Helmer i.Series Service Manual
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Helmer i.Series Service Manual

I.series, horizon series
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See also: Service Maintenance Manual , Service Manual
Refrigerator Service Manual
i.Series™ and Horizon Series™
Blood Bank Models
• i.Series: iB111 (Version B); iB120, iB125, iB245, iB256 (Version C)
• Horizon Series: HB111 (Version B); HB120, HB125, HB245, HB256 (Version C)
Laboratory Models
• i.Series: iLR111 (Version B); iLR120, iLR125, iLR245, iLR256 (Version C)
• Horizon Series: HLR111 (Version B); HLR120, HLR125, HLR245, HLR256 (Version C)
Pharmacy Models
• i.Series: iPR111 (Version B); iPR120, iPR125, iPR245, iPR256 (Version C)
• Horizon Series: HPR111 (Version B); HPR120, HPR125, HPR245, HPR256 (Version C)
ISO 13485:2003 CERTIFIED
Model
S/N
0086
360127-1/A
HELMER, INC.
14395 Bergen Boulevard
Noblesville, IN 46060 USA
Phone +1 (317) 773-9073
USA and Canada (800) 743-5637

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  • Page 1 Refrigerator Service Manual i.Series™ and Horizon Series™ Blood Bank Models • i.Series: iB111 (Version B); iB120, iB125, iB245, iB256 (Version C) • Horizon Series: HB111 (Version B); HB120, HB125, HB245, HB256 (Version C) Laboratory Models • i.Series: iLR111 (Version B); iLR120, iLR125, iLR245, iLR256 (Version C) • Horizon Series: HLR111 (Version B); HLR120, HLR125, HLR245, HLR256 (Version C) Pharmacy Models • i.Series: iPR111 (Version B); iPR120, iPR125, iPR245, iPR256 (Version C) • Horizon Series: HPR111 (Version B); HPR120, HPR125, HPR245, HPR256 (Version C) Model HELMER, INC. 14395 Bergen Boulevard Noblesville, IN 46060 USA 0086 Phone +1 (317) 773-9073...

  • Page 2: Table Of Contents

    Section II: i.Series™ Models........
  • Page 3 Refrigerator Service Manual 8 Parts ............36 8.1 Front .
  • Page 4 Contents 15 Maintenance ..........72 15.1 Recharging refrigerant .
  • Page 5 Refrigerator Service Manual This page left blank intentionally. 360127-1/A...

  • Page 6: Section I: General Information

    Section I: General Information Section I: General Information 360127-1/A...
  • Page 7 Refrigerator Service Manual This page left blank intentionally. 360127-1/A...

  • Page 8: 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. 360127-1/A...

  • Page 9: Safety

    Decontaminate parts prior to sending for service or repair. Items not CAUTION 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. 360127-1/A...

  • Page 10: Configuration

    3.2.1 i.C³ control system i.Series refrigerators 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 refrigerator door, displays operational information.

  • Page 11: Preparing Temperature Probes

    Temperature probes monitor chamber temperature. Number and location of probes varies by model. In addition to using standard probes installed by Helmer, external probes may be introduced through existing top ports and immersed in existing probe bottles. Probes can also be inserted through a side access port (availability varies by model).

  • Page 12: Preparing The Chart Recorder

    ► Calibrating the chart recorder to match the upper chamber temperature. 3.4.1 i.Series chart recorder access For iB, iLR, and iPR models (except 111 model), open the door by pressing and releasing it. For iB111 models, pull the door open.

  • Page 13: Changing Chart Paper

    Refrigerator Service Manual 3.4.2 Horizon Series chart recorder access For HB, HLR, HPR models, pull the door open. Horizon Series chart recorder access. 3.4.3 Changing chart paper One piece of chart paper records temperatures continuously for seven days. For additional information on changing the chart paper, see the Temperature Chart Recorder Operation and Service Manual on CD. 360127-1/A...

  • Page 14: Section Ii: I.series™ Models

    Section II: i.Series™ Models Section II: i.Series™ Models 360127-1/A...
  • Page 15 Refrigerator Service Manual This page left blank intentionally. 360127-1/A...

