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i.Series Ultra-Low Freezer Service Manual

1. SWITCH L O ESO H ib E nO P 1 03 Power PCBA Y dr e M ol ISLA Chorging POWER a e o ol MANAGEMENT 5 SOR OPTION m1 ik 3 gi eu LOW SIDE J lig DISCHARGE SENSOR 1 eot E E mi 8 TERMAL STE E LN artery surron cA iC3 POWER PCBA 8 A 8 CHAMBER TEMP PROBE za CHART 48g ee eh P 8889988 RECORDER ATL VACUUM 8 vado ow OPTION 2A PORT 3 HIGH SIDE 12v BOLL ercomma roan ies HEATER ig Te censos ey UTR ABI Pen OX BATTERY JA LOW SIDE SSR ro BACKUP Blo HIGH SIDE SSR E ee o LZ 3 Hpac SA 3 HEAT EXCHANGER PROBE D d o fal N T A io 12 gt TERMINAL STRIP ES AMBIENT PROBE o CONTROL Lo e m seo 03 POWER PCBA PRESSURE SWITCH DOOR A A LOW SIDE COMPRESSOR SWITCH HIGH SIDE o BR o 4 wen sive compressor DISCHARGE PROBE m 38 o EL conoensen Fan moror y
2. Helmer I ENTI Ultra Low Freezer Service Manual i Series i Series iUF118 iUF126 Version A iUF116 iUF124 Version A HELMER SCIENTIFIC 14400 Bergen Boulevard asal Noblesville IN 46060 USA PH 1 317 773 9073 FAX 1 317 773 9082 USA and Canada 800 743 5637 360173 A A ISO 13485 2003 CERTIFIED gt Helmer Document History Revision Date co Supersession Revision Description A DEC 29 2014 10184 n a Initial release Date submitted for Change Order review Actual release date may vary 360173 A A Helmer Contents Section I General Informati0N ooooooooonrrnnrrra nnn 5 1 About this Man al 0 3 cise esr x REOR ERR AUR M aC RETRO US US x RU wees na n RR Ro S oy OR eee 5 1 1 Intended Audiences sarre sss iR RhRRRPERERE C RRERZARATR SAOSERCRTERERIASEBAG EXEAT SAC PC SS 5 12 Model ReferenCes va5 4424444005408 rara DNE ERR MEER ERA RU EIE RUE AU DEAL SS 5 1 3 Copyright and Trademark csse esee eee ee DADA V Pan X RE Dad E S 5 2 Safety selec recaer radar e 5 2 1 Safety Definitions 22 4 226 00 ces exa xxm Ed VOR d a uin 5 2 2 Product Labels csse as A A ad Oe MGR EGRE UCR AUS KU ORE AAA 6 2 9 AVOIGING Inj Ey c sua e iaa A A Pers ala DRG A A ALA A BRASS 6 3 COMPISNCO 322x522 Rr RAE dece DP AAA ARA 7 3 1 Regulatory Compliance sii surasi a a A eee Ee pe cu A 7 3 2 WEEE Compliance sx x exer ste chess ant EROR Rr aes E ala i aa a ale Rn aaa UR AGS Se
3. 6 Enter the Settings password default password is 1234 7 Touch Sensor Calibration 8 Touch or on the Ambient offset spin box to increase or decrease the offset value until the displayed value matches the measured value NOTE After saving the new temperature value the displayed temperature may take several minutes to change to match the new value This is normal 9 Touch Home to exit the Sensor Calibration screen 10 Remove thermometer from the sensor 11 Replace the condenser grill Factory Calibrated Sensors NOTICE The low stage compressor discharge sensor cascade heat exchanger sensor high stage compressor discharge sensor and high stage condenser discharge sensor are factory calibrated and do not require field calibration These sensors are difficult to reach to verify the accuracy of any calibrations Factory Default Settings Settings listed below are calibration and operational settings that were set at the factory before the freezer was shipped NOTE Factory default settings may not be the same as the settings that were factory calibrated Setting Restored Value Home Screen Application Icons i C APPS Settings Temperature Graph Information Logs Download Display Brightness High 3 symbols Password for Settings screen 1234 Sounds On Alarm Volume 9 Alarm Tone 3 Temperature Calibration Values Varies calibrated at factory
4. gt Reset the circuit breaker Circuit breaker is faulty gt Replace the circuit breaker Power supply board is faulty gt Replace the power supply board Power filter is faulty gt Replace power filter 44 Helmer 360173 A A Problem Possible Cause Troubleshooting Action The Door Open alarm is activating sporadically Exterior door is not closing completely Confirm the hinges are not damaged Replace the hinges if necessary Exterior door is gt Defrost the exterior door gasket refer to Section closing but not sealing Ill Item 9 4 2 completely Connection for the gt Test the switch wiring connection and secure the exterior door switch is loose connection if necessary Exterior door switch is gt Replace the magnetic door switch faulty i C control board is gt Confirm the control board is operating correctly faulty Replace if necessary Door Open Timeout gt Check the time delay for the Door Open alarm is set to zero causing Change the time delay if necessary the alarm to activate immediately when the door is opened The Condenser Condenser filter is gt Check the condenser filter Clean if necessary Temperature alarm is dirty active Side panels missing Reinstall side panels to ensure proper airflow from cabinet base across condenser and compressors Condenser fan is not gt Check the condenser
5. 11 Troubleshooting A CAUTION gt Review all safety instructions prior to troubleshooting Refer to Section I Item 2 gt Troubleshooting should only be performed by trained refrigeration technicians NOTE To order Replacement Parts contact Helmer Technical Service 1 800 743 5637 11 1 General Operation Problems Problem Possible Cause Action The exterior door Exterior door handle gt Confirm the exterior door handle is firmly attached 360173 A A does not open easily bushings are worn to the freezer door Replace the door handle bushings if the handle is loose Excessive frost or ice build up on mullion because cleaned or defrosted gasket and closed while still wet Defrost the interior and verify it is dry before closing door An interior door does not open easily Frost accumulation around the interior door gasket Defrost the interior door refer to Section III Item 9 4 3 Interior door hinge is bent Replace the interior door hinge Interior door retaining clip is worn or bent Replace the interior door retaining clip The monitor display is difficult to read Screen brightness is set too low Change the screen brightness Touch i C APPS Brightness Touch the icon corresponding to the desired brightness setting The monitoring system is not responding Digital electronics are locked because of an interruption in power Reset the monitoring system b
6. z E ri AB o LZ rune pom sonon ACCESS CONTROL rro LL dis gd ga O SOLENOID E ae OPTION o Blo Door C meuo TERMINAL STRIP PUMP DOWN o SOLENOID E gi S 328v0C LOW SIDE G y elo 3r Thy ss U LOW SIDE o EA LOW SIDE COMPRESSOR HIGH SIDE 328voc gt lu COMPRESSOR o HIGH SIDE COMPRESSOR of tr 3A O CONDENSING UNIT sp Ye GOMPRESSORE Ee lt b Far 48 o 4 rume oown souenow FAN MOTOR S 7 sers LZ EE Ga SAFETY 2 o BALO PRESSURE o 6B 5 LZ SWITCH o SAL O a a Oo iu o Era Helmer 13 13 1 57 360173 A A Helmer Parts amp Schematics 13 2 Refrigeration Schematic HIGH STAGE COMPRESSOR STAGE SUCTION LINE HEAT EXCHANGER low pressure gas warm low pressure gas cool CASCADE HEAT EXCHANGER high stage evap low stage cond high pressure gas cool high pressure liquid cool SUCTION LOW esca STAGE SUBCOOL HEAT EXCHANGER high high pressure pressure liquid cool liquid cold FILTER DRIER 360173 A A CONDENSER quik high pressure liquid warm high pressure liquid cool gt THERMAL EXPANSION VALVE TXV low pressure gas warm e low pressure gas cool low pressure liquid CAPILLARY TUBES EVAPORATOR 80 C inside walls MULLION HEATER around door frame high pressure gas hot
7. DUVNEANUAAIOANI lll gt high pressure gas warm desuperheated FAN all UH CONDENSER high pressure liquid warm FILTER DRIER high pressure gas warm PRESSURE high pressure gas hot SWITCHES R 508B R 601 LOW STAGE COMPRESSOR CAPILLARY TUBE EXPANSION TANK CONDITIONED low pressure gas cool SPACE Low Stage R 508B R 601 high pressure liquid warm High Stage R 404A 58 Helmer Warranty Section VI Warranty 14 14 1 14 2 14 3 14 4 14 5 360173 A A Rel i Product Warranty USA and Canada For technical service needs please contact Helmer at 800 743 5637 or www helmerinc com Have the model and serial number available when calling Rapid Resolution When a warranty issue arises it is our desire to respond quickly and appropriately The service department at Helmer is there for you Helmer will oversee the handling of your warranty service from start to finish Therefore Helmer must give advance authorization for all service calls and or parts needs relating to a warranty issue Any repeat service calls must also be authorized as well This allows for proper diagnosis and action Helmer will not be responsible for charges incurred for service calls made by third parties prior to authorization from Helmer Helmer retains the right to replace any produc
8. on the Low Temperature setpoint spin box to change the value to 0 C b The low temperature alarm will activate immediately If the low temperature alarm does not activate contact Helmer Technical Service Change the Low Temperature setpoint to the original setting Touch Home Power Failure Alarm Test NOTE gt During a power failure the power failure alarm activates and the battery provides power to the monitoring system gt During the power failure test do not switch the battery switch off 4 Change Power Failure delay setting to 0 minutes a Touch i C APPS Settings b Enter the Settings password default password is 1234 c Touch Alarm Settings d Touch or on the Power Failure spin box to change the value to 0 minutes Switch AC ON OFF switch OFF gt Power failure alarm will activate immediately Switch AC ON OFF switch ON gt Power failure alarm will clear and audible alarm will cease Change the Power Failure time delay to the original setting Door Open Alarm Test 1 Change Door Open Time delay setting to O minutes a Touchi C APPS Settings b Enter the Settings password default password is 1234 c Touch Alarm Settings d Touch or on the Door Open Time spin box to change the value to 0 27 gt Helmer Maintenance amp Service 9 1 5 9 1 6 360173 A A 2 Open door gt Alarm will activate immediately 3 Close door gt Alarm will clear and audib
9. 7 3 3 Electromagnetic Compliance ve adi aa A TERRA ERR e Ad a 7 4 Model and Input Power cues zorro RUR RR RR cee A men 8 Section Il Installation 8 Configuration ooooooooommomooo 9 5 Location RequirementS ooooocooonrnr ern 9 6 Install Components iocus use eae RR Rh CR nm mcm min Rm RR RR eee e n mo n 9 0 1 Placement scm mcer SOR ore SOROR Re d pa eg Sales nC PUR RUR A ae DAT AU o A 9 6 2 Backup Refrigeration Systems Optional llli mh 9 6 2 1 Optional Backup Refrigeration System Installation llle 10 62 2 Backup System Contacts ise asia as SERES 10 6 3 Connect External Monitoring Devices llleiee mh 10 6 3 1 Connect to Remote Alarm Interface llli 11 0 4 Start i C3 Backup POoWerF um ry rca e SUR Mer dpa ARI NUN EO pews auld Belles A 11 0 5 Move Shelves veu ade es od Boe Re DONA WARRIOR RNC DR NER UAE ER EUIS E ME 12 f Prepare for Monitoring ccce eei mk REA RR RERERESSUE a EIER ARR RR E EORR 13 ki Temperature Sensor vto omine e Re e a MESE qe ERE REX MPO uu Re RATER 13 7 1 1 Install Additional Temperature Sensor Through Upper Rear Port o oooccccccccco 13 7 1 2 Install Additional Temperature Sensor Through Lower Rear Port ooococccccccco o 14 T2 Chant Recorder Optional isses dee tee a RR AR eR LER e ep TREE CE 14 7 2 4 Chart Recorder Access issus Re A ddr rada era 15 1 2 2 Install Chart Paper cisco lid Reo dod es LERRA ia
10. Alarm Test 00000 cece eee tees 27 9 1 3 Power Failure Alarm Test 2000 c cece eee eee 27 9 1 4 Door Open Alarm Iest omo vasa danse EH a ee a EROR re wade aC Eee ee aes 27 9 1 5 High Ambient Temperature Alarm TeSt o ooococcccocooco n 28 9 1 6 Low Ambient Temperature Alarm Test 00 00 cece es 28 9 1 7 Non configurable Temperature Alarms 0 nnana eee eae 29 9 2 Upgrade System Firmware occa eeean chads eedh degen ICE bee Gi whee eed DENIS DS 29 9 3 Test and Replace Backup Battery 0 00 0c cette eee 29 9 3 1 Test Monitoring System Backup Battery llli tee 29 9 3 2 Replace Monitoring System Backup Battery lille 30 94 Defrost Ultra EoW E Feezet oen Tode ale Gea als wy RE EGER CR su EROR o seu Sr NUR EIE MUR ee LaL 30 9 4 1 Defrost and Clean Chamber 0000 sr 30 9 4 2 Defrost and Clean Exterior Door Gasket oocoocooooocrnr ses 32 9 4 3 Defrost and Clean Interior Doors 00 000 rr 32 95 Clean Ultra Low Freezer ocio ges ao ee Und GR C ba ed 3c Oe c RURAL UR 33 9 01 Condenser ms ies E oO ETE eb re oe b e rad odd ee EH Re ir ee pce d 33 9 5 2 Condenser Filter o ooooooocooooooor rr 33 95 3 A A E ON 34 9 54 ECO lOUClIsCcreero sr A A NR REA ai 34 10 Service 4325555 rre AAA 35 10 1 Refrigerant icr a o A EA AD AAA AA ERGO AA AAA AA A AAA A 35 10 2 Chamber Temperature Sensor Error Recovery 00 re 35 10 3
