EasyCool ULTH-100 User manual

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OPERATION MANUAL
&
SERVICE MANUALN
FOR
ULTRA LOW TEMPERATURE FREEZER
Model No : ULTH-100
EASYCOOL REFRIGERATION
2, Colgate Estate, B/h. Chakudia Mahadev Mandir,
Rakhiyal, Ahmedabad-380023, Gujarat (INDIA)
Mobile: [phone]
E-mail: [email protected]
Website : www.easycool.co.in

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CONTENTS
Introduction …………………………………………………………………..3
Unpacking Freezer………………………………………………………….3
Pre-installation Requirements ……………………………………………..4
General Constructions……………………….……………………………..4
Refrigeration …………………………………………………………………4
Control panel & Electrical …………………………………………………..4
Installation & Pre-commissioning Checks ………………………………..4
Pre-commissioning Tests ………………………………………………….5
Do’s & Don’ts ………………………………………………………………..6
Operating Instructions ……………………………………………………...7
Working Principle ……………………………………………………………7
Programming the Controllers ……………..……………………………….8
Maintenance Schedule ……………………………………………………..8
List of Recommended Tools ……………………………………………….9
Electrical Circuit Diagram …………………………………………………..9
Refrigeration Flow Diagram ………………………………………………..9
Defrosting ……………………………………………………………………10
Simple Trouble Shooting …………………………………………………..10
Specifications ………………………………………………………………..11

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INTRODUCTION
Thank you for choosing this Ultra low Temperature freezer.
Cooling and heating have been essential processes which have greatly contributed to society
and development. For example, biomedical research and blood banking have greatly
benefited due to the availability of equipment with controlled thermal conditions. Deep
freezers are used to preserve a range of microorganisms, plant and animal tissues, vaccines,
blood components such as plasma, etc.
Our freezer provides precise control of temperature in laboratory, Research, Hospitals and
Blood Banks to meet their critical standards on reliability and user friendliness.
Keep this manual in an adequate place to refer to it as necessary.
The contents of the manual will be subject to change without prior notice due to the
improvement of performance or functions.
Only trained & authorized personnel could operate this Ultra low temperature freezer.
Only qualified service personnel or authorized agent could install and maintenance this
freezer.
Should inspect and maintenance the freezer in a specified time interval.
UNPACKING FREEZER
Place the equipment in upright position.
Four sides and wooden crates should be removed with necessary tools like hammer and
also safely removed the nails in the wooden crates.
Keep the uncrated wooden blocks and pieces with nails in a safe place and destroy it.
Look for any identical damages in the equipment and note it down and rectify the defects.
Inspect and remove any remains of packing, tape or printed material before powering on
the Freezer.
CAUTION:
Dispose the nails & other packing materials properly to avoid injury.
NOTE:Only Authorized person should handle the unpacking.

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PRE-INSTALLATION REQUIREMENTS:-
Main Door opening: - Please ensure that the entrance of main door to the building as well
as the entrance of user/lab room should have a minimum clearance of 4 feet (W) & 7 feet (H)
to take the equipment inside.
Electrical requirement: - 15 Ampssingle phase 3pin socket with 16 MCBsbreaker made of
good quality IS standards with proper earthing to avoid loose contact.
Ventilation :- The room where the equipment has to be installed should have adequate
crossventilation with large windows on two sides of the room so as to maintain ambient of
30°C to 10°Cair conditioned room.
GENERAL CONSTRUCTION
Interior is made of GIPP.
Exterior of CRC Powder Coated.
Non-CFC, high density, high temperature performance, six side of body withPUF 125mm
insulation.
Double foaming PUF insulated door, hinged main door with Door lock and Double circuit of
PU gaskets to prevent any air seepage.
Mounted on heavy-duty ball bearing castor wheels for smooth movements with lock.
Working temperature is from -40°C to -80°C (Control Accuracy ± 5°C)
REFRIGERATION:
Non-CFC Hermetically sealed compressors.
Non-CFC eco-friendly HFC refrigerants (mixture).
Copper cooling coils 99.97% purity on all sides of chamber.
External Fan motor condenser cooling fan.
CONTROL PANEL & ELECTRICAL:
Microprocessor Dual Display Controller.
Audio-visual alarms for High/Low temperature deviations.
Electronic interlock between pressure switch and Solenoid Valve.
Volt & Ampere Digital Indicator
High & Low Voltage & High Ampere safety cutoff for the compressor.
INSTALLATION & PRE COMMISSIONING CHECKS
The chamber is commercially packed and transported in a reasonably upright position.
It must not be carried on its back, front or side. To do this would strain the refrigeration
mount.
The chamber is completely assembled and tested at EASYCOOL REFRIGERATION prior to
shipment.