  • Page 16: 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 refrigerator 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 17: Refrigerator Setpoint Configuration

    Refrigerator Service Manual 4.2 Refrigerator setpoint configuration The temperature controller adjusts chamber temperature around the refrigerator 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 18 4.2.2 Changing refrigerator setpoint The default setpoint is 4.0 °C. Change the setpoint if: ► Your organization requires a chamber temperature different from 4.0 °C. ► The normal chamber temperature is too high or low, even after completing preventive maintenance and applicable troubleshooting tasks.

  • Page 19: External Monitoring Devices

    The refrigerator 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. The remote alarm interface is a relay switch with three terminals: Common (COM), Normally Open (NO), and Normally Closed (NC).

  • Page 20: Drawer Labels

    To remove a drawer or basket Pull the drawer or basket all the way out until it stops. On the right rail, locate the release tab and press it downward. While holding the right release tab downward, locate the release tab on the left rail and press it upward.

  • Page 21: Leveling The Refrigerator

    Single-door (111, 120 and 125) Right hinge or left hinge Double-door (245 and 256) Left door has left hinge, right door has right hinge Optional adapter kits for medication dispensing locks Call Helmer or your distributor for specific system information. 360127-1/A...

  • Page 22: Temperature Controller Programs

    “1234”. Hysteresis The hysteresis band (range) value for i.Series upright refrigerator models is factory preset according to the model and cabinet size. This value represents each side of the refrigerator setpoint value, for a combined total band (range). This value should not be changed.

  • Page 23: Temperature Setpoint Settings

    The hysteresis setpoint is factory-preset and should not be changed unless CAUTION 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 24: 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 25 Refrigerator 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 26: Maintenance

    Models: Maintenance Maintenance See operation manual for the preventive maintenance (PM) schedule. CAUTION 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 27: Checking The Monitoring System Backup Battery

    6.7 (Supplies). Replacing LED lamps Depending on the refrigerator configuration, the refrigerator is shipped with one or two LED lamp strips installed. Replacement LEDs are available from Helmer. CAUTION ► Follow all chemical handling and disposal requirements and procedures specified by your organization.

  • Page 28: Cleaning The Refrigerator

    Models: Maintenance Cleaning the refrigerator Condenser grill CAUTION ► Disconnect power to the refrigerator to eliminate the potential of electric shock and injury from surrounding components. ► Cleaning the condenser grill requires power disconnection. Protect items in the refrigerator from extended exposure to adverse temperatures.

  • Page 29: Removing And Installing The Unit Cooler Cover

    Refrigerator Service Manual Clean and refill probe bottles NOTE A replacement kit that includes a probe bottle and glycerin is also available from Helmer. CAUTION Protect stored items from extended exposure to adverse temperatures. Obtain: ► Fresh water-bleach solution (not provided) Solution is a 10% bleach solution (1 part bleach to 9 parts water, where bleach means a 5% solution of commercial sodium hypochlorite (NaOCl)).
  • Page 30 Models: Maintenance To remove the unit cooler cover In the lower front control panel, switch the ON/OFF AC switch OFF. Disconnect the refrigerator from outlet power as well. Switch the battery backup switch OFF. Peel the putty back to expose the vinyl tube inside the chamber. The putty may be hardened from exposure to cold temperature;...

  • Page 31: Removing And Replacing The Access Control Cartridge

    Refrigerator Service Manual Removing and replacing the Access Control cartridge The Access Control lock cartridge is a serviceable part and may be replaced if necessary. The lock cartridge is an assembly that is installed on the outside of the refrigerator cabinet. CAUTION ► Review all safety instructions prior to replacing the Access Control cartridge.
  • Page 32 Models: Maintenance Remove the (2) screws securing the cartridge assembly to the side of the cabinet. Cut zip tie Remove Remove the cartridge from the cabinet. To install the replacement Access Control cartridge Insert a screw through the upper hole in the cartridge body, then through the door latch, and latch bushings.