11. Low Stage Compressor Discharge Probe Offset Value 0 C High Stage Compressor Discharge Probe Offset Value 0 C Heat Exchanger Probe Offset Value 0 C High Stage Condenser Discharge Probe Offset Value 0 C Unit ID Serial number entered at factory Date Format MM DD YYYY Day Month Year Not affected maintained in real time clock Time Format 12 hour 23 Helmer 8 5 1 360173 A A Installation amp Configuration Setting Restored Value Minute Not affected maintained in real time clock Hour AM PM Language Language previously selected during setup Temperature Units C Password Protection for Settings screen On Ambient Temperature Display On LN CO System Input Off USB Port On RS 232 Port On Access Control as Home Page On High Chamber Temperature Alarm Setpoint 70 0 C High Chamber Temperature Alarm Time Delay 0 minutes Low Chamber Temperature Alarm Setpoint 90 0 C Low Chamber Temperature Alarm Time Delay 0 minutes High Ambient Temperature Alarm Setpoint 30 0 C High Ambient Temperature Alarm Time Delay 15 minutes Low Ambient Temperature Alarm Setpoint 15 0 C Low Ambient Temperature Alarm Time Delay 15 minutes Power Failure Alarm Time Delay 1 minute Sensor Failure Alarm Time Delay 0 minutes Door Open Alarm Time Delay 1 minute Chamber Setpoint 80 0 C Chamber Hysteresis 0 1 C Delay on Start Up 1 m
12. NOTICE gt Ifthe high and low stage compressors are automatically powered off the chamber temperature may rise above above the established limits necessary to maintain integrity of stored inventory gt Ifthe freezer has automatically powered down protect items in freezer from extended exposure to adverse temperature The chamber temperature sensor error may be cleared and the freezer returned to normal operation by following the chamber temperature sensor error recovery procedure Error recovery procedure 1 Switch battery ON OFF switch OFF 2 Switch AC ON OFF switch OFF gt Wait 30 seconds before powering the freezer back on 3 Switch AC ON OFF switch ON 4 Switch battery ON OFF switch ON 10 3 Replace Access Control Solenoid If there is an Access Control Solenoid failure the freezer must be accessed with the override key The Access Control Solenoid is a serviceable assembly installed in the door NOTE gt Areplacement Access Control Solenoid assembly is available from Helmer Technical Service Order Service Kit part number 800195 1 Complete installation instructions are included with the Access Control Solenoid Service kit 10 4 Replace Exterior Door Hinge and or Covers Cracked or broken hinges or hinge covers can be replaced Figure 11 Exterior door hinge with covers installed NOTE gt Areplacement Hinge and Cover Kit is available from Helmer Technical Service gt Order Service Kit part
13. Refrigeration Systems Optional A backup refrigeration system may be installed to ensure the chamber temperature remains below a critical level in the event of an extended power failure or an equipment failure If the chamber temperature rises to a pre determined setpoint the backup refrigeration system will inject carbon dioxide CO or liquid nitrogen LN into the chamber to keep the chamber temperature within a specified range NOTICE The temperature setpoint for the CO LN injection should be set to a value within the freezer operating range 50 C to 86 C 360173 A A Helmer 6 2 1 6 2 2 6 3 360173 A A Installation amp Configuration Optional Backup Refrigeration System Installation Follow the backup refrigeration system manufacturer s directions to install the backup system NOTICE Do not drill holes in the cabinet Drilling holes may damage the insulation in models equipped with vacuum insulated panels or may damage the evaporator coil causing a loss of refrigerant NOTE Helmer recommends installing the backup refrigeration system door switch along the handle side of the door This will prevent the door switch from interfering with the vacuum port located near the top of the door External sensors for the backup refrigeration system may be installed through ports in the side or rear of the freezer cabinet Refer to 7 1 1 Install Additional Temperature Sensor Through Upper Rear Por
14. Replace Access Control Solendid o o oooocoocooo s 36 10 4 Replace Exterior Door Hinge and or COVerS oooocccoo re 36 10 5 Adjust Exterior DOOF sx 00 a e A web iE add e ERREUR aed RUE Oe 37 10 0 Replace Castel 2x xe tees Questi CE M een oea dad E barba da PICS 38 Section IV Troubleshooting 000 e eee ees 39 11 Troubleshooting ricas a a A E O RR a e 39 11 1 General Operation Problems 00000 ccc tee eee 39 11 2 Chamber Temperature Problems sonit sasie a Vaa diaa cece ete hh 41 11 3 Alarm Activation Problems ecw tod on t ene en VEU EX has a Re fade oa ees 44 TVA Teing Probleims dae ore tene d adele Pa eT WI hea ete ae are E x db 46 Section V Parts amp Schematics 0 0 cee es 47 XC MC TIT err 47 A AAA E REA ERA DEG ua M M AME an ae ius UNE 48 121 2 Exterior DOOF sa 02 40 deka edad beheaded dada ESAE REPE ERE rada 50 PAS A R been tend orders Sta RA CARA EE RR SA RR exe BERI PE RE 51 12 3 Rear Panel 122i op edes E eee e eere opes d BEC eade Bote debe ddr 51 360173 A A Helmer 12 4 Electrical Panels ic 2440044 riadas riadas SARI RARO EG b ade A di 52 12 5 Refrigeration Components 0 occccccccoo eee hen a 53 12 5 1 Refrigeration Compartment oos sssri Erir hh rs 53 12 5 2 Cascade Heat Exchanger CompartMent o ocoocccooo es 55 12 6 DENOI cs eo d e de ROUES EA EE Ue des Iis eU que qo ad ata ce Vallae 56 13 SCHCMANCS E P 57 13 1 Electrical S
15. Voltage A V R AC Conditioned Low Voltage A VR Power Management System Failure Optional VR Power Up Door Open Time A V R Clean Filter VR CO LN Backup System Active Optional VR Communication Failure 1 Control Board A VR Communication Failure 2 Configuration File A V R Communication Failure 3 Database A V R Date Time Change 7 Settings Through the i C monitoring and control system current temperature and alarm settings may be viewed and changed The i C monitor and control system is programmed at the factory NOTE gt Ifthe Settings screen is password protected or if viewing settings for the first time enter factory default password of 1234 Chamber Temperature FP J Setpoint Display Settings Alarm Settings e Device Status and History Users and Passwords Sensor Calibration NN Display Settings mew Restore Factory Settings medie then a Figure 8 Settings screens To change a setting first access the Settings screen then the setting Bo 17 Helmer 8 3 1 8 3 2 360173 A A Chamber Temperature Setpoint Temperature setpoints are programmed at the factory Setpoints can be viewed and changed through the i C monitoring and control system Installation amp Configuration NOTE Default chamber temperature setpoint is 80 0 C The lowest setpoint that can be set is 86 0 C Change the setpoint if gt Your organization requires a
16. a backup battery system enabling a period of continuous monitoring if power is lost NOTE The monitoring system and chart recorder if equipped will start on battery power alone If the freezer was previously not connected to AC power and the battery is switched on the monitoring system and chart recorder will begin running on battery power Battery life varies by manufacturer as well as voltage level remaining Providing full power is available and no battery related alarms are active backup power for the monitoring system is available for approximately 20 hours the Low Battery alarm will activate after approximately 18 hours of battery use NOTICE Use only a replacement battery which meets specifications of the monitoring system Access Control backup battery 800174 1 found in Section V Item 12 4 NOTE If AC power is lost the monitoring system will automatically disable some features to prolong battery power Data collection will continue until battery power is depleted NOTE The backup battery system does not operate the refrigeration system The battery is located in the electrical compartment on the bottom left of the freezer 11 Helmer Installation amp Configuration 6 5 A CAUTION Figure 2 Monitoring system Access control backup battery Model Battery Service Kit UF all 1 rechargeable 12 V lead acid sealed battery 800174 1 Battery is switched off for shipping Swi
17. ambient temperature correctly by comparing sensor reading to temperature read by an independent calibrated and traceable thermometer If sensor is not reading correctly change the offset value displayed on the monitor CAUTION Avoid sharp edges when working inside the refrigeration compartment Sensor specifications gt Initial factory calibration setting varies gt Offset value can be changed from 10 0 C to 10 0 C gt Sensor is 100 Q platinum RTD Required tools gt Independent thermometer with a 5 1524mm lead or greater calibrated and traceable per national standards gt Zip tie to attach thermometer to sensor Calibrate sensor 1 Remove the condenser grill to gain access to the sensor 2 Using a zip tie attach the independent thermometer to the same point as the sensor NOTE Ensure the independent thermometer is not touching the condenser or any other metallic components surrounding the sensor 3 Allow the thermometer temperature to stabilize for a minimum of three minutes 4 Observe and note the thermometer temperature gt Ifthe temperature variance is within 1 0 C of the temperature displayed on the i C screen calibration is not necessary gt Ifthe temperature variance is greater than 1 0 C of the temperature displayed on the i C screen calibrate the ambient sensor 22 Helmer 8 4 3 8 5 360173 A A 5 Touch i C APPS Settings Installation amp Configuration
18. cover door side 322044 1 included in 8001 78 1 360173 A A 50 Helmer Parts amp Schematics 12 2 Side Panel Figure 20 Side panel features Label Description Service Kit Number A AC ON OFF switch 800171 1 B Circuit breakers 800172 1 C Monitoring system backup battery ON OFF switch 800173 1 12 3 Rear Panel A B C D E F Figure 21 Rear panel features Label Description A RJ 45 Ethernet port USB port RS 232 serial port Remote alarm interface LN CO backup system interface nim OJO AC power connector 360173 A A 51 Helmer 12 4 Electrical Parts amp Schematics Panel A WARNING Removal of the electrical compartment access panel will expose electrical wiring carrying line voltage and control voltage Ensure the freezer is powered off before removing the access panel Avoid sharp edges when working inside the electrical compartment The i C control board is sensitive to static electricity and can be damaged by electrostatic discharge Use proper ESD precautions when handling the control board Figure 22 Electrical panel features Label Description Service Kit Number A i C control board 800167 1 B Power supply board 800168 1 C Low stage compressor relay 800170 1 D High stage compressor relay 800170 1 E Power management module optional 800194 1 F Monitoring system Access Control backup
19. filter must be installed so the wire mesh faces toward the condenser inside 6 Pivot the top of the grill toward the freezer until the magnets engage the condenser grill NOTE If the condenser filter is damaged a replacement filter may be ordered from Helmer Technical Service Order Service Kit 800159 1 Exterior Required tools gt Dry cotton cloth gt Non abrasive liquid cleaner Clean exterior surfaces with soft cotton cloth and non abrasive liquid cleaner i C e Touchscreen Clean touchscreen with a soft dry cotton cloth NOTE Do not use solvent or alcohol based cleaners to clean the i C touchscreen 34 Helmer 10 Servic e Maintenance amp Service A CAUTION gt Review all safety instructions prior to servicing refrigeration system s Refer to NOTICE 10 1 10 2 360173 A A Section Item 2 vv Service should only be performed by trained refrigeration technicians Avoid sharp edges when working inside the refrigeration compartment The refrigeration systems are sealed at the factory Do not connect gauge manifolds or add refrigerant to either system unless directed by Helmer Technical Service Refrigerant Full initial refrigerant charge varies by models and can be found on the chart below Model Power Refrigerant Requirements Initial Charge iUF116 iUF118 iUF124 iUF126 R 404A high stage R 508B low stage R 601 low stage 48 oz 1361
