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Haskris R1600 Instruction Manual

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I
NSTRUCTION
M
ANUAL
For the
Installation, Start-up,
Operation and Maintenance
of your Haskris System.
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Summary of Contents for Haskris R1600

  • Page 1 NSTRUCTION ANUAL For the Installation, Start-up, Operation and Maintenance of your Haskris System. [Type text]...

  • Page 2: Table Of Contents

    2.2 Proper System Location .............3-5 2.3 Space Requirements..............5 2.4 Unpacking and Handling..............6 2.5 Electrical Requirements.............7 - 8 2.6 Chiller Water (Glycol Solution from R1600)........9-16 2.7 Install Checklist.………………………………........16 Section 3: Start Section 3: Start- - - - Up Section 3: Start Section 3: Start 3.1 Remove Liquid Refrigerant Prior to Compressor Start-Up …....17...
  • Page 3 Haskris Model R1600 Install Checklist …........37-38 Haskris Model R1600 No Load 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...

  • Page 4: Schedule Of Events

    Instruction Manual. The installing contractor must fill in the requested information and return this card to our office. This will be used to verify the start-up date and shipment condition of your Haskris system. All warranty claims are contingent upon the start-up date of your system. Please refer to the Section 6 of this manual for the Product Warranty details.

  • Page 5: Installation Support (Haskris Co.)

    PLEASE NOTE: When contacting us, we ask that you have the Serial Number (located on the front cover of this manual, or on your Haskris system) available when you call. This serial number allows us to access pertinent information about your system so we can address problems quickly and effectively.

  • Page 6: Receiving Your Haskris System

    Contact the delivering carrier immediately to file a claim. All shipping containers and packaging materials should be retained to help 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 Proper System Location...
  • Page 7 Section 2: Installation 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 2.2 Airflow Figure 2.

  • Page 8: Space Requirements

    Remove any snow and/or ice accumulation on top of chiller prior to start-up. The ambient air temperature range for Model R1600 is -20°F to +120°F. A lack of cool/fresh air to the condenser will result in reduced cooling capacity and possibly the complete shutdown of the refrigeration compressors.

  • Page 9: 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.

  • Page 10: Electrical Requirements

    Please refer to the nameplate label on the front cover of this manual for electrical requirements. A copy of the nameplate can be also found on the supply and return side of the R1600. The wiring diagram for the R1600 can be found at the end of this Instruction Manual.
  • Page 11 CONDUIT ! ! ! ! CONNECTORS AT THE ELECTRICAL BRACKET. Main power will terminate inside the unit power box of the R1600. Figure 2.7 below indicates main power termination point on electrical block. Main Power Termination Point on Electrical Block...

  • Page 12: Chiller Water (Glycol Solution From R1600)

    Instruction Manual) to calculate recommended line size. Consult your state, local, or municipal codes for other requirements. 3. Install vibration isolators at the R1600 on both glycol solution supply and return lines. 4. Install a drain at the base of every rise to allow for complete drainage of piping.
  • Page 13 11. Provide and install a 12’ long loop of 1-1/2” reinforced opaque hose between supply and return outlets in equipment room to allow for start-up and no load testing of R1600 chiller. Hose will be used by HMSA for connection of heat exchanger at time of installation.
  • Page 14 Installation 2.6.2 Piping Line Flush Close isolation valves on R1600 (as shown in Figure 2.9 below). Remove protective cap from flush valves and connect hose to each of the ¾” GHT (Garden Hose Thread) connections (as shown in Figure 2.10).
  • Page 15 (It is recommended to initially fill the system 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. www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 16 DO NOT USE AUTOMOTIVE ANTIFREEZE. USE OF AUTOMOTIVE ANTIFREEZE MAY DAMAGE SYSTEM. www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 17 Tank Drain Tank Drain Tank Drain Valve Valve Valve Valve Figure 2.11 Glycol Tank Filling Figure 2.11 Glycol Tank Filling Figure 2.11 Glycol Tank Filling Figure 2.11 Glycol Tank Filling www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 18 See Table 2 below for approximate volume in gallons per 100 feet of piping. CIRCULATING DO NOT USE THE PUMP IN THE R1600 TO FILL ! ! ! ! PIPING. www.haskris.com Copyright © 2011 Haskris Company...

  • Page 19: Install Checklist

    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 R1600 No Load Start-Up date. Haskris will notify the Installer of the Haskris Authorized Start-Up Agent.

