Service Manual 17.2.1 Access Control option Access Control cartridge and door handle. Label Description Replacement part Label on number schematic Access Control cartridge Left-hinged door: 400959-1 Right-hinged door: 400959-2 Nylon spacer Door handle with keyed lock (lock functions as manual override) Screw Access control keypad...
  • Page 111 Horizon Series™ Models: Parts Label Description Replacement part Label on number schematic Nut flanges for brace bars used in stacking undercounter units Rear access port Drain line fan 115 V: 400909-1 230 V: 400909-2 Cover for communication ports and remote shown alarm contacts Drain line heater...
  • Page 112 Undercounter Freezer Service Manual 17.3.3 Electrical tray parts Label Description Replacement part Label on number schematic Compressor relay 115 V: 120426 230 V 50 Hz: 120669 230 V 60 Hz: 120671 Temperature control transformer 115 V: 401097-1 230 V: 401098-1 Control/monitor board 800006-1 Defrost timer...

  • Page 113: Side Access Panel

    Horizon Series™ Models: Parts 17.4 Side access panel Undercounter freezers feature easy access for servicing, removal, and replacement of the compressors and condensers and their respective parts. Access is available from the rear and side. This chapter demonstrates the side access panel. Using a screwdriver, remove the screws holding the side access cover (below left), and the cover itself.

  • Page 114: Unit Cooler

    Undercounter Freezer Service Manual 17.5.2 Unit cooler parts Left: Unit cooler with fan guard. Middle: Unit cooler fan. Right: Temperature control probe. Label Description Replacement part Label on number schematic Unit cooler assembly 115 V: 120592 230 V: 120657 Fan guard Unit cooler fan motor 115 V: 120540 230 V: 120658...
  • Page 115 Drawer slide kit for drawer or roll out 400753-2 basket Roll-out basket (optional) 400815-1 Standard for shelf, drawer, or roll out 321173-1 basket Shelf (laboratory model) 400814-1 Optional adapter kit for medication Call Helmer or your distributor for information shown dispensing lock 360142-1/E...

  • Page 116: Door And Hinge Parts

    Undercounter Freezer Service Manual 17.6 Door and hinge parts Hinge, hinge spring and pin assembly, and door handle with key lock. NOTE Spring tension is controlled at the point where the pin is stopped by the side plate (C, D). Label Description Replacement part number...

  • Page 117: Schematics

    Horizon Series™ Models: Schematics Schematics 18.1 HPF and HLF models; 105 configuration (HN) 12V DC POWER SUPPLY (HJ) FAN DELAY/ *Option (F) UNIT COOLER L2-5 DEFROST THERMOSTAT L1-5 BLACK AUDIBLE (HE) ALARM JUNCTION BOX L1-6 DEFROST SNUBBER 12V~/DC 12VAC HEATER CIRCUIT L2-6 (HO) TEMP CONTROL XFMR (HD) ALARM KEY EXTERIOR...

  • Page 118: Settings

    Undercounter Freezer Service Manual Settings 19.1 Touring the monitoring and control system A B C D Label Description Function HIGH TEMP lamp Indicates when the freezer is in a high temperature alarm condition. Also indicates high alarm temperature setpoint is being changed.

  • Page 119: Viewing Current Settings

    Horizon Series™ Models: Settings 19.2 Viewing current settings The monitoring and control system has alarms which activate if the temperature is too high or too low. The High Temp alarm setpoint specifies the temperature at which the High Temperature Alarm should activate. If the temperature detected by the chamber probe is greater than or equal to this value, the alarm activates.

  • Page 120: Changing Settings

    Undercounter Freezer Service Manual 19.3 Changing settings 19.3.1 Changing setpoints for chamber temperature alarms The monitoring and control system has alarms which activate if the temperature is too high or too low. The setpoints for both High and Low Alarms can be changed to a value from -100.0 °C to +50.0 °C. The High Alarm setpoint specifies the temperature at which the High Temperature Alarm should activate.

  • Page 121: Testing Alarms

    To ensure the freezer maintains the correct temperature, the evaporator temperature probe has been calibrated at the factory. Changing the calibration setting for the evaporator probe is not typically necessary, and should not be performed unless directed to do so by Helmer Technical Service. 19.4 Testing alarms 19.4.1...
  • Page 122 Undercounter Freezer Service Manual Activate the Low Temperature Alarm by doing the following: while constantly stirring the chilled water and watching the temperature on the monitor, slowly add ice so the temperature decreases 0.5 °C per minute. This is approximately 1 teaspoon (5 ml) of ice every 15 to 25 seconds. Be sure to keep the ends of the thermometer and probe in the lower liquid and not in the upper ice.

  • Page 123: Warranty

    20.1.3 Parts For a period of two (2) years, Helmer will supply at no charge, including freight, any part that fails due to defects in material or workmanship under normal use, with the exception of expendable items. Expendable items such as glass, filters, light bulbs, and door gaskets are excluded from this warranty coverage.

  • Page 124: Outside Of Usa And Canada

    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.

  • Page 125: References And Compliance

    Horizon Series™ Models: References and Compliance References and Compliance 21.1 Alarm reference If an alarm condition is met, an alarm activates. Some alarms are visual only, while others are visual and audible. Some alarms are sent through the remote alarm interface. The table below indicates if an alarm for a particular model is audible (A), visual (V), or sent through the remote alarm interface (R).
  • Page 126 HELMER, INC. 14395 Bergen Boulevard Noblesville, IN 46060 USA Phone +1 (317) 773-9073 Fax +1 (317) 773-9082 www.helmerinc.com...

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