20. from the freezer c Lift the grill and disengage the tabs at the bottom of the grill from the freezer cabinet 2 Clean the condenser using a soft brush and a vacuum cleaner 3 Install the condenser grill a insert the tabs at the bottom of the grill into the corresponding holes on the freezer cabinet b Pivot the top of the grill toward the freezer until the magnets engage the condenser grill Condenser Filter In environments where freezer is exposed to excessive lint or dust the condenser filter may require cleaning more frequently than stated in preventive maintenance schedule CAUTION gt Avoid sharp edges when removing and installing the condenser grill and filter gt Use appropriate gloves when handling stored inventory Required tools gt Sink with hot and cold water taps Clean the filter 1 Tilt the condenser grill forward 2 Remove the condenser filter from the condenser grill a Liftthe filter upward b Remove the filter from the slots on the back of the grill 3 Clean the condenser filter with warm water and a mild detergent a Rinse the filter under warm water b The filter must be rinsed from back to front so that water flows in the opposite direction of the airflow 4 Allow the condenser filter to dry thoroughly 33 gt Helmer Maintenance amp Service 9 5 3 9 5 4 360173 A A 5 Install the condenser filter in the condenser grill a Insert the filter into the slots on the back of the grill b The
21. gt Battery icon will appear on the screen gt Ifthe display is blank replace battery 2 Switch AC ON OFF switch ON Replace Monitoring System Backup Battery The monitoring system backup battery is a serviceable part installed behind the electrical compartment access panel below the chamber WARNING Removal of the electrical compartment access panel will expose electrical wiring carrying line voltage and control voltage Ensure the freezer is powered off before removing the access panel CAUTION Avoid sharp edges when working inside the electrical compartment NOTE Replacement of the battery will not require stored inventory to be removed from the freezer during the replacement procedure It is not recommended that the chamber door be opened until after this procedure is completed A replacement battery is available from Helmer Technical Service Order Service kit 800174 1 Refer to the installation instructions included with the battery service kit Defrost Ultra Low Freezer Defrost and Clean Chamber Frost accumulation is normal The freezer chamber must be periodically defrosted to prevent excessive frost from interfering with door operation and storage of product or the freezer s ability to maintain temperature If the freezer door or interior doors do not operate correctly or if the freezer cannot maintain the chamber setpoint temperature defrost the chamber A WARNING Do
22. handle with care NOTE If the i C monitoring and control system did not display a low ambient temperature alarm during the alarm test contact Helmer Technical Service 28 gt Helmer Maintenance amp Service 9 2 9 3 9 3 1 360173 A A Required tools gt 1 8 oz 250 mL glass half full of ice water gt Clean shop rag or several clean paper towels used together Test the low ambient alarm 1 Touchi C APPS Settings 2 Enter the Settings password default password is 1234 3 Touch Alarm Settings 4 Change the Low Ambient time delay setting to 0 minutes gt Touch on the Low Ambient time delay spin box to change the value to 0 minutes Observe and note the Low Ambient setpoint 6 Liftthe condenser grill from the magnetic anchor points at the top of the grill and remove by pulling the grill forward to about a 30 angle and lifting the tabs out of the tab holes 7 Using the half full glass of ice and water mixture dip the rag or paper towel into the ice water mixture saturating the rag or towels 8 Wrap the moistened rag or towel around the ambient probe 9 Observe the ambient display temperature begin to drop 10 When the alarm is activated note the temperature on the monitor 11 Compare the recorded temperature at which the alarm activated to the low ambient alarm setpoint The recorded temperature should be within 1 C of the low alarm setpoint If the alarm triggers outside of the 1 C range
23. not calibrated gt Check the chamber temperature calibration Change the calibration if necessary refer to Section Il Item 8 4 1 Connections for the chamber temperature sensor are loose gt Check the sensor wire connection to the control board and secure the connection if necessary gt Check the continuity of the sensor wiring Replace the sensor if necessary gt Confirm the sensor is providing resistance in the range of 73 Q to 110 O Replace the sensor if resistance is outside of specified range gt Check the CP performance by utilizing jumper at J11 Place the jumper across both pins The screen should display 4 0 C 1 C Digital electronics are locked because of an interruption in power gt Reset the monitoring system by turning battery and AC power off and back on Compressor solid state relay is faulty gt Confirm the relay is operating correctly Replace the relay if necessary A component is faulty or internal connections are loose gt Contact Helmer Technical Service The compressors run continuously Freezer setpoint is set too low gt Confirm the setpoint is set within the operating range and change it if necessary refer to Section Il Item 8 3 1 Chamber temperature sensor is not calibrated gt Check the chamber temperature sensor calibration Change the calibration if necessary refer to Section II Item 8 4 1 Compressor solid state
24. not use a secondary heat source to defrost the freezer The use of an electrical heat source such as a heat gun could create an electrocution hazard if the user comes into contact with water from the defrosted chamber Defrosting the freezer will create excessive water in the work area Take necessary precautions to prevent slip hazards The freezer is extremely heavy Helmer recommends that two people work together to move the freezer Oo gt E o z vv 360173 A A Use appropriate gloves when handling cold interior components and stored inventory Keep hands away from pinch points when closing the door 30 gt Helmer Maintenance amp Service NOTICE gt Before defrosting chamber protect items in freezer from extended exposure to 360173 A A adverse temperature gt Do not use a secondary heat source to defrost the freezer The use of a secondary heat source such as a heat gun may create additional pressure within the refrigeration system and may damage system components gt Allow chamber temperature to stabilize at setpoint before moving product back into the freezer Required tools gt Dry cotton cloth Defrost the chamber Move stored product to an equivalent freezer Switch battery ON OFF switch OFF Switch AC ON OFF switch OFF Disconnect the freezer from AC power Remove the AC power cord from the freezer Move the freezer to a location where water can be captured as the chamber
25. number 800178 1 gt Complete installation instructions are included with the Hinge and Cover service kit 360173 A A 36 Helmer 10 5 360173 A A Maintenance amp Service Adjust Exterior Door Required tools Vvwvvvvvv 1 Phillips screwdriver 2 Phillips screwdriver 20 Torx driver 1 2 box wrench Ratchet strap Straight edge ruler Loctite 242 Calipers Adjust the cabinet to door gap 1 Verify door gasket is outside of the desired gap of 0 46 to 0 52 12mm to 13mm measured between the door plastic mullion a and the cabinet plastic mullion b 2 Using a Z2 Phillips screwdriver remove the screws securing the hinge covers 3 Remove the hinge covers from the hinge 4 Place the ratchet strap around the cabinet adjacent to the hinge being adjusted 5 Tighten the ratchet strap to secure the door 6 Using a 1 Phillips screwdriver remove the four screws in door side of the hinge 7 Tighten or loosen the ratchet strap as necessary to achieve a gap of 0 46 to 0 52 12mm to 13mm between the door and the cabinet 8 Apply Loctite 242 to the four screws that were removed from door side of the hinge 9 Install the four screws 10 Using a 1 Phillips screwdriver tighten the screws 11 Remove the ratchet strap 12 Verify that gap remains within tolerance If not repeat steps to adjust 13 Reinstall the hinge covers on the hinge 14 Using a Z2 Phillips screwdriver reinstall the screws securing the hinge c
26. 360173 A A General Information Caution Safety hazard to operator p Caution Unlock all casters or service technician Caution Electrocution shock hazard i Earth ground terminal Caution Electrostatic discharge Protective earth ground ESD hazard terminal Avoiding Injury VvVvVVVVvVVVYVVY vVvvvvyv Review safety instructions before installing using or maintaining the equipment Before moving unit remove contents from the chamber Before moving unit ensure door is closed and latched and casters are unlocked and free of debris Before moving unit disconnect the AC power cord and secure the cord When moving unit use assistance from a second person Please refrain from grasping handle when moving unit to avoid injury from the door opening Never physically restrict any moving component Avoid removing electrical service panels and access panels unless so instructed Use appropriate gloves when handling cold internal components and stored inventory Keep hands away from pinch points when closing the door Avoid sharp edges when working inside the electrical compartment and refrigeration compartment Ensure biological materials are stored at recommended temperatures determined by standards literature or good laboratory practices Proceed with caution when adding and removing samples from the freezer Total freezer weight including contents is not to exceed 1400 Ibs 635 kg Individual shelf weight is not to
27. AUTION Review all safety instructions prior to performing maintenance Refer to Section I Item 2 NOTICE v Before performing maintenance protect items in freezer from extended exposure to adverse temperature gt Allow chamber temperature to stabilize at setpoint before moving product back into the freezer NOTE Refer to the operation manual for the preventive maintenance schedule Maintenance Alarm Tests Test alarms to ensure they are working correctly The freezer has alarms for high chamber temperature low chamber temperature door open time high ambient temperature low ambient temperature and power failure NOTE There is no testing method for non configurable alarms CAUTION Use appropriate gloves when handling cold interior components and stored inventory NOTICE Before testing alarms protect items in freezer from extended exposure to adverse temperature High Chamber Temperature Alarm Test NOTE gt The high chamber temperature alarm test should require no more than 90 seconds gt lf the i C monitoring and control system did not display a high temperature alarm during the alarm test contact Helmer Technical Service Required tools gt Electric heat gun or equivalent heat source Test the high alarm 1 Identify setting for high alarm setpoint a Touch i C APPS Settings b Enter the Settings password default password is 1234 c Touch Alarm Settings d Observe a
28. C screen calibration is not necessary gt Ifthe temperature variance is greater than 1 0 C of the temperature displayed on the i C screen calibrate the sensor Touch i C APPS Settings Enter the Settings password default password is 1234 Touch Sensor Calibration Touch or on the Offset Chamber spin box to increase or decrease the offset value until the Offset ce YN 0 0 displayed value matches the measured value 21 Helmer Installation amp Configuration 8 4 2 360173 A A NOTE After saving the new temperature value the displayed temperature may take several minutes to change to match the new value This is normal 9 Touch Home to exit the Sensor Calibration screen 10 Remove thermometer from the sensor cover 11 Replace the contents of the freezer Calibrate Ambient Temperature Sensor NOTICE gt The ambient temperature sensor is factory calibrated and should not be changed unless directed by Helmer Technical Service gt Calibration must be done with an independent thermometer that is calibrated and traceable standard gt Temperature sensor is fragile handle with care NOTE gt The ambient temperature sensor should be calibrated only if the sensor calibration is found to be outside of the acceptable calibration range gt Ifthe displayed temperature is within 1 0 C of the measured temperature calibration is not required Verify ambient temperature sensor is reading