  • Page 33: Supplies

    Refrigerator Service Manual Once the refrigerator has reached operating temperature, enable the high temperature alarm by touching the Mute button to cancel the alarm. Allow the refrigerator temperature to stabilize at the setpoint before moving CAUTION contents back into the refrigerator. Supplies Refrigerant: non-CFC, R-134A Chart paper: 220366 (52 sheets)

  • Page 34: Troubleshooting

    ► Confirm the upper temperature probe is reading calibrated. correctly. Calibrate the probe if necessary. Digital electronics are ► Reset the monitoring system. locked because of an interruption in power. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. 360127-1/A...

  • Page 35: Troubleshooting Chamber Temperature Problems

    ► Check refrigeration lines for leaks and repair too low. if necessary. Check the refrigerant level. Recharge refrigerant if necessary. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. Troubleshooting chamber temperature problems Problem Possible Cause...

  • Page 36: Troubleshooting Alarm Activation Problems

    ► Verify audible alarms are not muted. Touch the been muted. Mute button repeatedly until the Mute timer indicates no time delay. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. The refrigerator meets The temperature ► Confirm the temperature monitor/controller...
  • Page 37 ► Check the setpoint. Change the setpoint if alarm setpoint is set too necessary. low. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. The refrigerator is The outlet connection is ► Verify power at the outlet. Repair the original connected to power, but faulty.
  • Page 38 Replace the board is faulty. if necessary. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. The condenser alarm is The refrigerant level is ► Check refrigeration lines for leaks and repair active.

  • Page 39: Troubleshooting Testing Problems

    Refrigerator Service Manual Troubleshooting testing problems Problem Possible Cause Action The automatic The connections for the ► Test the probe connections. Secure the temperature tests do not upper chamber temperature connections if necessary. work. probe are loose. The upper chamber probe ► Confirm the probe is providing accurate is out of calibration.

  • Page 40: Troubleshooting Condensation Problems

    ► Confirm the refrigerator is level, and the the bottom of the chamber. door is aligned, closing tightly, and sealing refrigerator. correctly. Excessive water is found ► Contact Helmer Technical Service to correct in the evaporation tray issues as necessary. inside the refrigerator. 360127-1/A...

  • Page 41: Refrigerator Service Manual

    Refrigerator Service Manual Parts This chapter concerns replaceable parts and part numbers. It also includes references to schematics, as appropriate. See chapter 9 (Schematics). CAUTION Before replacing parts that affect chamber temperature, take precautions to protect items in the refrigerator from extended exposure to adverse temperatures. Front A B C D E F G H I Front features. Left: iB120 refrigerator. Center: iB111 refrigerator.

  • Page 42: Access Control Option

    Models: Parts Label Description Replacement part Label on numbers schematic Chart paper (52 sheets) 220366 Chart recorder backup battery 120218 Caster (swivel with brake) 220467 8.1.1 Access Control option Optional Access Control door lock. Label Description Replacement part Label on number schematic Access Control cartridge cover...
  • Page 43 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. 360127-1/A...

  • Page 44: Top

    Models: Parts A B C D Top features. Label Description Replacement part numbers Label on schematic Condenser probe 800039-1 120 V Condenser fan motor 111 model: 120451 120 and 125 models: 120467 245 models: 120469 230 V 111 model: 120561 120 models: 120471...

  • Page 45: Rear

    Refrigerator Service Manual Rear Rear features (iB111 model shown). Label Description Replacement part numbers Label on schematic Electrical box See subsequent section(s) for part numbers. Power cable North American models 120 V: 120630 230 V: 120631 European models 230 V: 120156 Condensate evaporator kit (includes 115 V condensate evaporator, tray, and cover) 111 model: 400791-1...
  • Page 46 Models: Parts 8.3.1 Electrical box parts Electrical box features (iPR125 model shown). Label Description Replacement part Label on numbers schematic Power supply board 800035-1 Compressor relay 120426 Power line filter 120400 i.C³ control board 8000034-1 Lighting power supply 120624 360127-1/A...

