Haskris R1600, Instruction Manual

Page 1: ... Type text INSTRUCTION MANUAL For the Installation Start up Operation and Maintenance of your Haskris System ...

Page 2: ...s 7 8 2 6 Chiller Water Glycol Solution from R1600 9 16 2 7 Install Checklist 16 Section 3 Start Section 3 Start Section 3 Start Section 3 Start Up Up Up Up 3 1 Remove Liquid Refrigerant Prior to Compressor Start Up 17 3 2 No Load Start Up 18 19 3 3 Full Load System Check 20 21 Section 4 Operating Features and Functions Section 4 Operating Features and Functions Section 4 Operating Features and Fu...

Page 3: ...Start Haskris Model R1600 No Load Start Haskris Model R1600 No Load Start Haskris Model R1600 No Load Start Up Checklist Up Checklist Up Checklist Up Checklist 39 41 Haskris Model R1600 Full Load System Check Haskris Model R1600 Full Load System Check Haskris Model R1600 Full Load System Check Haskris Model R1600 Full Load System Check 42 44 Haskris Model R1600 Preventative Maintenance PM Haskris ...

Page 4: ...2 6 5 Complete Install Checklist Submit to Haskris Section 2 7 Perform No Load Start Up Delivery Install of MRI Perform Full Load System Check Section 3 3 1 2 1 2 1 2 1 2 Registration Registration Registration Registration We have included an Owner s Registration Card on the back cover of this Instruction Manual The installing contractor must fill in the requested information and return this card ...

Page 5: ... information about your system so we can address problems quickly and effectively 1 4 1 4 1 4 1 4 After Installation and Service Support After Installation and Service Support After Installation and Service Support After Installation and Service Support Hitachi Hitachi Hitachi Hitachi Medical Systems America Medical Systems America Medical Systems America Medical Systems America HMSA HMSA HMSA HMS...

Page 6: ...substantiate the claim We also ask that you call Haskris if the system has been damaged in shipment We will assist in rectifying the situation 2 2 2 2 2 2 2 2 Proper System Location Proper System Location Proper System Location Proper System Location The Haskris Model R1600 chiller is designed for outdoor installation on a level concrete pad or level perimeter roof curb ROOF CURB MUST INCLUDE A CE...

Page 7: ...ion Isolators and Pipe support 3 Vibration Isolators and Pipe support Figure 2 2 below illustrates the airflow of the R1600 chiller The unit draws in air from all four sides and releases it back into the surrounding environment via the four top mounted fans Figure 2 3 below illustrates vibration isolators and pipe supports Pipe supports are needed to support R1600 piping Figure 2 Figure 2 Figure 2...

Page 8: ...s Avoid dusty areas and periodically check to make sure that the condenser is clean refer to Section 5 3 for air cooled condenser cleaning instructions Secure the system to the concrete pad or roof curb using the mounting holes see Figure 2 1 at the base of the chiller Consult local codes for proper anchoring methods PLEASE NOTE Do NOT affix any labels or stickers to the interior or exterior of th...

Page 9: ...B 2 4 2 4 2 4 2 4 Unpacking and Handling Unpacking and Handling Unpacking and Handling Unpacking and Handling The Haskris Model R1600 chiller is shipped in a wooden crate and bolted to a wooden skid as shown in Figure 2 4 below Remove the bolts which attach the chiller base to the skid Use the two fork openings as shown in Figure 2 4 above to remove the chiller from the skid and transport the chil...

Page 10: ...nd of this Instruction Manual PLEASE NOTE Consult your local electrical codes for specific requirements that apply to your area Haskris recommends contacting a licensed electrician to perform the electrical installation We recommend a service disconnect switch and time delay fusing be installed per the wiring diagram nameplate Have your electrician ensure that the proper wiring is installed in the...

Page 11: ...ee phase single side protection and monitors for phase reversal phase loss and phase unbalance as a function of input voltage If any fault exists the red FAULT LED indicator will blink or be lit After the fault is corrected there will be a 3 minute delay before the unit restarts Proper phase should be checked with the Mode Selector Switch in the center position Stop Mode When the service disconnec...

Page 12: ...s recommends removing excess flux from any external solder joint 2 Install Type L hard copper piping in a method as short and direct as possible in order to minimize the pressure drop across the piping See Worksheet 1 located at the end of this Instruction Manual to calculate recommended line size Consult your state local or municipal codes for other requirements 3 Install vibration isolators at t...