29. O Speaker Included in 800165 1 48 Helmer Label Description Parts amp Schematics Service Kit Number Display assembly includes interface cable power cable display board touch screen speaker and bezel 800165 1 Not shown Front bezel without chart recorder door iUF116 800191 1 iUF118 800190 1 iUF124 800193 1 iUF126 800192 1 Leveling legs 800199 1 NOTICE The i C display assembly is sensitive to static electricity and can be damaged by electrostatic discharge Use proper ESD precautions when handling the display assembly 360173 A A 49 Helmer Parts amp Schematics 12 1 2 Exterior Door Fig 15 Left Exterior door features Fig 16 Center Top Exterior door handle features handle removed for clarity Fig17 Right Top Vacuum port cover removed for clarity Fig 18 Center Bottom Hinge Fig19 Right Bottom Hinge Cover Label Description Service Kit Number A Door includes handle handle bushings gasket vacuum port and Access Control solenoid B Door handle includes keyed lock C Exterior door gasket iUF 116 800176 1 iUF 118 800176 2 iUF 124 800177 1 iUF 126 800177 2 D Access Control solenoid assembly 800195 1 E Latch roller B F Door handle bushing 800179 1 G Padlock hasp H Vacuum port 800175 1 Hinge 8001 78 1 J Hinge cover cabinet side 322045 1 included in 8001 78 1 K Hinge
30. Oo E ee 15 7 2 8 Reorder Chart Paper o o oo ooocoo lerra 15 B LG Control System ripio RGA CELA R CROP ARIAS 16 Gal Home Screen asus caseo ERG e RR E Rau aUe p eU UR GER WR Rer SR ad aR a 16 8 1 1 Home Screen FUNCIONS axe 2445 a eee SCAG AAA A AER SD NE E Ye 16 98 2 Alarm Reference a REA DSR ETE ERREUR A E CR ERR EA RIO 16 8 3 Settlrigs sb me a re eue a a kl eit eee la bee RR RUP Ro lex e E ta dU 17 8 89 1 Chamber Temperature Setpoint 0 20 ees 18 8 3 2 User Configurable Alarm Settings o ooooocccocccccooor n 18 8 3 3 Non Configurable AlarMS ooooooooooooooo rrr 19 8 4 Sensor Calibration sssi cuina en cae e o eda bd O4 ER e edd Pee ened ad ea bee 20 8 4 1 Calibrate Chamber Temperature Sensor llli sees 21 360173 A A Helmer 8 4 2 Calibrate Ambient Temperature Sensor 2 00 lees 22 8 4 3 Factory Calibrated Sensors 0 0 hr 23 8 5 Factory Default Settings ao A pae Rhee RU A ERTEAN ERRA Waa RUE UR ADAE RT ACROSS RA 23 8 5 1 Restore Factory Default Settings 2 2 eae ves pu ERE RR esa ERE E we ares 24 98 5 2 Edit Factory Settings cod Rex AAA nee nore SEDES ER E 25 Section Ill Maintenance Service ellen 26 9 IMamtenantces usasaca nectar rra aca paar ie ar trece us 26 9 1 Alarm Tests ici Ro rU A A di NUR A ROI AR dee EA 26 9 1 1 High Chamber Temperature Alarm TeSt oooococccocoooccee ae 26 9 1 2 Low Chamber Temperature
31. a screwdriver or similar tool to pierce the insulating foam Insert the tool from the outside through the foam to the inside of the cabinet NOTE Use a tool with a diameter only large enough to accommodate the sensor wiring 3 Secure the sensor inside the cabinet as necessary 4 Seal the hole in the foam using Permagum putty or press in cork tape ensuring a tight seal Chart Recorder Optional If installed refer to the Temperature Chart Recorder Operation and Service Manual on CD The temperature chart recorder has a battery system enabling a period of continuous operation if power is lost Battery life varies by manufacturer as well as voltage level remaining Providing full power is available backup power for the chart recorder is available for up to 14 hours Prior to use gt Add paper gt Calibrate chart recorder to match chamber temperature 14 Helmer Installation amp Configuration 7 2 1 7 2 2 7 2 3 360173 A A Chart Recorder Access Open door by pressing and releasing the door Figure 5 Chart recorder access door Install Chart Paper 1 Press and hold C button When stylus begins to move left release button The LED flashes to indicate current temperature range 2 When stylus stops moving remove chart knob then move knob up and away 3 Place chart paper on chart recorder 4 Gently lift stylus and rotate paper so current time line corresponds to time line groove 5 Hold chart pap
32. battery 800174 1 Not RFI filter shown 360173 A A 52 Helmer Parts amp Schematics 12 5 Refrigeration Components 12 5 1 Refrigeration Compartment Removal of the refrigeration compartment access panel will expose electrical wiring carrying line voltage and control voltage Ensure the freezer is powered off before removing the access panel Avoid sharp edges when working inside the refrigeration compartment A B C D EF G H Figure 23 Refrigeration system features in the refrigeration compartment Label Description Service Kit Number A Condenser 800153 1 B Condenser fan motor includes fan blade 800154 1 C High stage compressor start components 800151 1 D Low stage compressor start components 800152 1 E Low stage high pressure safety switch line voltage 800161 1 F Low stage high pressure safety switch control voltage 800160 1 G High stage compressor 800155 1 H High stage condenser discharge temperature sensor 800169 3 Not Ambient temperature sensor 800169 1 Shown 360173 A A 53 Helmer J K LMNO Figure 24 Refrigeration system features in the refrigeration compartment Parts amp Schematics Label Description Service Kit Number High stage compressor discharge temperature sensor 800169 2 J Low stage compressor 800162 1 K Low stage compressor discharge temperature sensor 800169 4 L Recei
33. blesville IN USA www helmerinc com Voltage 208 230 V a c 60 Amps 11 0A D Power 2 53 kW C Refrigerant Type O High Stage R404A 48 oz R404A low 174 psig high 331 psig Certified Low Stage R508B 13 5 oz R508B low 554 psig high 554 psig UL 61010 1 CSA 61010 1 HZ Design Pressures This unit is intended for use in laboratories in commercial industrial or institutional occupanies as defined in the Safety Standard for Refrigeration systems ASHRAE 15 HZ iUF116 i Series amp Voltage 208 230 V a c 60 BE 0000000 C Version A _www helmerinc com UF116 Voltage HZ i Series 60 0000000 Version A www helmerinc com 208 230 V a c Top Product specification label Bottom Chamber labels Label Description A Model REF B Serial number C Version D Power requirements 360173 A A Helmer Installation amp Configuration Section Il Installation amp Configuration 5 Location Requirements Has a dedicated 15 A grounded circuit with dedicated single point receptacle meeting the electrical requirements listed on the product specification label gt Is clear of direct sunlight high temperature sources and heating and air conditioning vents gt Minimum 8 203 mm above and minimum 4 102 mm behind gt Meets limits specified for ambient temperature and relative humidity 6 Install Components 6 1 Placement A WARNING gt To prevent ti
34. chamber temperature other than 80 0 C Confirm gt Freezer has been placed per location requirements in Section Il Item 5 gt Preventive maintenance has been completed per operation manual Perform the following 1 Touch C APPS i C Settings 2 Enter the Settings password default password is 1234 3 Touch or on the Chamber Temperature Setpoint spin box gt The setpoint is the temperature at which the freezer operates 4 Touch Home to exit the Settings screen Setting Initial Factory Value Chamber Temperature Setpoint 80 0 C Delay on Start Up 1 minute User Configurable Alarm Settings The following alarm settings may be changed by the operator The setpoint for temperature alarms may be changed where applicable as well as the time delay between when the alarm condition commences and when the visual and audible alarms are initiated Alarm Default Default Description Setpoint Time Delay High Temperature Low Temperature Chamber temperature reading is above high temperature 70 0 C 0 minutes alarm setpoint Chamber temperature reading is below low temperature alarm setpoint 0 minutes Power Failure Power to unit has been disrupted 1 minute Sensor Failure Door Open Time 0 minutes Temperature sensor is not functioning properly Door is open beyond user specified duration n a 1 minute High Ambient Ambient temperature reading is above h
35. ched CO LN Active CO LN backup refrigeration system has been activated Low Battery Rechargeable battery voltage is low No Battery Rechargeable battery voltage is too low or battery is disconnected Refrigeration System Refrigerant pressure is too high High stage compressor temperature is above the upper limit Low stage compressor temperature is above the upper limit High stage compressor has failed Low stage compressor has failed Emergency Mode Chamber temperature sensor has failed and i C system is operating high stage and low stage compressors at 100 duty cycle VvVvvVY 360173 A A 19 Helmer Installation amp Configuration Alarm Description Communication Failure Communication Failure 1 gt Triggered if communication is lost between i C display board and control board gt Unit will continue to run with previously saved settings gt Screen will not display temperature changes or alarm conditions gt i C system will continue to reset until connection is re established Communication Failure 2 gt Triggered if communication is lost between i C display board and internal system memory gt Unit will continue to run with previously saved settings Communication Failure 3 gt Triggered if the database is corrupted gt The database is archived and a new database is automatically created gt Unit will continue to run with previously saved settings 8 4 Sensor Calibration Sensor ca
36. chemat eve XE ER RUE RE REI A E AAA Aa Na 57 13 2 Refrigeration Schematic comi cil se m y GRO A A ee ee OR 58 Section VI Warranty cov ce Equos orunEes EROR E Ed elotes e 59 14 Rel i Product Warranty USA and Canada 0 000 a 59 14 1 Rapid Resolution a is oe Rade Rena A aoe KA kd AGAR UG RO eee A 59 14 2 COMPIESSONs sse acteaakatonrbhaoedheeiad a rta ridad eed Aq ERI PAR dno 59 14 3 Pants i ccscecties gaa ia dosed Hed ohana CELERE dake EL EPDUPERRA ee dade eee edd oe 59 14 4 Labor ei rnini ida ceed Rec CR oak o Pedo od sew A AG bea Fk dri e 59 14 5 Additional Warranty Information sss ssresssrerere sidst r Eer hh es 59 14 6 Outside of USA and Canada 60 360173 A A gt Helmer General Information Section I General Information 1 1 1 2 1 3 2 1 About this Manual Intended Audience This manual is intended for use by end users of the freezer and authorized service technicians Model References Generic references are used throughout this manual to group models that contain similar features For example UF models refers to all models of that size UF116 iUF118 iUF124 iUF126 This manual covers all ultra low freezers which may be identified singly by their size or by their respective Series Copyright and Trademark Helmer i Series C and Rel i are registered trademarks or trademarks of Helmer Inc in the United States of America Copyright 2015 Helmer Inc All other tra
37. demarks and registered trademarks are the property of their respective owners Helmer Inc doing business as DBA Helmer Scientific and Helmer Safety The operator or technician performing maintenance or service on Helmer Scientific products must a inspect the product for abnormal wear and damage b choose a repair procedure which will not endanger his her safety the safety of others the product or the safe operation of the product and c fully inspect and test the product to ensure the maintenance or service has been performed properly Safety Definitions The following general safety alerts appear with all safety statements within this manual Read and abide by the safety statement that accompanies the safety alert symbol A WARNING The safety statement that follows this safety alert symbol indicates a hazardous situation which if not avoided could result in serious injury A CAUTION The safety statement that follows this safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE The safety statement that follows this safety alert symbol indicates a situation which if not 360173 A A avoided could result in damage to the product or stored inventory Helmer Product Labels The following general safety and information alerts appear on the product to identify potential hazards to the operator or service technician 2 2 2 3