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Uncrate and carefully inspect the entire cabinet, control panel, etc. for signs of damage. Look
for signs of rough treatment in shipment; broken tubing, dents, sagged door, loose
instrument, loose compressor or other heavy component.
Any damage due to rough handling in transit should be reported to the carrier.
Inspect the door, door gasket and Door lock. Door must be a good fit.
Place the chamber where ventilation is good and leave space between the cabinet’s side and
the wall of at least 30 cm.
Place the unit in position making sure that the cabinet is level. If the unit is air cooled the inlet
and outlet grills must be at least 30 cm from walls or other fixtures.
Allow sufficient room to get at all access panel.
PRE-COMMOSSIONING TESTS:
Check for completeness of installation
Check Ambient Temperature between 10 to 30 Deg C & Relative Humidity below 60%.
Check for tightness of all outgoing cable connections and internal wiring termination.
Check for proper connection of the earth us.
Continuity check for external wiring.
Megger test for power cable wiring and control cable wiring.
Verification of operating sequence for control circuits.
The Freezer should be located in a clean, cool and well ventilated area or in an air
conditioned space.
DON’T shift the unit without blowing all water from the system.
Don’t plug several appliances in to the same socket.
This could cause overheating and the risk of fire.
Keep the power plug away from the rear of the freezer.
A damaged power plug may cause fire due to overheating.
Don’t spray the water directly inside or outside of the freezer.
There is a risk of fire or electric shock.
Don’t spray flammable gas near the freezer.
There is a risk of explosion or fire.
Don’t bend the power cord excessively or place heavy articles on it.
This continuous the fire hazards. If the power cord is damaged, have it replaced
immediately by the manufacturer or its service agent.
Don’t insert the power plug with wet hands.
You may receive a electric shock.
Don’t install the freezer in a damp place, where it may come in the contact with water.
Incorrect insulation of the electrical parts may cause an electric shock or fire.
Pull the power plug out of the socket before replacing the accessories.
Otherwise there is a risk of electric shock.

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DO’S & DON’T’S
Don’t plug the several appliances in to the same socket
This could cause overheating and the risk of fire.
Keep the power plug away from the rear of the freezer
A damaged power plug may cause fire or overheating.
Don’t spray the water directly inside or outside of the freezer
There is a risk of explosion or fire.
Don’t bend the power cord excessively or place heavy articles on it.
This continuous the fire hazards. If the power cord is damaged, have it replaced
immediately by the manufacturer or its service agent.
Don’t insert the power plug with wet hands.
You may receive a electric shock.
Don’t install the freezer in a damp place, where it may come in the contact with water.
Incorrect insulation of the electrical parts may cause an electric shock or fire.
Caution:
If fresh air is not available, then refrigeration system will be damaged.
Level the chamber.
Inspect the conditioner fan inside the chamber.
Occasionally, during shipment the motor is pushed out of vertical alignment.
As consequence, the fan blade will strike the casing.
Make sure that the fan motor is pushed back into its proper alignment on its mount.
Inspect the electrical control panel containing the wiring and electrical for any wires or
screws that may have become loose during shipment.
Checking Compressors:
Check compressors for loosened fasteners, terminal loose connections, etc. and rectify.
The cabinet must be on a level floor as it is most essential that the compressors are level.
Each unit is double checked and then charged and run for several days.
It is brought to room temperature several times and then brought from the ambient
temperature to specified temperature.
Also included are the setting for all the controllers, regulators, oil and refrigerant charges,
etc.
Until maintenance department become thoroughly familiar with the operation of the unit,
this data can be a very helpful reference.

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When the power is switched on the display controller should start.
When the controller output turns ON after time display (approx.. 1 minute) the condenser
fan and compressor will start.
OPERATING INSTRUCTIONS:
Once the cabinet is comfortably positioned, connect the plug top to the power line and
ensure that there are no loose contacts.
Ensure that the earthing is also proper.
Switch on the mains.
The power to the equipment should have high and low voltage cut off and time delay
restart to the power.
Once the main is on the indication of the controller will glow.
Set the required temperature (-80°C set default) by using the Controller.
Once the temperature is set, the compressor is starts running with relay.
When the set temperature is reached in the chamber, the compressor is made
ON/OFF by the controller for maintaining the temperature.
If any temperature deviation arises due to some reason, the audio-visual alarms
automatically activated to indicate the same.
WORKING PRINCIPAL
When the main supply is switched ON, the controller is in ON position.
The compressor and fan motor is directly connected with the supply.
When the output of the main temperature controller is on, the relay coil will energize
the supply goes to the compressor and fan motor.
When the compressor is switched on, the temperature comes down.
The compressor is continuously running up to the set temperature.
Once the set temperature is reached, the compressor will get switched off
automatically.
The temperature controller controls the temperature of the chamber by ON / OFF
method within ± 3° C accuracy.
Upper readout of the temperature controller will display process value in °C and the
lower readout shows set temperature value in °C.
Normal running indicates that refrigeration system working smoothly.
If the system gets alarm, indication will appear on the controller display.
Safety alarms Indicate when high / low Temperature deviation.
Voltage& Current indicator will not flash due to abnormal voltage or abnormal current
condition.
Programming the Controller