  • Page 20: Section 3: Start

    Prior to Compressor Start Up Energize the crankcase heaters (#8 in wiring diagram located inside your Haskris system, inside the top panel of the supply/return side of the R1600) 12 hours prior to start-up to evaporate any liquid refrigerant accumulated in the refrigeration compressors during shipment. The...

  • Page 21: No Load Start-Up

    • Complete Pre Start-Up Checklist portion of No Load Start-Up Checklist. • Install refrigeration manifold gauge on both high and low side. • Access the R1600 Control Panel (See Section 4) in the upper half of the R1600. • Confirm the Cooling Mode – Stop - Pump Only Mode toggle switch is in the center position.
  • Page 22 • Turn off the system once system is operating satisfactorily. • Remove refrigerant manifold gauge. • Close control box and replace all sheet metal panels on the R1600. www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...

  • Page 23: Full Load System Check

    • Complete Pre Full Load Checklist portion of Full Load System Check. • Install refrigeration manifold gauge on both high and low side. • Access the R1600 Control Panel (See Section 4) in the upper half of the R1600. • Confirm the Cooling Mode – Stop - Pump Only Mode toggle switch is in the center position.
  • Page 24 • System should remain on and operational under load. • Remove refrigerant manifold gauge. Close control box and replace all sheet metal panels on the R120 • www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...

  • Page 25: Section 4: Operating Features And Functions

    4.0 Operating Features and Functions Operating Features and Functions Operating Features and Functions Operating Features and Functions Figure 4.0 R1600 Control Panel Figure 4.0 R1600 Control Panel Figure 4.0 R1600 Control Panel Figure 4.0 R1600 Control Panel 1) Fan A VFD VFD controller for the A fans.

  • Page 26: Temperature Control

    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...
  • Page 27 Setting temperature below the dew point could also cause condensation on the surfaces of the equipment being cooled, with resultant damage. To calculate the dew point in your environment, consult the Technical Documents on the Haskris website (www.haskris.com). 4.1.2 Electronic (PID) Controller Press the UP or DOWN arrow button to adjust the glycol solution temperature set value (SV).

  • Page 28: Water Pressure Bypass/Relief Valve

    This reduces the flow through the equipment, thereby reducing the pressure required to complete the circuit. 4.2.1 Bypass/Relief Valve Adjustment Procedure: www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...

  • Page 29: Refrigerant Sight Glass/Moisture Indicator

    The sight glass/moisture indicator is located behind the front panel, near the bottom of the midpoint of the frame. The sight glass/moisture www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 30 Bubbles 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.

  • Page 31: High And Low Refrigerant Pressure Controls

    The low-pressure cutout will automatically reset when the refrigerant pressure increases back to normal. 4.4.2 High-Pressure Cut-Out. Model R1600 includes a high-refrigerant pressure safety cutout with manual manual manual manual reset.

  • Page 32: Liquid Low Level Indicator Light

    THE RESERVOIR IS BELOW MINIMUM REQUIRED LEVEL WHEN THE LIGHT IS When the glycol solution is below the minimum required operating level the low liquid level switch will close, the light will go on, and the R1600 will shut down (refer to the wiring diagram).

  • Page 33: Frequency Of Glycol Solution Changes

    5.1.4 Glycol Change Haskris recommends that the entire glycol solution in the system be changed whenever the pH is outside the allowable range as stated in Section 5.1.1. If a glycol change is required, follow the instructions below to remove all the glycol from the system.
  • Page 34 Figure 5.3 Glycerol Reservoir Drain Valve Figure 5.3 Glycerol Reservoir Drain Valve • Remove protective cap from drain valve and connect hose to the ¾” GHT connection (as shown in Figure 5.3 above). www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...

  • Page 35: Blow-Off Wye Strainer

    Off Wye Strainer Off Wye Strainer The Haskris R1600 chiller is furnished with a 1-1/2” bronze Wye Strainer with 20 mesh perforated stainless steel screen for mechanically removing solids from the glycol solution. The Wye Strainer is fitted with a blow-off valve that includes a ¾”...
  • Page 36 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.

  • Page 37: Air-Cooled Condenser Cleaning

    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 THE...

  • Page 38: Section 6: Standard Product W Section 6: Standard Product Warranty Standard Product W Arranty

    Limited Warranty: Haskris’ warranty is limited to the following provisions, and does not apply to claims where the product has been mishandled or used in a manner inconsistent with this instruction manual. Haskris makes no other warranty, express or implied, including all implied warranties of merchantability and fitness for a particular purpose.