38. er and install chart knob NOTE For accurate temperature reading ensure that current time is aligned with time line groove when chart knob is tightened 6 Confirm temperature range is set to the correct value 7 Press and hold C button When stylus begins to move right release button 8 Confirm stylus is marking temperature correctly Reorder Chart Paper Chart paper 800197 1 52 sheets Available on the Helmer estore at http store helmerinc com or directly from Helmer Scientific at 1 800 743 5637 15 S Helmer Installation amp Configuration 8 8 1 8 1 1 8 2 360173 A A i C Control System i Series Ultra Low freezers are equipped with the i C monitoring and control system The i C system combines temperature monitoring and control into a single user interface Home Screen The Home screen is the default screen and is displayed when gt The Home button is touched from any other screen gt There is no interaction for two minutes on any screen other than those used to enter a password Figure 7 Home Screen Home Screen Functions NOTE Refer to the i C User Guide for options available on all i C screens View current interior cabinet and ambient temperature readings View the current system time and date Access any of the five home screen apps touch i C APPS for additional applications View information about current alarm events View whether the monitoring system is running on batte
39. exceed 160 lbs 73 kg Use supplied power cord only Do not drill holes in the cabinet or door Drilling holes may damage the insulation in models equipped with vacuum insulated panels or may damage the evaporator coil causing a loss of refrigerant Using the equipment in a manner not specified by Helmer may impair the protection provided by the equipment Decontaminate parts prior to sending for service or repair Contact Helmer or your distributor for decontamination instructions and a Return Authorization Number Ensure biological materials are stored safely in accordance with all applicable organizational regulatory and legal requirements The freezer is not considered to be a storage cabinet for flammable or hazardous materials gt Helmer General Information 3 3 1 3 2 3 3 360173 A A Compliance Regulatory Compliance This product is certified to applicable UL and CSA standards by a NRTL WEEE Compliance The WEEE waste electrical and electronic equipment symbol right indicates compliance with European Union Directive WEEE 2002 96 EC and applicable provisions The directive sets requirements for labeling and disposal of certain products in affected countries E When disposing of this product in countries affected by this directive gt Do not dispose of this product as unsorted municipal waste gt Collect this product separately gt Use collection and return systems available locally For more
40. fan wiring connection running Secure the connection if necessary gt Check power to the fan and electrical connections If power to the fan replace fan If no power to the fan call Helmer Technical Support gt Check the CP operation of relay at J42 Connection for gt Check the sensor wire connection to the control the condenser board and secure the connection if necessary temperature sensor is gt Ohm out loose Condenser gt Check the sensor wire connection to the control temperature sensor is board and secure the connection if necessary faulty gt Check the continuity of the sensor wiring Replace the sensor if necessary gt Confirm the sensor is providing resistance in the range of 100 O to 115 O Replace the sensor if resistance is outside of specified range The No Battery Monitoring system gt Replace the monitoring system backup battery alarm is activating backup battery refer to Section III Item 9 3 2 sporadically voltage is low Power supply board gt Contact Helmer Technical Service voltage is incorrect The High Temperature Chamber temperature gt Check the chamber temperature sensor alarm is activating sensor is not calibration Change the calibration if necessary sporadically calibrated refer to Section II Item 8 4 1 A component is gt Contact Helmer Technical Service faulty or internal connections are loose 45 Helmer 11 4 360173 A A Icing Problem
41. g 13 5 oz 383 g 0 56 oz 26 g 208 230 V 60 H R 404A high stage R 508B low stage R 601 low stage Chamber Temperature Sensor Error Recovery 48 oz 1351 g 16 oz 454 g 0 56 oz 26 g If the i C monitoring and control system loses communication with the chamber temperature sensor or if the sensor fails the i C system will operate the refrigeration system in Emergency Mode to preserve the inventor y stored in the freezer NOTE The alarm display on the Home screen will display Emergency Mode The Emergency Mode alarm setting is not adjustable The alarm is only displayed on the Home screen If the Emergency Mode alarm is active contact Helmer Technical Service If the refrigeration system is operating in Emergency Mode the high stage compressor will operate continuously and the low stage compressor will operate normally unless one or more of the following conditions are met An over pressure condition exists in the high stage refrigeration system A second Sensor Failure alarm compressor temperature condenser temperature or heat exchanger temperature is active beyond the duration specified in the Sensor Failure time delay setting The cascade temperature is above 20 C If one or more of the conditions above are met the high stage and low stage compressors will be automat ically powered off 35 gt Helmer Maintenance amp Service
42. igh ambient alarm 30 0 C 15 minutes setpoint Low Ambient Ambient temperature reading is below low ambient alarm 15 0 C 15 minutes setpoint 18 Helmer Installation amp Configuration 3 48 pm 10 31 2013 Set Point Time Del non mos CA pers Low Temperature IL 2 Sensor Failure omn ap Power Failure Door Open Time er e ipd EENES CEEXJ Door Open Time imn Low Ambient 150 Figure 9 Alarm Settings screens Change an alarm setting 1 Touch i C APPS Settings 2 Enter the Settings password default password is 1234 3 Touch Alarm Settings 4 Touch or on the spin box corresponding to the alarm setting to be changed 5 Touch Home to exit the Alarm Settings screen NOTE Changing a temperature alarm setting to a value within the operating range of the freezer may trigger a temperature alarm 8 3 3 Non Configurable Alarms The freezer has alarms that are not user configurable These alarms indicate operational conditions that require the attention of the operator or a qualified service technician Refer to 11 Troubleshooting for information regarding non configurable alarms NOTE gt Touch Mute to silence the alarm Alarm Description Compressor Temperature Low stage or high stage compressor discharge temperature is too high Condenser Temperature High stage condenser discharge temperature is too high Clean Filter Filter cleaning interval has been rea
43. iguration 7 1 2 7 2 360173 A A Install the Sensor 1 Remove the plastic plugs on the outside and inside of the cabinet 2 Use a screwdriver or similar tool to pierce the insulating foam Insert the tool from the outside through the foam to the inside of the cabinet NOTE Use a tool with a diameter only large enough to accommodate the sensor wiring 3 Secure the sensor inside the cabinet as necessary 4 Seal the hole in the foam using Permagum putty or press in cork tape ensuring a tight seal Install Additional Temperature Sensor Through Lower Rear Port Additional temperature sensors may be installed through a port on the rear wall of the cabinet in the bottom left corner The port consists of two plastic caps one inside the cabinet and one on the outside The cabinet insulation fills the void between the plugs NOTICE Do not drill holes in the cabinet Drilling holes may damage the insulation in models equipped with vacuum insulated panels or may damage the evaporator coil causing a loss of refrigerant NOTE gt Helmer recommends installing additional sensors through the upper or lower rear ports provided gt The lower rear port may also be used to install a temperature sensor for an optional field installed CO LN backup refrigeration system Refer to Section Il Item 6 2 for additional information Install the Sensor 1 Remove the plastic plugs on the outside and inside of the cabinet 2 Use
44. in a manner other than for its intended use Installation and calibration are not covered under this warranty agreement Outside of USA and Canada Consult your local distributor for warranty information END OF MANUAL 60 HELMER SCIENTIFIC 14400 Bergen Boulevard Noblesville IN 46060 USA PH 1 317 773 9073 FAX 1 317 773 9082 www helmerinc com e C E Imer N T F C
45. information on the return recovery or recycling of this product contact your local distributor Electromagnetic Compliance This device is suitable for use in a specific electromagnetic environment The end user of this device is responsible for ensuring the device is used in compliance with the following European Union directives and standards regarding EMC electromagnetic compliance EMC Directive 2004 108 EC with Standards gt EN 55011 2009 inc A1 2010 EN 61000 3 2 2006 inc A2 2009 Electromagnetic compatibility EMC Part 3 2 EN 61000 3 3 2008 Electromagnetic compatibility EMC Part 3 3 EN 61000 6 1 2007 Electromagnetic compatibility vvv See Operations Manual for complete specifications Helmer 4 Model and Input Power General Information NOTE Service information varies depending on the model and power requirements Series Model Voltage Frequency Current Draw i Series iUF116 208 230V 60Hz 11 0A iSeries iUF118 208 230V 60Hz 11 0A i Series iUF124 208 230V 60Hz 11 0A i Series iUF126 208 230V 60Hz 11 0A This information appears on the product specification label located on the rear of the freezer The model also appears on a label located in the chamber on the upper side of the right wall BSN iUF116 i Series amp 0000000 C Version A ULT Freezer Weight 625 Ib 284 kg 2014 Made in USA R601 0 9 oz wl Helmer 14400 Bergen Boulevard No
46. inute Restore Factory Default Settings Factory settings may be simultaneously returned to factory default values NOTE gt Factory default settings may not be the same as the settings that were factory calibrated gt If Factory Default Settings are restored all calibration values will be lost Touch Home i C APPS Settings Touch Restore Factory Settings NON Enter the Settings password default password is 1234 The Restore Factory Settings message appears Do one of the following gt Touch Yes The message screen closes and factory settings are restored gt Touch No The message screen closes and factory settings are not restored 24 Helmer 8 5 2 Edit Factory Settings Installation amp Configuration NOTE gt Contact Helmer Technical Service for instructions in changing factory settings Several of the i C3 screens and functions are configured at the factory The screens and functions listed below are set at the factory and may be changed at the direction of Helmer Technical Service Setting Description Device Control Settings Screen Toggle the Device Control Settings screen on or off Alternate Home Screen Toggle the Alternate Home screen on or off Access Control Screen 360173 A A Toggle the Access Control screen on or off 25 Helmer Maintenance amp Service Section Ill Maintenance amp Service A 9 9 1 A 9 1 1 360173 A A C
47. le alarm will cease 4 Change the Door Open Time setting to the original setting High Ambient Temperature Alarm Test CAUTION Avoid sharp edges when working inside the refrigeration compartment NOTICE Temperature sensor is fragile handle with care NOTE If the i C monitoring and control system did not display a high ambient temperature alarm during the alarm test contact Helmer Technical Service Test the high ambient alarm Required tools P Electric heat gun or equivalent heat source Test the high ambient alarm 1 Identify setting for high ambient alarm setpoint a Touch i C APPS Settings b Enter the Settings password default password is 1234 c Touch Alarm Settings d Observe and note the setting for the high ambient alarm e Touch Home 2 Remove the condenser filter grill 3 Using a heat gun or similar auxiliary heat source use low setting if available apply short bursts of heat to the chamber sensor 4 Observe the temperature on the i C display at which the high ambient temperature alarm activates 5 The alarm should activate within 2 0 C of high alarm setpoint If the value is more than 2 0 C different contact Helmer Technical Service for further instruction 6 Remove the heat gun 7 Reinstall the condenser filter grill Low Ambient Temperature Alarm Test CAUTION Avoid sharp edges when working inside the refrigeration compartment NOTICE Temperature sensor is fragile