Page 13: ...l valve on both the supply and return lines at the indoor WW4 heat exchanger to allow isolation for service or unit replacement if necessary The R1600 chiller includes factory installed isolation valves at both the supply and return connections 13 Provide a temperature gauge 0 100 F on both the supply and return side between the ball valve and indoor WW4 heat exchanger to measure supply and return...

Page 14: ... as shown in Figure 2 10 A female to female GHT adapter if needed has been included in the Preventative Maintenance PM Test Kit provided separately to the Installer Figure 2 9 Valve Close Figure 2 9 Valve Close Figure 2 9 Valve Close Figure 2 9 Valve Close ups All Valves Illustrated in the CLOSED Position ups All Valves Illustrated in the CLOSED Position ups All Valves Illustrated in the CLOSED Po...

Page 15: ...em through a water meter to help establish the correct quantity of glycol solution required at fill Continue to flush piping for an additional 20 minutes Figure Figure Figure Figure 2 10 Valve Positions for Flushing 2 10 Valve Positions for Flushing 2 10 Valve Positions for Flushing 2 10 Valve Positions for Flushing Supply Side Isolation Valve Not Illustrated but CLOSED Supply Side Flush Valve wit...

Page 16: ...ssed dry air or dry nitrogen may be used to assist in purging piping of excess water and to dry piping prior to charging system with glycol solution 2 6 5 Fill System Fill 50 gallon tank and entire water piping loop independently as outlined below with a mixture of propylene glycol potable distilled water 35 by volume If city water is used in place of potable distilled water run city water through...

Page 17: ...d return side isolation valves 2 Locate the fill valve on the side of the glycol reservoir see Figure 2 11 3 Remove protective cap from fill valve and connect hose to the GHT connection as shown in Figure 2 10 4 Open the fill valve and fill the tank with glycol solution The level of glycol solution in the tank should rise as viewed through the liquid level indicator 5 Continue to fill tank until t...

Page 18: ...ose to the GHT connections as shown in Figure 2 9 3 Remove protective cap from the return side flush valve and connect hose to the GHT connection as shown in Figure 2 9 Place the other end of the hose in a large bucket This will be used as a vent when filling the piping with 35 glycol solution through the supply side flush valve Open the return side flush valve 4 Open the supply side flush valve a...

Page 19: ... 6 2 2 2 2 2 7 7 7 7 Install Checklist Install Checklist Install Checklist Install Checklist CHECKLIST MUST BE COMPLETED BY INSTALLER FOR NO LOAD START UP TO BE SCHEDULED R1600 CANNOT BE STARTED UNTIL COMPLETED CHECKLIST HAS BEEN RETURNED VIA FAX TO HASKRIS 1 Complete Install Checklist located at back of this Manual 2 Fax completed checklist to Haskris no less than 5 business days prior to desired...

Page 20: ...sors during shipment The compressors crankcase heaters will energize when main power is supplied to the R1600 and is not controlled by the three position switch located on the R1600 Control Panel See R1600 Control Panel description at the beginning of Section 3 Failure to energize the compressor crankcase heater 12 hours prior to the no load start up will shorten the lifetime of the compressor If ...

Page 21: ...ocation of I O switch Confirm both displays are lit Temperature Control Display and Head Pressure Display Do not proceed with the No Load Start up until both displays are lit Move the Cooling Mode Stop Pump Only Mode toggle switch to the Cooling Mode position to the left The pump motor compressor motor and condenser fan motors will energize Add glycol solution to the reservoir as necessary to main...

Page 22: ...n electrical enclosure 3 Repeat the step 1 above to increase the head pressure value to the original pre set value of 220 Use the key to increase the head pressure value 4 Press both keys simultaneously when done to return to the default display Turn off the system once system is operating satisfactorily Remove refrigerant manifold gauge Close control box and replace all sheet metal panels on the ...

Page 23: ...disconnect switch is turned on there will be a 3 minute delay before the unit starts Turn the I O switch on See R1600 Control Panel description at the beginning of Section 4 for location of I O switch Confirm both displays are lit Temperature Control Display and Head Pressure Display Notify on site Haskris Authorized Representative if these displays are not energized Do not proceed with the Full L...