  • Page 47: Interior

    Refrigerator Service Manual Interior F G H Interior features (iPR245 model shown). Label Description Replacement part Label on numbers schematic Chart recorder probe 800024-1 Upper chamber probe 800038-1 Probe bottle and glycerin kit 400922-1 Lower chamber probe (except 111 model) 800037-1 Lamp assemblies See subsequent section(s) for part numbers.
  • Page 48 Models: Parts 8.4.1 Light parts CAUTION Disconnect refrigerator from power when removing and replacing LED lamps. Light features. Label Description Replacement part Label on numbers schematic LED lamp 800049-1 360127-1/A...
  • Page 49 Refrigerator Service Manual 8.4.2 Unit cooler parts A B C Left: Unit cooler (single-door model shown). Right: Unit cooler parts. Label Description Replacement part numbers Label on schematic Unit cooler assembly 115 V 111 model: 120536 120 and 125 models: 120594 245 model: 120595 230 V 111 model: 120553 120 and 125 models: 120615 245 model: 120616 Unit cooler fan motor 115 V models: 120540...
  • Page 50 Models: Parts 8.4.3 Storage parts Storage features (iPR245 model shown). Label Description Replacement part numbers Half shelf (includes hardware) 120, 125, 245, and 256 models: 400413-1 shown Full shelf (includes hardware) 111 model: 400414-3 120 and 245 models: 400414-1 125 and 256 models: 400414-2...
  • Page 51 Refrigerator Service Manual 8.4.4 Door and hinge parts Door and hinge features (iLR120 model shown). Label Description Replacement part Label on numbers schematic Door lock 220540 Door handle pad 320684-1 Upper hinge assembly (includes hinge bearing, Left hinge: 400960-2 hinge pin, and upper hinge bracket) Right hinge: 400960-1 Door gasket 111 model: 321082-1 120, 125, 245, and 456...
  • Page 52 Models: Parts A B C Left: Unit cooler (single-door model shown). Right: Unit cooler parts. Label Description Replacement part numbers Label on schematic Unit cooler assembly 115 V 111 model: 120536 120 and 125 models: 120594 245 models: 120595 230 V 111 model: 120553 120 and 125 models: 120615 245 models: 120616...
  • Page 53 Refrigerator Service Manual 8.4.3 Storage parts Storage parts (iPR245 model shown). Label Description Replacement part numbers Half shelf (includes hardware) 120, 125, 245, and 256 models: 400413-1 shown Full shelf (includes hardware) 111 model: 400414-3 120 and 245 models: 400414-1 125 and 256 models: 400414-2 Roll out basket assembly (includes 111 model: 400751-1 basket, 2 slides, and hardware)
  • Page 54 Models: Parts 8.4.4 Door and hinge parts Door and hinge features (HLR120 model shown). Label Description Replacement part Label on numbers schematic Door lock 220540 Upper hinge bracket Left hinge: 400960-2 Right hinge: 400960-1 Upper hinge bearing 220541 Door gasket 111 model: 321082-1 120, 125, 245, and 456...

  • Page 55: Schematics

    111, 120, 125, 245, and 256 configurations MAIN POWER 115V~ (±10%) 60 Hz 230V~ (±10%) 50 Hz i.Series Refrigerator 230V~ (±10%) 60 Hz iB, iPR, and iLR 111, 120, 125, 245, and 256 models POWER CORD...

  • Page 56: I.series Refrigerator Ib, Ipr, And Ilr 111, 120, 125, 245, And 256 Models

    Models: Schematics i.Series Refrigerator (iQ) Bezel Mount iB, iPR, and iLR Components Reset 111, 120, 125, 245, and 256 models Page 2 of 2 Speaker (iM) USB Host i.C3 Display PCBA SD Memory Card i.C3 LCD w/ Touch Screen...

  • Page 57: Settings

    Refrigerator 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 58: 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 59 To ensure the refrigerator 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. 10.2.3 Restoring factory defaults The settings listed below may be simultaneously changed to the factory default value.

  • Page 60: Testing Alarms

    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 61 Refrigerator Service Manual 10.3.1 Testing temperature alarms automatically NOTE The automatic test can be aborted at any time by touching the Cancel Test button. When performing an automatic low alarm test, the Peltier device cools the probe until the low alarm setpoint is reached.
  • Page 62 Models: Settings To automatically test the high temperature alarm Identify the current setting for the high alarm setpoint. Touch Home, i.C³ APPS, Temperature Alarm Test. The Temperature Alarm Test screen is displayed. Touch the High Alarm Test button to start the high alarm test. The button begins to flash.
  • Page 63 Refrigerator Service Manual 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. This is approximately 1 teaspoon (5 ml) of ice every 15 to 25 seconds.