48. libration values are programmed at the factory Sensor values can be viewed and changed through the i C monitoring and control system 3 50 pm 10 31 2013 Current em Sensor Reading Offset Discharge Es Reference Offset mmm mm Chamber RTD4 86 7 C Exchanger epe mi 9e Ambient at intake RTO2 250 C Discharge hal High Stage Condenser RTDS 35 4 C 10 C Low Stage Compressor ANT 23 5 C E Discharge Discharge a a Figure 10 Sensor Calibration screens NOTICE Changing calibration settings affects operation of the freezer Do not change settings unless instructed in product documentation or by Helmer Technical Service NOTE gt If password protection is enabled enter factory default password of 1234 to reach the Sensor Calibration screen gt When there is no interaction for two minutes the Sensor Calibration screen closes and returns to the Home screen gt To change sensor offset values other than Chamber and Ambient enter the technician password available from Helmer Technical Service 360173 A A 20 S Helmer Installation amp Configuration 8 4 1 Calibrate Chamber Temperature Sensor NOTICE gt The chamber temperature sensor is factory calibrated and should be verified on 360173 A A an annual basis and calibrated when required or as dictated by facility standard operating procedures gt Calibration must be done with an independent thermometer that is calibrated and t
49. lt After four hours verify that the interior door is free of frost and moisture in metal framework 5 Clean interior door with soft cotton cloth and non abrasive liquid cleaner 6 Wipe the interior door with a dry cotton cloth to remove moisture 7 Install the interior door a Align the hinge pins on the interior door with the corresponding hinges in the cabinet b Lower the interior door so the hinge pins are inserted into the hinges c Close the interior door 8 Close the chamber door NOTE Repeat steps 1 through 8 for each of the interior doors 32 gt Helmer Maintenance amp Service 9 5 9 5 1 9 5 2 360173 A A Clean Ultra Low Freezer Condenser WARNING If a solvent based liquid cleaner is used to clean the condenser an electrocution hazard could exist if the user comes into contact with the liquid cleaner and a power source Disconnect the freezer from AC power prior to cleaning with a liquid cleaner CAUTION Avoid sharp edges when working inside the refrigeration compartment NOTICE gt Ifthe freezer has been powered down to clean the condenser protect items in freezer from extended exposure to adverse temperature gt Allow chamber temperature to stabilize at setpoint before moving product back into the freezer Required tools gt Soft brush gt Vacuum cleaner Clean the condenser 1 Remove the condenser grill from the freezer a Liftthe grill upward b Pull the top of the grill away
50. meets an alarm condition but the appropriate alarm is not active Alarm setpoint was changed gt Check the current setpoints for the alarms refer to Section Il Item 8 3 2 A component is faulty or internal connections are loose gt Contact Helmer Technical Service The High Temperature alarm activates when the door is opened then clears shortly after the door is closed High temperature alarm setpoint is set too low gt Check the setpoint and change it if necessary refer to Section II Item 8 3 2 Connections for the chamber temperature sensor are loose gt Check the sensor wire connection to the control board and secure the connection if necessary A component is faulty or internal connections are loose gt Contact Helmer Technical Service The freezer is connected to power but the AC Power Failure alarm is active Outlet connection is faulty gt Verify power at the outlet Repair the original outlet or connect to a different outlet if necessary Power cord is faulty gt Confirm the power cord is connected securely Secure the power cord if necessary ON OFF AC power Switch is faulty gt Replace the ON OFF AC power switch ON OFF AC power switch is OFF gt Switch the ON OFF AC power switch ON A component is faulty or internal connections are loose gt Contact Helmer Technical Service Circuit breaker is tripped
51. n the standard 2 Pivot the shelf clip downward and insert the lower tab into the corresponding slot in the standard Install a shelf 1 Insert shelf into chamber holding it at an angle 2 Lower one end of the shelf onto the shelf clips 3 Pivot the shelf downward lowering the opposite end onto the shelf clips Prepare for Monitoring Temperature Sensor The i C3 monitoring and control system obtains temperature readings from the chamber temperature sensor The sensor is located on the lower back wall of the chamber Figure 4 Chamber temperature sensor located behind cover Install Additional Temperature Sensor Through Upper Rear Port Additional temperature sensors may be installed through a port on the rear wall of the cabinet in the top left corner The port consists of two plastic caps one inside the cabinet and one on the outside The cabinet insulation fills the void between the plugs NOTICE Do not drill holes in the cabinet Drilling holes may damage the insulation in models equipped with vacuum insulated panels or may damage the evaporator coil causing a loss of refrigerant NOTE gt Helmer recommends installing additional sensors through the upper or lower rear ports provided gt The upper rear port may also be used to install tubing for an optional field installed CO LN backup refrigeration system Refer to Section Il Item 6 2 for additional information 13 Helmer Installation 8 Conf
52. nd note the setting for the high alarm e Touch Home 2 Move contents within the freezer to gain access to the chamber sensor 3 Using a heat gun or similar auxiliary heat source use low setting if available apply short bursts of heat to the chamber sensor 4 Observe the temperature on the i C display at which the high temperature alarm activates 26 Helmer 360173 A A 6 7 Maintenance amp Service The alarm should activate within 2 0 C of high alarm setpoint If the value is more than 2 0 C different contact Helmer Technical Service for further instruction Remove the heat gun and replace the contents of the freezer Close the freezer door Low Chamber Temperature Alarm Test NOTE gt To simulate a low temperature alarm condition raise the low alarm temperature setpoint to a point above current chamber temperature displayed on the C monitoring and control system gt The low chamber temperature alarm test does not test the accuracy of the low chamber alarm the test verifies that the low chamber alarm is functional gt Ifthei C monitoring and control system did not display a low temperature alarm during the alarm test contact Helmer Technical Service Test the low alarm 1 2 3 4 5 6 T Touch i C APPS Settings Enter the Settings password default password is 1234 Touch Alarm Settings Change the Low Temperature alarm setpoint to a point above the chamber temperature a Touch
53. nd user Additional Warranty Information The time periods set forth above begin two 2 weeks after the original date of shipment from Helmer Warranty procedures set forth above must be followed in all events THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE SHALL APPLY THE LIABILITY IF ANY OF HELMER FOR DIRECT DAMAGES WHETHER ARISING FROM A BREACH OF ANY SALES AGREEMENT BREACH OF WARRANTY NEGLIGENCE OR INDEMNITY STRICT LIABILITY OR OTHER TORT OR OTHERWISE WITH RESPECT TO THE 59 Helmer Warranty 14 6 360173 A A GOODS OR ANY SERVICES IS LIMITED TO AN AMOUNT NOT TO EXCEED THE PRICE OF THE PARTICULAR GOODS OR SERVICES GIVING RISE TO THE LIABILITY IN NO EVENT SHALL HELMER BE LIABLE FOR ANY INDIRECT INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES INCLUDING WITHOUT LIMITATION DAMAGES RELATED TO LOST REVENUES OR PROFITS OR LOSS OF PRODUCTS This warranty does not cover damages caused in transit during installation by accident misuse fire flood or acts of God Further this warranty will not be valid if Helmer determines that the failure was caused by a lack of performing recommended equipment maintenance per Helmer manual or by using the product
54. olid state relay Replace if control power is present but relay is not allowing voltage to pass gt Compressor buzzing or humming replace start components gt Amperage check and OHM compressor Contact Helmer Technical Support Both compressors gt Check cascade temperature touch i C3 settings running user password device status and history Cascade temperature maintaining below 20 C BUT greater than 50 C Normal Allow to stabilize gt Cascade temperature 50 C or colder Oil logging Defrost unit per Section III Item 9 4 1 Low stage low on charge Contact Helmer Technical Support to utilize tech service thermocouples 360173 A A 43 Helmer 11 3 360173 A A Alarm Activation Problems Problem Possible Cause Troubleshooting Action The freezer is in an alarm condition but alarms are not audible Audible alarms are muted gt Verify that audible alarms are not muted If time remaining is greater than five minutes change MUTE timer value to five minutes and wait until timer resets gt Check alarm volume level and tone selection touch i C3 settings enter password sound settings i C control board is faulty gt Confirm the control board is operating correctly Replace if necessary Speaker is faulty gt Replace display assembly A component is faulty or internal connections are loose gt Contact Helmer Technical Service The freezer
55. oor Gasket If the exterior door gasket has excessive frost or ice build up and requires defrosting Helmer recommends defrosting the entire chamber Please refer to Section Ill Item 9 4 1 for instructions After defrost is complete carefully inspect the door gasket for tears or damage and ensure proper adhesion to the exterior door Defrost and Clean Interior Doors Frost accumulation is normal The interior doors must be periodically defrosted to prevent excessive frost from interfering with door operation and storage of product or the freezer s ability to maintain temperature Defrost the interior doors according to the preventive maintenance schedule outlined in the operation manual CAUTION Use appropriate gloves when handling cold interior components NOTE v This procedure does not require the freezer door to remain open for an extended period of time Stored inventory may be kept in the freezer while this procedure is performed Do not use warm water to defrost the interior doors A heat gun may be used to defrost the interior doors vvv Required tools gt Dry cotton cloth Defrost the doors 1 Open the chamber door 2 Remove one interior door a Open the interior door b Liftthe interior door up to free the hinge pins from the hinges c Remove the interior door from the freezer 3 Close the chamber door 4 Allow the interior door to set for approximately four hours to allow accumulated frost to me
56. overs Door Cabinet Screws Door Flush alignment screws screw Hinge Jam nut Cabinet Figure 12 Exterior door hinge detail Align the door flush with the cabinet NOTE This procedure provides instruction for adjusting one hinge Any of the three hinges may be adjusted using this procedure 1 2 Using a 2 Phillips screwdriver remove the screws securing the hinge covers Remove the hinge covers from the hinge 37 Helmer 10 6 360173 A A Maintenance amp Service 3 Hold a straight edge ruler on the side of the freezer spanning the door and cabinet adjacent to the hinge being adjusted 4 Using a 20 Torx driver tighten or loosen the adjustment screw in the hinge until the right edge of the door is flush with the right side of the cabinet 5 While holding the adjustment screw with a 20 Torx driver tighten the jam nut with a 1 2 box wrench Reinstall the hinge covers on the hinge 7 Using a 2 Phillips screwdriver reinstall the screws securing the hinge covers o Cabinet Check for flush alignment Door Verify door is aligned flush with side of cabinet Replace Caster If a caster is bent or broken it can be replaced NOTE gt Areplacement Caster Kit is available from Helmer Technical Service gt Order Service Kit part number 800188 1 gt Refer to the instructions included with the Caster service kit 38 gt Helmer Section IV Troubleshooting Troubleshooting