Page 24: ...Measure and record amperage and voltage at the Fan Motor Inverter Contactor in main electrical enclosure 3 Repeat the step 1 above to increase the head pressure value to the original pre set value of 240 Use the key to increase the head pressure value 4 Press both keys simultaneously when done to return to the default display System should remain on and operational under load Remove refrigerant ma...

Page 25: ... VFD VFD controller for the A fans 2 Fan B VFD VFD controller for the B fans 3 Temperature Control and Display Displays glycol solution temperature set value SV and current glycol solution temperature process value PV See Section 4 1 4 Head Pressure Display A Indicates refrigerant head A pressure set value SV and current head A pressure process value PV 1 2 3 4 5 6 Figure 4 0 R1600 Control Panel F...

Page 26: ...p will not operate more glycol must be added to system Power must be off See page 29 9 I O Switch Energizes or De energizes entire R1600 system with exception to the crankcase heater Crankcase heater is energized when main power is supplied to the R1600 and is not controlled by R1600 I O switch 4 4 4 4 1 1 1 1 Temperature Control Temperature Control Temperature Control Temperature Control 4 1 1 No...

Page 27: ...Adjustments Allow up to 15 minutes for any temperature adjustments to take effect this is due to the thermal mass of the system design and the nature of the cooling system 6 Condensation Reminder If the temperature setting is below the ambient dew point the piping should be insulated to prevent condensation Setting temperature below the dew point could also cause condensation on the surfaces of th...

Page 28: ...evaporator and into the storage tank The valve opens when the closed loop becomes restricted such as when a filter or strainer becomes restricted or some other flow restriction develops The bypass would also open if the pressure relief setting was not set above the required pressure to overcome the resistance to flow pressure drop in the closed loop 2 Partial Flow Diversion As a secondary function...

Page 29: ... outward counterclockwise to reduce pressure required to bypass glycol solution When reducing pressure make sure that you do not completely remove the screw this prevents the valve from leaking Tighten the locking nut Replace brass valve stem cap Make sure o ring is in place and not pinched Open the supply side of the isolation valve Close needle valve at inlet to pressure gauge 4 4 4 4 3 3 3 3 Re...

Page 30: ...ubbles flowing through the sight glasses when the compressors are running may indicate that the Haskris system is low on refrigerant NOTE It is normal to see bubbles immediately after the compressors turns on and immediately after they turn off The sight glasses should be clear when the system is continuously running Figure 4 3 Sight Glasses Figure 4 3 Sight Glasses Figure 4 3 Sight Glasses Figure...

Page 31: ...rigeration system in order to make adjustments 4 4 1 Low Pressure Cut Out This control provides an added level of freeze protection and serves as a low pressure cutout of the refrigeration compressors in case of a refrigerant leak or a restriction in the refrigeration circuit The low pressure cutout will automatically reset when the refrigerant pressure increases back to normal 4 4 2 High Pressure...

Page 32: ...about these features or require assistance 4 4 4 4 5 5 5 5 Low Liquid Level Indicator Light Low Liquid Level Indicator Light Low Liquid Level Indicator Light Low Liquid Level Indicator Light For your convenience a low liquid level indicator light has been installed on the control panel as seen in the photograph at the beginning of this section THE RESERVOIR IS BELOW MINIMUM REQUIRED LEVEL WHEN THE...

Page 33: ...rformed per Section 2 6 2 5 1 2 Percentage of Propylene Glycol Solution The allowable range of propylene glycol in the system is 34 to 38 by volume with the optimum level at 35 If the glycol solution percentage is outside the allowable range adjust the glycol solution percentage in the system accordingly 5 1 3 Glycol Percentage Adjustment If the glycol percentage is outside the allowable range as ...

Page 34: ... Valve Figure 5 3 Glycerol Reservoir Drain Valve Figure 5 3 Glycerol Reservoir Drain Valve Figure 5 3 Glycerol Reservoir Drain Valve Tank Tank Tank Tank Drain Drain Drain Drain Valve Valve Valve Valve Liquid Level Liquid Level Liquid Level Liquid Level Indicator Indicator Indicator Indicator Orange Orb Orange Orb Orange Orb Orange Orb inside to inside to inside to inside to indicate level indicate...