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Programming the Controllers
PPI zenex Controller Operating Manual : Attachment 1
Subzero Sz 7569-P Controller Operating Manual : Attachment 2
MAINTANANCE SCHEDULE :
SR.
NO.
DESCRIPTION
DAILY
WEEKLY
MONTHLY
QUARTARLY
YEARLY
1
Clean the inner chamber completely.
-
-
-
-
2
Clean the external body fully
-
-
-
-
3
Check the compressor rating
-
-
-
-
4
Clean the condenser coil
-
-
-
-
5
Check any oil trace in refrigerant line
-
-
-
-
6
Clean the condenser grill mash
-
-
-
-
7
Check any loose connection for power supply &
instrumentation lines
-
-
-
-
8
Clean the electrical panel
-
-
-
-
9
Cleaning the switches
-
-
-
-
10
Check the miscellaneous electrical components
and the tightening the terminal end
-
-
-
-
11
Cleaning the gasket door
-
-
-
-

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COMMON MAINTENANCE IN 6 MONTHS OR AS NECESSORY:
Wipe the exterior of the equipment with mildly damp cloth and clean only with a dry
cloth.
Examine the interior of the unit for any loose contacts, metal fatigue in the refrigerant
lines and the fasteners for the tightness.
Scrap the ice / snow from the top of the sub-doors, sub-door joints, interior or cabinet.
This will prevent hardening of ice & help minimize defrost frequency and time, cleaning
of gasket will prevent formation of grease, stubborn strains, fungus etc.
Switch of the unit of 24 hours.
Open the side grills to clean the condensing area using a vacuum cleaner / air blower.
Check for loose connections for electrical circuits.
Check for any loosened components / fasteners and correct it.
Restart the unit and observe the unit closely for stable performance.
LIST OF RECOMMENDED TOOLS
Box spanner for flare nut - 3/8.
Digital clamp meter.
Pressure gauge (0-500 PSIG)
Pressure gauge (compound)
Refrigerant service hose with valve.
refrigeration manifold.
Digital micron vacuum gauge.
Double stage vacuum pump 4.5 LPM.
Spanner set.
Screw driver set.
Wire cutter.
Insulation remover.
Continuity tester.
Crimping tools.
Test lamp.
ELECTRICAL CIRCUIT DIAGRAM
Electrical Circuit Diagram: Attachment3
Refrigeration Flow Diagram
Refrigeration Flow Diagram: Attachment 4

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Defrosting
To defrost, complete the following steps:
Remove all products and place in another cabinet.
Turn off the freezer.
Open the outer door and all inner doors.
Let the freezer stand with doors open for at least 24 hours.
This allows both the interior and foamed refrigerant system to warm to room temperature.
Dispose of the ice and wipe out any water standing in the bottom of the cabinet.
If there is freezer odor, wash the interior with a solution of baking soda and warm water. Clean the
exterior with any common household cleaning wax.
Close the doors, restart the freezer and reload.
Trouble Shooting
problem
Cause
Solution
Unit set to –80°C but can’t
make temperature (Not
reaching set point).
Unit recovers slowly to set
point.
Warm load / Over load.
Allow ample time to recover
from loading warm product. Do
not overload cabinet.
Hot environment.
Check, if the location meets
ambient requirements (within
15°C to 30°C and away from hot
objects.
Dirty condenser.
Clean condenser.
Not enough space for air
circulation.
Install the unit in a level area
free from vibration with a
minimum of 30 cm of space on
the both sides.
Icing/Frost due to high relative
humidity
Check if the location meets
requirements. Maximum relative
humidity 60% for temperatures
within 15°C to 32°C
Excess frost build-up in chamber
Defrost the unit
Frost build-up on outer door
gasket.
Occasionally scrape the ice on
the gasket.
Prolonged door openings.
Avoid opening of door for longer
duration. Allow ample time for
recovery after door opening
Inadequate power supply.
Check for proper voltage to the
unit.
Either of the compressors are
not working.
Check and Replace if necessary.
Refrigerant is insufficient
Check and charge if necessary.
Volt & Ampere (Display not
working more than 1 minute
Check the Current Protector
Check the power supply over or
under voltage. If Voltage is

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before reach power supply)
failure.
correct replace the unit.
Unit is ON but display is not
showing.
not powered on.
Check the power switch is on
position.
Fan does not rotate
Fan wiring is loose
Checking the wiring
Fan motor is fail
Change parts
High temperature in cabinet
The temperature setting of
outage is too high
Set the proper temperature set
point.
Refrigerant leaks
Find leak location and make
repair welding. Infuse refrigerant
again
Temperature probe is damaged
Change parts
Capillary tube or system is
blocked by dirt\ greasy
Clean the capillary tube or
change filter.
High ambient temperature
Turn on air-conditioner，reduce
ambient temperature.
Specifications
Model
ULTH-100
Capacity
100 LITER
Rating voltage
230 V
Rating Frequency
50 Hz
Rated current
5.5 A
Compressor 1st stage
EMBRACO 2155
Compressor 2ndstage
EMBRACO 2140
Refrigerant 1st stage
R-404a (350 gm)
Refrigerant 2ndstage
R-508b (200 gm)
R-290 (20 gm)
Temperature Controller
PPI ZENEX 44
Cascade Controller
Subzero Sz-7569-P
Voltage Current Protector
Gelco AaCcSvch
Design or Specifications will be changed without noticedue to the improvement of performance or functions.