57. pping ensure door is closed and latched and casters are unlocked and free of debris before moving freezer gt The freezer is extremely heavy Helmer recommends that two people work together to move the freezer 1 Ensure all casters are unlocked and door is closed and latched 2 Roll freezer into place and lock casters 3 Adjust leveling feet as necessary to ensure freezer is level 4 Connect AC power cord to a grounded outlet meeting the electrical requirements stated in Section Item 4 Leveling 1 Seta bubble level on top of freezer cabinet Orient the level front to back on the top of the cabinet 2 Using a 9 16 open end wrench back the jam nut away from the weld nut 3 Hand thread the leveling legs downward until they make contact with the floor 4 Using a 5 8 open end wrench rotate the leveling legs downward until the front casters touch the floor 5 Check the bubble level to ensure the freezer is parallel to the floor front to back or angled slightly back from vertical 6 Check the leveling legs and rear casters to ensure the freezer contacts the floor at four points gt Adjust both leveling legs as necessary to achieve four contact points 7 Hand thread the jam nuts upward until they make contact with the weld nut 8 Place a 5 8 open end wrench on the leveling legs to prevent them from rotating while the jam nut is tightened 9 Using a 9 16 open end wrench snug the jam nuts against the weld nuts 6 2 Backup
58. r doors Label Description Service Kit Number A Inner door iUF 116 12 25 800183 1 iUF 118 9 25 800183 2 iUF 124 12 25 800183 3 iUF 126 9 25 800183 4 B Inner door hinge 800185 1 C Inner door gasket iUF 116 118 800184 1 iUF124 126 800184 3 D Chamber temperature sensor cover E Chamber temperature sensor wire cover Not Chamber chart recorder temperature sensor 800169 6 shown behind cover F Shelf standard G Shelf clip H Inner door mullion gasket iUF 116 800187 2 iUF 118 800187 1 iUF 124 800187 4 iUF 126 800187 3 Shelf J Inner door retaining clip 800186 1 K Inner door catch 800186 1 360173 A A 56 Parts amp Schematics MAIN POWER a GI Bezel Mount EMI Components HELMER INC 400937 1 a Speaker POWER CORD r j Scd REAR ELECTRICAL PANEL SD Memory Gard TOS DRM FORK icaLco wi Touch Soren E Ethernet Port B USE Port C20 Power Entry Module L1 12 LIN GND L2IN TOO Race TGR GF USB Port iG Serial Port R23 EXTERIOR COZILN2 R ALARM BACKUP s CONTACTS CONTACTS cow Nel No fe He no com Tete LCD Touch Screen c RFI Filter LiOUT L20UT G e 0 CIRCUIT BREAKERS
59. raceable standard gt Temperature sensor is fragile handle with care NOTE If the displayed temperature is within 1 0 C of the measured temperature calibration is not required Verify chamber monitor control temperature sensor is reading chamber temperature correctly by comparing sensor reading to temperature read by an independent calibrated and traceable thermometer If sensor is not reading correctly change the offset value displayed on the monitor CAUTION Use appropriate gloves when handling cold interior components and stored inventory Sensor specifications P Initial factory calibration setting varies gt Offset value can be changed from 10 0 C to 10 0 C gt Sensor is 100 Q platinum RTD Required tools gt Independent thermometer with a 5 1524mm lead or greater calibrated and traceable per national standards gt Zip tie to attach thermometer to sensor Calibrate sensor 1 Move contents within the freezer to gain access to the sensor 2 Using a zip tie attach the independent thermometer to the cover surrounding the sensor NOTE Ensure the independent thermometer is not touching the cabinet wall or any other metallic components inside the cabinet 3 Close the door and allow the chamber temperature to stabilize for a minimum of five minutes 4 Observe and note the thermometer temperature gt Ifthe temperature variance is within 1 0 C of the temperature displayed on the i
60. relays are faulty gt Confirm the control board indicates both compressors should not be running Touch i C APPS Settings enter the Settings password Device Status and History gt If both compressors should not be running check the compressor solid state relays gt Ifthe compressor solid state relays are closed replace the relays i C control board is faulty gt Confirm the control board is calling for both compressors to be running Touch i C APPS Settings enter the Settings password Device Status and History gt If both compressors should be running no further action is needed gt If both compressors should not be running check the control board compressor relays If the relays are closed replace the control board 41 Helmer Problem Possible Cause Troubleshooting Action The chamber temperature meets an alarm condition but the appropriate temperature alarm is not active Temperature alarm setpoint was changed Check the current setpoints for the temperature alarms Change the setpoints if necessary refer to Section Il Item 8 3 1 The chamber temperature does not reach or stabilize at setpoint Ambient air gt Confirm freezer location meets requirements temperature is too Refer to Section Il Item 5 high Warm product was gt Move product and monitor chamber temperature placed at sensor Wait to see if temperature ha
61. ry power Mute audible alarms Shortcut to Event log View Unit ID vVvvvvvvvy Alarm Reference If an alarm condition is met an alarm activates Some alarms are visual only others are visual and audible Some alarms are sent through the remote alarm interface The table indicates if an alarm is audible A visual V or sent through the remote alarm interface R Alarm Alarm Type High Chamber Temperature A V R Low Chamber Temperature A V R Sensor Failure Chamber Temperature Control A V R High Ambient Temperature VR Low Ambient Temperature VR Sensor Failure Ambient Temperature A V R Refrigeration System High Stage Compressor Temperature A VR Sensor Failure High Stage Compressor Temperature A VR 16 Helmer 8 3 360173 A A Installation amp Configuration Alarm Alarm Type Sensor Failure High Stage Condenser Temperature A V R Refrigeration System High Stage Compressor Failure A V R Refrigeration System High Refrigerant Pressure A V R Refrigeration System Low Stage Compressor Temperature A V R Sensor Failure Low Stage Compressor Temperature A V R Refrigeration System Low Stage Compressor Failure A V R Sensor Failure Heat Exchanger Temperature A V R Low Battery VR No Battery A V R AC Power Failure A V R AC Power Failure High Voltage A V R AC Power Failure Low Voltage A V R AC Conditioned High
62. s Problem Possible Cause Troubleshooting Action There is excessive ice in the chamber on the interior doors or on the exterior door gasket Humid air is entering the chamber gt Verify the door is aligned gap is within spec closing tightly and sealing correctly Correct issues as necessary Check for tears loose door gasket or damaged door gasket Replace if necessary Defrost the chamber exterior door gasket and interior doors if necessary refer to Section III Items 9 4 1 9 4 2 and 9 4 3 Exterior door is not closing completely vv v v Defrost the exterior door gasket if necessary refer to Section Ill Item 9 4 2 Confirm the hinges are not damaged Replace the hinges if necessary Confirm door gaps and alignment are appropriate Check door latch to ensuer it is securing and remains secure Relative humidity around freezer is too high v Confirm freezer location meets requirements refer to Section Il Item 5 46 Helmer Section V Parts amp Schematics 12 NOTICE 360173 A A Parts amp Schematics vv Review all safety instructions prior to replacing parts refer to Section I Item 2 Replacing parts should only be performed by trained refrigeration technicians v Before replacing parts protect items in freezer from extended exposure to adverse temperature Allow chamber temperature to stabilize at setpoint after replacing parts or af
63. s stabilized or lowers gt Check remaining items Excessive frost has gt Defrost chamber Refer to Section Ill Item 9 4 1 accumulated in the chamber Temperature control gt Check accuracy of temperature probe sensor is faulty gt Confirm the sensor is providing resistance in the range of 73 O to 110 O Replace the sensor if resistance is outside of specified range gt Install jumper across J11 on the CP board Display 4C 1 NO call Helmer Technical support gt Display 4C 1 YES CP board process is good check connections at CP board and under connector pin wait 8 hours to see if unit stabilizes Condenser filter is gt Check condenser filter clean as needed dirty Condenser fan gt Check voltage and wiring to fan motor at connector running slowly or not gt Check voltage output at CP board relay J42 at all gt Replace motor Low stage gt Check cascade temperature touch i C3 settings compressor starting and stopping after 2 to 10 minutes run time enter password device status and history Cascade temperature maintaining below 20 C NO Contact Helmer Technical Service YES During pull down and starting at 35 C normal behavior YES Check compressor amperage OHMs and start components 42 Helmer Problem Possible Cause Troubleshooting Action Low stage not running High Stage running Check cascade temperature touch i C3 settings enter pass
64. t and 7 1 2 Install Additional Temperature Sensor Through Lower Rear Port for instructions on installing sensors or tubing through the rear ports Three threaded screw holes have been provided on the interior back wall of the cabinet to assist in installing and routing the backup refrigeration system Holes are 8 32 thread with Phillips screws temporarily installed Backup CO and LN Refrigeration Systems are available from Helmer Scientific Figure 1 Threaded screw holes and distribution port for backup refrigeration system installation Backup System Contacts Remote contacts are provided on the back of the freezer for the backup refrigeration system The backup System may be connected to the i C monitoring and control system with the remote contacts If the backup system is activated the system activation will be communicated to the i C through the remote contacts An icon will be displayed on the i C to indicate that the backup system has been activated NOTICE The i C monitoring and control system does not control the operation of the backup refrigeration system Connect External Monitoring Devices CAUTION The interface on the remote alarm monitoring system is intended for connection to the end user s central alarm system s that uses normally open or normally closed dry contacts If an external power supply exceeding 30 V RMS or 60 V DC is connected to the remote alarm monitoring system s circuit
65. t in lieu of servicing it in the field Compressor For the warranty period listed below Helmer will supply the refrigeration compressor if it is determined to be defective at no charge including freight Helmer will not be liable for installation refrigerant or miscellaneous charges required to install the compressor beyond the first year of the warranty period gt i Series model compressor warranty period is five 5 years 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 door gaskets and monitoring system backup battery are excluded from this warranty coverage Inspection of defective parts by Helmer will be final in determining warranty status Warranty procedures must be followed in all events Labor For a period of two 2 years Helmer will cover repair labor costs including travel and the cost of refrigerant and supplies necessary to perform authorized repairs Repair service must be performed by an authorized Helmer service agency following the authorization process detailed above Alternatively your facility s staff may work with a Helmer technician to make repairs Labor costs for repairs made by unauthorized service personnel or without the assistance of a Helmer technician will be the responsibility of the e