Page 35: ...he supply side flush valve and drain as much glycol solution from the supply side as possible Then open the return side flush valve and drain as much glycol solution from the return side as possible Repeat this process for all other drains located at the base of every rise 3 Fill System See Section 2 6 5 for instructions on how to fill system with glycol solution 5 5 5 5 2 2 2 2 Blow Blow Blow Blo...

Page 36: ... connect hose to the GHT connection as shown in Figure 5 4 above 3 Place the other end of the hose in a large bucket Open the blow off valve while the pump on the R1600 is running to clean the screen of any debris The bucket will catch any debris which had collected on the screen in the strainer 4 Close the blow off valve and install the protective cap back on the GHT connection 5 Dispose of the g...

Page 37: ...ressure Setting of the Bypass Valve Finding the Pressure Setting of the Bypass Valve Finding the Pressure Setting of the Bypass Valve Finding the Pressure Setting of the Bypass Valve To find the pressure setting of the bypass valve restrict the flow water from the Haskris R1600 chiller by closing the Supply Side Isolation Valve Figure 2 9 THIS SHOULD NOT BE DONE WHILE THE EQUIPEMENT ATTACHED TO TH...

Page 38: ...f start up in no event longer than 18 months from the date of shipment Start up date must be confirmed through the completion and return of the Owner s Registration Card located on the back cover of this manual within six months of the original shipment date from Haskris The warranty includes parts and labor NOTE Labor must be authorized by Haskris in writing prior to proceeding with repairs Parts...

Page 39: ...size Total run ft _______________ A Find total number of fittings Find total number of fittings Find total number of fittings Find total number of fittings 90º Elbows_____________ x factor from chart ______ ______________ B 90º LR Elbows __________ x factor from chart ______ ______________ C 45º Elbows_____________ x factor from chart ______ ______________ D Add A B C D Add A B C D Add A B C D Add...

Page 40: ...t Checklist Checklist ___Unit is securely mounted and level ___No Refrigeration Service Contactor labels have been affixed to the interior or exterior of the R1600 ___Clearances for service ventilation and access to control panel are adequate per R1600 Instruction Manual ___Electrical service to R1600 per table below Record Inlet Voltage and Branch Circuit Rating ___Confirm proper phase by verifyi...

Page 41: ...has provided an additional 10 gallons of propylene glycol distilled water 35 by volume to top off system when no load start up is performed ___Confirm compressor crankcase heater has been energized See Section 3 1 Install Completed By Install Completed By Install Completed By Install Completed By Company _____________________________________ Phone _________________ Fax __________________ Installer...

Page 42: ...l piping exposed to low ambient temperatures as required ___ Supply Return lines labeled over insulation ___ 12 long loop of 1 1 2 reinforced opaque hose between supply and return outlet in equipment room provided ___ Supply and return ball valves provided at indoor WW4 ___ Supply side temperature 0 100 F and pressure 0 100psig gauges provided at indoor heat exchanger ___ Return side temperature 0...

Page 43: ...r 30 Minutes To Stabilize Electrical Electrical Electrical Electrical Component Check Values at Contactors L1 L1 L2 L2 L2 L3 L3 L1 L3 A V A V A V Compressor A Compressor B Pump Motor Fan Motor Inverter A See Section 3 2 Fan Motor Inverter B See Section 3 2 Fluid Fluid Fluid Fluid Supply Water Temperature ºF PV SV Supply Pressure psi Return Pressure psi Bypass Relief Valve Setting psi Volume of wat...

Page 44: ...leted By Company _____________________________________ Phone _________________ Fax __________________ Name ________________________________________________________ Title __________________________ Please Print Signature ______________________________ Date _________________ Haskris Co Haskris Co Haskris Co Haskris Co 100 Kelly Street Phone 847 956 6420 Please contact Haskris Co Elk Grove Village IL...

Page 45: ...h pages of completed checklist to Haskris Fax 847 956 6595 Pre Full Load Pre Full Load Pre Full Load Pre Full Load Checklist Checklist Checklist Checklist ___No Refrigeration Service Contactor labels have been affixed to the interior or exterior of the R1600 ___Confirm compressor crankcase heater has been energized for a minimum of 12 hours See Section 3 1 ___ Confirm 1 1 2 reinforced opaque hose ...