  • Page 64: 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 65: 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 66: 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 67: References And Compliance

    Refrigerator 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 68: Section Iii: Horizon Series™ Models

    Section III: Horizon Series™ Models Section III: Horizon Series™ Models 360127-1/A...
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  • Page 70: 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 refrigerator 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 71: Refrigerator Setpoint Configuration

    Refrigerator Service Manual 13.2 Refrigerator setpoint configuration The temperature controller adjusts chamber temperature around the refrigerator 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 72: External Monitoring Devices

    The refrigerator 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. The remote alarm interface is a relay switch with three terminals: Common (COM), Normally Open (NO), and Normally Closed (NC).

  • Page 73: Moving Drawers, Shelves, And Baskets

    Refrigerator Service Manual 13.4 Moving drawers, shelves, and baskets Not all containers are available for all models. Storage features (availability of shelves, drawers, and baskets varies by model). CAUTION ► Before moving drawers, shelves, baskets, slides or brackets, protect stored items from extended exposure to adverse temperatures. ► Before moving drawers, be sure they are completely empty for safe lifting. To remove a drawer or basket Pull the drawer or basket all the way out until it stops.

  • Page 74: Leveling The Refrigerator

    After the refrigerator 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 refrigerator front-to-back Use a wrench to adjust the leveling feet.

  • Page 75: Door Characteristics

    Single-door (111, 120 and 125) Right hinge or left hinge Double-door (245 and 256) Left door has left hinge, right door has right hinge 13.7 Optional adapter kits for medication dispensing locks Call Helmer or your distributor for specific system information. 360127-1/A...

  • Page 76: Temperature Controller Programs

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

  • Page 77: Maintenance

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

  • Page 78: Checking The Monitoring System Backup Battery

    15.3 Replacing LED lamps Depending on the refrigerator configuration, the refrigerator is shipped with one or two LED lamp strips installed. Replacement LEDs are available from Helmer. CAUTION ► Follow all chemical handling and disposal requirements and procedures specified by your organization. See chapter 2 (Safety).

  • Page 79: Cleaning The Refrigerator

    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. CAUTION ► Removing the temperature probe from the bottle may cause the chamber temperature to fluctuate.

  • Page 80: Removing And Installing The Unit Cooler Cover

    Horizon Series™ Models: Maintenance Remove all probes from bottle. Remove bottle from bracket and clean with water-bleach solution. Fill with approximately 4 oz (120 ml) of product simulation solution. Cap tightly to minimize evaporation. Place bottle in bracket and replace probes, immersing at least 2 inches (50 mm) in solution. 15.5 Removing and installing the unit cooler cover The unit cooler cover has a port to drain condensation generated in the cooling process.

  • Page 81: Removing And Replacing The Access Control Cartridge

    Refrigerator Service Manual To reinstall the unit cooler cover In the chamber, verify the wiring for the unit cooler fan is connected and routed correctly. The wiring should be routed above the copper tube inside the unit cooler. If the wires have separated, reconnect them (the two wires marked with wire ties should be connected to each other).
  • Page 82 Horizon Series™ Models: Maintenance To remove the Access Control cartridge On the electrical box on the back of the refrigerator, switch the AC ON/OFF switch OFF. Disconnect the refrigerator from outlet power as well. Disable the power failure alarm by disconnecting the backup battery or turning the Alarm Disable key switch OFF.
  • Page 83 Refrigerator Service Manual To install the replacement Access Control cartridge Insert a screw through the upper hole in the cartridge body, then through the door latch, and latch bushings. Insert a screw through the lower hole in the cartridge body and the nylon spacer. Hold the cartridge against the refrigerator cabinet and align the screws with the holes in the cabinet.

  • Page 84: Supplies

    Horizon Series™ Models: Maintenance 15.7 Supplies Refrigerant: non-CFC, R-134A Chart paper: 220366 (52 sheets) Glycerin solution: 400922-1 LED lamp: 400954-1, ≈ 1.3 W NOTE Number of LEDs will vary depending on refrigerator model. 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 360127-1/A...