  • Page 39: Worksheet 1

    DO NOT USE AUTOMOTIVE ANTIFREEZE. DO NOT USE AUTOMOTIVE ANTIFREEZE. DO NOT USE AUTOMOTIVE ANTIFREEZE. DO NOT USE AUTOMOTIVE ANTIFREEZE. The R1600 pumping system will not to be used to fill glycol loop. • Equivalent length of pipe in feet Nom. Pipe Head Loss per 90º...

  • Page 40: Haskris Model R1600 Install Checklist

    Note: Checklist MUST be completed for “No Load” Start-up to be scheduled. R1600 cannot be started Note: Note: until completed checklist has been returned via fax to Haskris no less than 5 business days prior to no load start-up. Directions:...
  • Page 41 ___ Reservoir is at tank full level. ___ Lines air purged per R1600 Instruction Manual. ___ Glycol solution % (Record actual measurement here). ___ Installer 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.

  • Page 42: Haskris Model R1600 No Load Start

    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):...
  • Page 43 Haskris Model R1600 No Load Start-Up Checklist No Load Start No Load Start- - - - Up Up Data Log Data Log for Haskris for Haskris R1600, S/N HL R1600, S/N HL ____________ ____________ No Load No Load Start Start...
  • Page 44 Haskris Model R1600 No Load Start-Up Checklist No Load Start No Load Start- - - - Up No Load Start No Load Start Up Completed By: Completed By: Completed By: Completed By: Company: _____________________________________ Phone: _________________ Fax: __________________ Name: ________________________________________________________ Title: __________________________...

  • Page 45: Haskris Model R1600 Full Load System Check

    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 between connected to WW4.
  • Page 46 Haskris Model R1600 Full Load System Check Full Full Load System Check Full Full Load System Check Load System Check for Haskris Load System Check for Haskris for Haskris R1600, S/N HL for Haskris R1600, S/N HL R1600, S/N HL...
  • Page 47 Haskris Model R1600 Full Load System Check Full Load System Full Load System C C C C heck Full Load System Full Load System heck heck By: heck Company: _____________________________________ Phone: _________________ Fax: __________________ Name: ________________________________________________________ Title: __________________________ (Please Print) Signature: ______________________________ Date: _________________ Haskris Co.

  • Page 48: Haskris Model R1600 Preventative Maintenance (Pm)

    REPRESENTATIVE. 3. Install refrigeration manifold gauge on both high and low side. 4. Access the R1600 Control Panel (See Section 4) in the upper half of the R1600. 5. Confirm the Cooling Mode – Stop - Pump Only Mode toggle switch is in the COOLING MODE position (to the left).
  • Page 49 Complete PM Data Log Sheet. Complete PM Data Log Sheet. Complete PM Data Log Sheet. FOLLOWING ITEMS TO BE PERFORMED BY A HASKRIS AUTHORIZED ! ! ! ! REPRESENTATIVE AT A MINIMUM OF ONCE A YEAR, BEGINNING ONE YEAR AFTER DATE OF INSTALL.
  • Page 50 Haskris Model R1600 Preventative Maintenance (PM) Project Name ______________________________ Location ___________________________________ Full Load System Full Load System Full Load System Full Load System Check: Check: Check: Record Values After System Has Run For 30 Minutes To Stabilize Check: Record Values After System Has Run For 30 Minutes To Stabilize...
  • Page 51 Haskris Model R1600 Preventative Maintenance (PM) PM System PM System PM System PM System C C C C heck heck heck By: heck Company: _____________________________________ Phone: _________________ Fax: __________________ Name: ________________________________________________________ Title: __________________________ (Please Print) Signature: ______________________________ Date: _________________ Haskris Co.

  • Page 52: Maintenance Notes

    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 flashing. www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 53 If the screen reads “- -” then there are no further faults recorded. • 8. Press the “esc” key until you return to the first screen reading “F 0.00” www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 54 1. The fault history has been erased. 4. Return to the home screen by pressing the “esc” key until the display shows “F 0.00” again. www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...
  • Page 55 After Installation and Service Support (HMSA) Maintenance Action: Performed By: Date: www.haskris.com Copyright © 2011 Haskris Company Version R1600-X-R407C-XXX Instruction Manual Rev00...

  • Page 56: After Installation And Service Support (Hmsa)

    After Installation and After Installation and Service Support Service Support (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 •...

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