Page 46: ...es To Stabilize Electrical Electrical Electrical Electrical Component Check Values at Contactors L1 L1 L2 L2 L2 L3 L3 L1 L3 A V A V A V Compressor A Compressor B Pump Motor Fan Motor Inverter A See Section 3 2 Fan Motor Inverter B See Section 3 2 Fluid Fluid Fluid Fluid Supply Water Temperature ºF PV SV Supply Pressure psi Return Pressure psi Bypass Relief Valve Setting psi Volume of water used ga...

Page 47: ...Company _____________________________________ Phone _________________ Fax __________________ Name ________________________________________________________ Title __________________________ Please Print Signature ______________________________ Date _________________ Haskris Co Haskris Co Haskris Co Haskris Co 100 Kelly Street Phone 847 956 6420 Please contact Haskris Co Elk Grove Village IL 60007 Fa...

Page 48: ...satisfactorily 8 Begin filling out PM Data Log Sheet Replace all sheet metal panels except outer panel at R1600 Control Panel o To record electrical data for Fan Motor Inverter lower head pressure on Head Pressure Display to drive condenser fan motors to full speed per steps below 1 On the Head Pressure Display See Section 4 press and hold the key repeatedly to lower the head pressure value until ...

Page 49: ... REPRESENTATIVE AT A MINIMUM OF ONCE A YEAR BEGINNING ONE YEAR AFTER DATE OF INSTALL 15 Clean Blow off Wye Strainer per Section 5 2 16 Perform complete system glycol change per Section 5 1 4 Tank and Piping 17 Tighten all electrical terminal connections PM System Check for Haskris PM System Check for Haskris PM System Check for Haskris PM System Check for Haskris R1600 R1600 R1600 R1600 S N HB S N...

Page 50: ... L3 A V A V A V Compressor A Compressor B Pump Motor Fan Motor Inverter A See Section 3 2 Fan Motor Inverter B See Section 3 2 Fluid Fluid Fluid Fluid Supply Water Temperature ºF PV SV Supply Pressure psi Return Pressure psi Bypass Relief Valve Setting psi Volume of water used gallons Volume of Propylene Glycol used gallons Glycol Solution pH Glycol Solution from Refractometer Pump Isolation Valve...

Page 51: ...ny _____________________________________ Phone _________________ Fax __________________ Name ________________________________________________________ Title __________________________ Please Print Signature ______________________________ Date _________________ Haskris Co Haskris Co Haskris Co Haskris Co 100 Kelly Street Phone 847 956 6420 Please contact Haskris Co Elk Grove Village IL 60007 Fax 847...

Page 52: ... Fault Sequence VFD Fault Sequence VFD Fault Sequence 1 Open the electrical panel slide out to locate the VFD controllers 2 Press the down arrow button until is flashing on the display 3 Press the enter key followed by the esc key The display screen should read U1 01 with the U1 flashing 4 Press the up arrow key twice so that the display screen reads U3 01 Press the enter key 01 should now be flas...

Page 53: ... Code VFD A Error Code VFD B Error Code VFD B Error Code VFD B Error Code VFD B U3 01 U3 02 U3 03 U3 04 U3 05 U03 06 U03 07 U03 08 U03 09 U03 10 6 Press the up arrow key to set the display to U3 02 This will display the second most recent fault in the VFD Press enter again to view the fault code 7 Repeat the previous two steps and check all of the parameters The VFD can store the 10 most recent fa...

Page 54: ... then the down arrow key until the screen reads o1 01 Press enter to change the second value to 4 so the screen now reads 04 01 Press enter again and change the last value to 11 The screen should now read o4 11 3 Press the enter key again Press the reset key and now the second zero should be flashing Press the up arrow and change the selection to 1 Press enter and the display will display the word...

Page 55: ...After Installation and Service Support HMSA Copyright 2011 Haskris Company 52 www haskris com Version R1600 X R407C XXX Instruction Manual Rev00 Maintenance Action Performed By Date ...

Page 56: ...ation and After Installation and After Installation and After Installation and Service Support Service Support Service Support Service Support HMSA HMSA HMSA HMSA Contact HMSA if at any time you have questions encounter problems or need spare parts for your Haskris System Phone 800 800 4925 Fax 330 963 0749 Email csc hitachimed com Website www hitachimed com ...