  • Page 85: Troubleshooting

    Digital electronics are ► Reset the monitoring system. locked because of an interruption in power. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. A component is faulty or ► Contact Helmer Technical Service. Prob appears on the...

  • Page 86: Troubleshooting Chamber Temperature Problems

    ► Check refrigeration lines for leaks and repair too low. if necessary. Check the refrigerant level. Recharge refrigerant if necessary. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. 16.2 Troubleshooting chamber temperature problems Problem...

  • Page 87: Troubleshooting Alarm Activation Problems

    Audible alarms have ► Verify audible alarms are not muted. Verify the been muted. Alarm Disable key switch is not turned OFF. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. The refrigerator meets The temperature ► Confirm the temperature monitor/controller...
  • Page 88 ► Check the setpoint. Change the setpoint if alarm setpoint is set too necessary. low. A component is faulty or ► Contact Helmer Technical Service. internal connections are loose. The refrigerator is The outlet connection is ► Verify power at the outlet. Repair the original connected to power, but faulty.

  • Page 89: Troubleshooting Condensation Problems

    ► Confirm the refrigerator is level, and the the bottom of the chamber. door is aligned, closing tightly, and sealing refrigerator. correctly. Excessive water is found ► Contact Helmer Technical Service to correct in the evaporation tray issues as necessary. inside the refrigerator. 360127-1/A...

  • Page 90: Parts

    Horizon Series™ Models: Parts Parts This chapter concerns replaceable parts and part numbers. It also includes references to schematics, as appropriate. See chapter 18 (Schematics). CAUTION Before replacing parts that affect chamber temperature, take precautions to protect items in the refrigerator from extended exposure to adverse temperatures. 17.1 Front A B C...
  • Page 91 Refrigerator Service Manual 17.1.1 Access Control option Optional Access Control door lock and keypad. Label Description Replacement part number Label on schematic Access Control cartridge cover Access Control door catch (door side) Access Control cartridge assembly (includes Left-hinged door: 800020-1 shown manual override key) Right-hinged door: 800020-2 Bezel (all models except 111) With chart recorder: 800074-1 Without chart recorder: 800073-1...

  • Page 92: Top

    Horizon Series™ Models: Parts 17.2 A B C Top features. Label Description Replacement part numbers Label on schematic Condenser fan motor 120 V 111 model: 120451 120 and 125 models: 120467 245 models: 120469 230 V 111 model: 120561 120 models: 120471 245 models: 120473 Compressor 120 V 111 model: 800005-1...

  • Page 93: Rear

    Refrigerator Service Manual 17.3 Rear Rear features (HB111 model shown). Label Description Replacement part numbers Label on schematic Electrical box See subsequent section(s) for part numbers. Power cable North American models 120 V: 120630 230 V: 120631 European models 230 V: 120156 Condensate evaporator kit (includes 115 V condensate evaporator, tray, and cover) 111 model: 400791-1...
  • Page 94 Horizon Series™ Models: Parts 17.3.1 Electrical box parts Electrical box features (HPR111 model shown). Label Description Replacement part numbers Label on schematic Alarm buzzer 120160 Chart recorder transformer (optional) 12 V DC power supply for Access 120505 Control (optional) Defrost timer 115 V 111 model: 800030-1 120, 125, 245, 245 models: 800016-1 230 V 120, 125, 245, 245 models: 800016-2...

  • Page 95: Interior

    Refrigerator Service Manual 17.4 Interior F G H Interior features (HPR245 model shown). Label Description Replacement part Label on numbers schematic Chart recorder probe 800024-1 Upper chamber probe 800029-1 Probe bottle and glycerin kit 400922-1 Lower chamber probe (except 111 model) 800037-1 Lamp assemblies See subsequent section(s) for part numbers.
  • Page 96 Horizon Series™ Models: Parts 17.4.1 Light parts CAUTION Disconnect refrigerator from power when removing and replacing LED lamps. Label Description Replacement part Label on numbers schematic LED lamp 800049-1 360127-1/A...