66. tch battery on to provide monitoring system with backup power in the event of AC power failure Move Shelves Figure 3 Interior Shelves Shelf clip and doors shelf standard gt Use appropriate gloves when handling cold interior components and stored inventory gt Keep hands away from pinch points when closing the door gt Before moving shelves ensure they are empty for safe lifting gt Maximum shelf load is not to exceed 160 lbs 73 kg gt Total freezer weight including contents is not to exceed 1400 Ibs 635 kg NOTICE gt Before moving storage components protect stored items in freezer from extended 360173 A A exposure to adverse temperature gt When removing or replacing storage racks do not allow the storage rack to set on the top edge of a partially open interior door gt To avoid damage to the interior door hinges do not apply upward or downward force to the interior doors 12 Helmer Installation amp Configuration 7 1 360173 A A Remove a shelf 1 With one hand lift one end of the shelf from the shelf clips 2 With the other hand lift the opposite end of the shelf from the shelf clips 3 While holding the shelf at an angle remove it from the chamber and set aside Remove a shelf clip 1 Grip the shelf clip and pivot it upward to remove the lower tab from the standard 2 Remove the upper tab from the standard Install a shelf clip 1 Insert the upper tab into a slot i
67. temperature is too high because the high stage compressor is not operating when it should be One or more system gt Contact Helmer Technical Service components has failed Sensor Failure alarm One or more of the gt Check the i C Event Log Detail screen for is displayed on the monitor temperature sensors has failed or sensor wiring is an open circuit the specific sensor failure Touch i C APPS Information Logs Event Logs Touch the individual event to view the sensor failure code Check the sensor wire connection to the control board and secure the connection if necessary Confirm the sensor is providing resistance in the range of 73 O to 110 O Replace the sensor if resistance is outside of specified range 360173 A A The chart recorder is not marking the temperature The chart paper knob is not tight Tighten the chart paper knob Stylus pressure is not Confirm stylus is pressing firmly against paper correct The chart recorder gt Remove the chart paper and press the reset button motor has stopped behind the chart paper Reinstall the chart paper running The chart recorder is Replace the chart recorder defective 40 Helmer 11 2 360173 A A Chamber Temperature Problems Problem Possible Cause Troubleshooting Action The chamber temperature displayed is higher or lower than the actual temperature Chamber temperature sensor is
68. ter extended door opening NOTE Replacement parts that are included in a service kit are designated with an 800 level part number 800XXX X All Service Kits have been designed to aid in field service and installation Service kits include all parts and installation instructions needed for field installation Individual replacement parts are designated with part numbers other than 800 level part numbers Service kits and replacement parts are available from Helmer Technical Service 1 800 743 5637 47 Helmer 12 1 NOTICE 360173 A A Front Figure13 Helmer Figure14 Parts amp Schematics The i C display assembly is sensitive to static electricity and can be damaged by electrostatic discharge Use proper ESD precautions when handling the display assembly Label Description Service Kit Number A Door B i C user interface 800165 1 C Door handle with key lock electronic lock and padlock hasp D Condenser grill 800202 1 E Condenser grill filter 800159 1 F Chart recorder optional 800196 1 G Chart recorder door H Chart paper 52 sheets 800197 1 Caster swivel with brake 800188 1 J Front bezel with chart recorder door iUF116 800191 2 iUF118 800190 2 iUF124 800193 2 iUF126 800192 2 K Interface cable L Power cable M Display board Included in 800165 1 N Touch screen Included in 800165 1
69. thaws preferably close to a floor drain 7 Open the chamber door Prop the door open ensuring the method used does not damage the door gasket 8 Remove and defrost the interior doors aoanh wn NOTE Refer to Section III Item 9 5 3 for instructions on defrosting interior doors 9 Allow the freezer to set for 24 hours to allow accumulated frost to melt After 24 hours check to verify that the interior is free of frost 10 Clean interior surfaces and door gasket with soft cotton cloth and non abrasive liquid cleaner 11 Wipe the interior surfaces and door gaskets with a dry cotton cloth to remove moisture NOTE All moisture must be removed before powering the freezer on Any remaining moisture will re freeze in the chamber and may require more frequent defrosting than indicated in the preventive maintenance schedule 12 Install the interior doors 13 Close the chamber door 14 Remove any accumulated moisture from the floor 15 Move the freezer to the original location 16 Reattach the AC power cord to the freezer 17 Reconnect the freezer to AC power 18 Switch AC ON OFF switch ON 19 Switch battery ON OFF switch ON 20 Touch Mute to disable the high temperature alarm while freezer reaches operating temperature 21 Once the freezer reaches the setpoint it is ready for use 22 Return stored product to the freezer 31 Helmer Maintenance amp Service 9 4 2 9 4 3 360173 A A Defrost and Clean Exterior D
70. the remote alarm will not function properly may be damaged or may result in injury to the user 10 Helmer Installation amp Configuration 6 3 1 6 4 360173 A A NOTE All alarm conditions including power failure are transmitted through the remote alarm contacts The remote alarm interface is a relay switch with three terminals gt Common COM gt Normally Open NO gt Normally Closed NC Terminals are dry contacts and do not supply voltage Interface circuit is either normally open or normally closed depending on terminals used Requirements for your alarm system determine which alarm wires must connect to terminals The terminals on the remote alarm interface have the following maximum load capacity gt 0 5 Aat 30 V RMS 1 0 A at 60 V DC Connect to Remote Alarm Interface 1 Switch battery ON OFF switch OFF Switch AC ON OFF switch OFF 2 On the back of the freezer locate the remote alarm terminals 3 Connect remote alarm wires to appropriate terminals according to requirements for your alarm System 4 Usea cable tie to relieve strain on alarm wires as necessary Switch AC ON OFF switch ON Switch battery ON OFF switch ON 6 Touch Mute or raise the high alarm limit to disable the high temperature alarm while freezer reaches operating temperature If high alarm limit is changed it must be changed back prior to operation of freezer a Start i C3 Backup Power The monitoring system has
71. ver M Oil separator low stage Included in 800162 1 N Expansion tank balancing line low stage 800164 1 O Dryer high stage Included in multiple kits P Dryer low stage Included in multiple kits Q High stage solenoid kit includes valve coil and dryer 800158 1 R Expansion tank low stage 360173 A A 54 Helmer Parts 8 Schematics 12 5 2 Cascade Heat Exchanger Compartment A CAUTION Avoid sharp edges when working inside the cascade exchanger compartment NOTICE The TXV thermal expansion valve is not a serviceable component To replace the TXV the cascade heat exchanger assembly must be replaced m O QO U Figure 25 Refrigeration system features in the cascade heat exchanger compartment Label Description Service Kit Number A Cascade heat exchanger assembly with TXV 800156 1 B Cascade exchanger temperature sensor 800169 1 C TXV thermal expansion valve 800157 1 D Dryer low stage Included in multiple kits E Capillary metering line low stage 800163 1 360173 A A 55 Helmer Parts amp Schematics 12 6 Interior Figure 26 Interior features A CAUTION Keep hands away from pinch points when closing the door NOTICE gt When removing or replacing storage racks do not allow the storage rack to set on the top edge of a partially open interior door gt To avoid damage to the interior door hinges do not apply upward or downward force to the interio
72. verify sensor calibration 12 Remove moistened rag towels from the sensor 13 Replace the condenser grill 14 Change the Low Ambient time delay to the original setting 15 Touch Home a Non configurable Temperature Alarms NOTICE gt Some temperature alarms are not user configurable As such the alarm setpoint cannot be changed to simulate a high temperature alarm gt Due to the inaccessibility of the temperature sensor it is not recommended that an alarm condition be simulated through manual means for these alarms Non configurable temperature alarms gt Low Stage Compressor Discharge Temperature Alarm gt High Stage Compressor Discharge Temperature Alarm gt High Stage Condenser Discharge Temperature Alarm gt Cascade Heat Exchanger Temperature Alarm Upgrade System Firmware Helmer may occasionally issue updates for the i C firmware Follow upgrade instructions included with the firmware update Test and Replace Backup Battery Test Monitoring System Backup Battery On all i C screens the Battery icon will appear in the header bar when the system is running on battery power and the screen brightness will automatically be reduced The monitoring system will automatically disable some features to extend battery life 29 Helmer 9 3 2 9 4 9 4 1 Test the battery Maintenance amp Service 1 Switch AC ON OFF switch OFF gt Screen will continue to display information with reduced brightness
73. word device status and history Cascade has to reach 35C before low stage will start Did cascade reach 35C NO contact Helmer Technical Service YES it is normal to see the cascade heat exchanger elevate above 35C and could reach 20C if this happens the low stage will cycle off NORMALL Y until the low stage reaches 35C and the low stage will start again This is most typical during pull down At normal operation when at setpoint this will not occur Check i C3 Control board for lit compressor LEDs D21 and D22 to energize compressor relays ON check remaining items OFF Contact Helmer Technical Support gt Check i C3 Control board for lit compressor LEDs D21 and D22 to energize compressor relays ON check remaining items OFF Contact Helmer Technical Support gt Check solid state relay replace if control power is present but relay is not allowing voltage to pass gt Verify operation of High pressure switch s control and line is not open gt Check start components gt Contact Helmer Technical Service Compressor s not gt Check power to unit running gt Verify call for both compressors touch i C3 settings enter password device status and history call for both on NO Reboot YES Check remaining items gt Check i C3 Control board lit compressor LEDs D21 and D22 to energize compressor relays OFF Contact Helmer Technical Support ON Check remaining items gt Check s
74. y turning battery and AC power off and back on 39 Helmer Troubleshooting Problem Possible Cause Action Refrigeration System Refrigerant pressure gt Ensure that freezer has been installed with proper alarm is displayed on or temperature is too clearances the monitor high due to improper Check that ambient temperature is in the acceptable airflow range gt Check the air filter and condenser face and clean or replace as needed gt Check condenser face clean as needed gt Check the operation of the consenser fan and repair or replace as needed Refrigerant pressure gt Ensure that products being placed in the freezer are or temperature is too pre frozen to avoid introducing an excessive heat high because the load freezer is not being used as intended Refrigerant pressure Check the status of the low stage compressor or temperature is too high because the low stage compressor is Touch i C APPS Settings enter the Settings password Device Status and History Scroll as needed to view the compressor status not operating when it gt Verify CP is initiating SSR2 to be ON by checking should be that the LED for SSR2 is lit gt Verify control voltage is leaving the SSR2 relay gt Check the line voltage high pressure switch ensuring switch is closed gt Check the low stage compressor start components Refrigerant pressure gt Contact Helmer Technical Service or

i.Series Ultra-Low Freezer Service Manual

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