  • Page 97: Unit Cooler

    Refrigerator Service Manual 17.4.2 Unit cooler parts A B C Left: Unit cooler (single-door model shown). Center and right: Unit cooler parts. Label Description Replacement part numbers Label on schematic Unit cooler assembly 115 V 111 model: 120536 120 and 125 models: 120594 245 models: 120595 230 V 111 model: 120553 120 and 125 models: 120615 245 models: 120616 Unit cooler fan motor 115 V models: 120540...
  • Page 98 Horizon Series™ Models: Parts 17.4.3 Storage parts Storage parts (HPR245 model shown). Label Description Replacement part numbers Half shelf (includes hardware) 120, 125, 245, and 256 models: 400413-1 shown Full shelf (includes hardware) 111 model: 400414-3 120 and 245 models: 400414-1 125 and 256 models: 400414-2 Roll out basket assembly (includes 111 model: 400751-1 basket, 2 slides, and hardware)
  • Page 99 Refrigerator Service Manual 17.4.4 Door and hinge parts Door and hinge features (HLR120 model shown). Label Description Replacement part Label on numbers schematic Door lock 220540 Upper hinge bracket Left hinge: 400960-2 Right hinge: 400960-1 Upper hinge bearing 220541 Door gasket 111 model: 321082-1 120, 125, 245, and 456 models: 320726-1 Lower hinge cam 320742-1...

  • Page 100: Schematics

    Horizon Series™ Models: Schematics Schematics 18.1 HB, HLR, and HPR models; 120, 125, 245, and 256 configurations Door Lock Solenoid (HN) *Option 12V DC POWER SUPPLY *Option INTERIOR LIGHT L2-11 L1-11 (HE) AUDIBLE ALARM Double Door Only L2-3 Lighting Power Supply *Option (HG) L1-3 LIGHT SWITCH L1-4 12VAC L2-4 (HO) TEMP CONTROL XFMR (HD) ALARM KEY...

  • Page 101: Hlr And Hpr Models; 111 Configuration

    Refrigerator Service Manual 18.2 HLR and HPR models; 111 configuration Door Lock Solenoid (HN) *Option 12V DC POWER SUPPLY *Option L2-11 L1-11 INTERIOR LIGHT (HE) AUDIBLE L2-3 Lighting Power Supply ALARM (HG) L1-3 LIGHT SWITCH L1-4 12VAC L2-4 (HO) TEMP CONTROL XFMR L2-7 L1-7 L1-5 ALARM KEY (HD) SWITCH...

  • Page 102: Settings

    Horizon Series™ Models: Settings Settings 19.1 Touring the monitoring and control system Label Description Function COOL lamp Indicates the compressor is running Display Displays real-time temperature information, setpoints, and alarms HIGH TEMP lamp Indicates when the refrigerator is in a high temperature alarm condition.

  • Page 103: Viewing Current Settings

    Refrigerator Service Manual Label Description Function SET lamp Indicates a control or alarm setpoint is being changed SET button Accesses Configuration mode CONTROL lamp Indicates when the display is showing the refrigerator setpoint MONITOR lamp Indicates when the display is showing temperature readings from the monitor probe.

  • Page 104: Changing Settings

    Horizon Series™ Models: Settings 19.3 Changing settings The Control Offset and Control Hysteresis are factory preset and should not be NOTE changed. 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 these alarms may be changed.
  • Page 105 Refrigerator Service Manual 19.3.2 Calibrating the monitor readout To ensure the high and low temperature alarms are activated properly, the chamber temperature that is read by the temperature probe must be accurate. Verify the probe is reading correctly by comparing the reading to that from an independent thermometer.

  • Page 106: Testing Alarms

    To ensure the refrigerator 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 Test the alarms to ensure they are working correctly.
  • Page 107 Refrigerator Service Manual 19.4.2 Testing the power failure alarm CAUTION Testing the power failure alarm requires that users disconnect power from the refrigerator, which may affect the chamber temperature. Before testing the alarm, take precautions to protect items in the refrigerator from extended exposure to adverse temperatures.

  • Page 108: 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 109: 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 110: 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 111 HELMER, INC. 14395 Bergen Boulevard Noblesville, IN 46060 USA Phone +1 (317) 773-907 Fax +1 (317) 773-9082 www.helmerinc.com...

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