Haskris Standard Manual - R1600-R407C-001 Rev05 · Listed below is a flowchart of the typical...

[Type text]

INSTRUCTION

MANUAL

For the

Installation, Start-up,

Operation and Maintenance

of your Haskris System.

Table of Contents

Section 1: GeneralSection 1: GeneralSection 1: GeneralSection 1: General InformationInformationInformationInformation

1.1 Schedule of Events........................................................................1

1.2 Registration ................................................................................1

1.3 Installation Support (Haskris Co.) ...................................................2

1.4 After Installation and Service Support (HMSA) ................................2

Section 2: Section 2: Section 2: Section 2: InstallationInstallationInstallationInstallation

2.1 Receiving Your Haskris System.......................................................3

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: StartSection 3: StartSection 3: StartSection 3: Start----UpUpUpUp

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 FunctionsSection 4: Operating Features and FunctionsSection 4: Operating Features and FunctionsSection 4: Operating Features and Functions

4.0 Operating Features and Functions................................................22

4.1 Temperature Control..............................................................23-24

4.2 Water Pressure Bypass/Relief Valve. ......................................25-26

4.3 Refrigerant Sight Glass/Moisture Indicator...............................26-27

4.4 High and Low Refrigerant Pressure Controls..............................28-29

4.5 Liquid Low Level Indicator Light …...............................................29

Table of Contents

Section 5: Section 5: Section 5: Section 5: Maintenance RecommendationsMaintenance RecommendationsMaintenance RecommendationsMaintenance Recommendations

5.1 Frequency of Glycol Solution Changes. ...................................30-32

5.2 Blow-Off Wye Strainer ……………….......................................32-33

5.3 Air-Cooled Condenser Cleaning…...............................................34 5.3 Finding the Pressure Setting of the Bypass Valve............................34

Section 6: Section 6: Section 6: Section 6: Standard Product WStandard Product WStandard Product WStandard Product Warrantyarrantyarrantyarranty............................................35

Worksheet 1 Worksheet 1 Worksheet 1 Worksheet 1 –––– Recommended Line SizeRecommended Line SizeRecommended Line SizeRecommended Line Size…….....................................36 Haskris Model R1600 Install ChecklistHaskris Model R1600 Install ChecklistHaskris Model R1600 Install ChecklistHaskris Model R1600 Install Checklist…......................................37-38

Haskris Model R1600 No Load StartHaskris Model R1600 No Load StartHaskris Model R1600 No Load StartHaskris Model R1600 No Load Start----Up ChecklistUp ChecklistUp ChecklistUp Checklist…..................39-41

Haskris Model R1600 Full Load System CheckHaskris Model R1600 Full Load System CheckHaskris Model R1600 Full Load System CheckHaskris Model R1600 Full Load System Check…........................42-44

Haskris Model R1600 Preventative Maintenance (PM)Haskris Model R1600 Preventative Maintenance (PM)Haskris Model R1600 Preventative Maintenance (PM)Haskris Model R1600 Preventative Maintenance (PM)...............45-48

Maintenance NotesMaintenance NotesMaintenance NotesMaintenance Notes……………………………....................................49-52

After Installation and Service Support (HMSA)After Installation and Service Support (HMSA)After Installation and Service Support (HMSA)After Installation and Service Support (HMSA).................................53

Troubleshoot Data LogTroubleshoot Data LogTroubleshoot Data LogTroubleshoot Data Log..........................................................................55

Wiring DiagramWiring DiagramWiring DiagramWiring Diagram...............................................................................56-60

Piping DiagramPiping DiagramPiping DiagramPiping Diagram.....................................................................................61

Section 1: General Information

Copyright © 2011 Haskris Company 1 www.haskris.com Version R1600-X-R407C-XXX Instruction Manual Rev00

1.11.11.11.1 Schedule of EventsSchedule of EventsSchedule of EventsSchedule of Events

Listed below is a flowchart of the typical schedule of events for the

installation and start-up of the Haskris R1600 chiller.

Delivery of R1600 (Section 2.1)

Locate and Secure R1600 at Installation Site

(Section 2.2 thru 2.4)

Connect Power (Section 2.5)

Connect Plumbing (Section 2.6.1)

Plumbing Flush, Leak Check & Purge

(Section 2.6.2 thru 2.6.4)

Fill R1600 and Piping (Section 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)

1.21.21.21.2 RegistrationRegistrationRegistrationRegistration

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 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.

No Load Start-Up to be Performed Within 60 Days of Delivery of R1600

No Load Start-Up to be Complete 1 Week Prior to Delivery of MRI

Section 1: General Information


1.31.31.31.3 Installation Support (Haskris Co.)Installation Support (Haskris Co.)Installation Support (Haskris Co.)Installation Support (Haskris Co.)

If at any time you have questions, encounter problems, or require technical

support during installation of your Haskris system, please contact us by any

of the following means:

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.

1.41.41.41.4 After Installation and Service Support After Installation and Service Support After Installation and Service Support After Installation and Service Support

HitachiHitachiHitachiHitachi Medical Systems America Medical Systems America Medical Systems America Medical Systems America (HMSA)(HMSA)(HMSA)(HMSA)

Contact HMSA if at any time you have questions, encounter problems, or

need spare parts for your Haskris System.

• Phone: 847-956-6420

• Fax: 847-956-6595

• Email: [email protected]

• Website: www.haskris.com (contains information

addressing frequently-asked questions and

technical documentation)

• Phone: 800-800-4925

• Fax: 330-963-0749


• Website: www.hitachimed.com (contains information

addressing frequently-asked questions and

technical documentation)

Section 2: Installation


2.12.12.12.1 Receiving Receiving Receiving Receiving Your Haskris SystemYour Haskris SystemYour Haskris SystemYour Haskris System

Upon delivery, visually inspect your Haskris system for any obvious damage. If

damage is found, and there is reason to believe the system was mishandled, note

the damage in detail on the delivery receipt. We recommend taking photographs

if possible. 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.

2.22.22.22.2 Proper System LocationProper System LocationProper System LocationProper 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

CENTER SUPPORT.

Position the R1600 chiller per the concrete pad drawing below (see Figure 2.1).

Haskris recommends a minimum of 36” of clearance on all sides to allow for

service accessibility and free air movement across the condenser.

Mounting Holes 0.63” Dia. Qty (16)

Allow 36” of clearance all around R1600 Chiller on a level concrete pad.

!!!!

Figure 2.Figure 2.Figure 2.Figure 2.1 R1600 Clearance1 R1600 Clearance1 R1600 Clearance1 R1600 Clearance



FigurFigurFigurFigureeee 2.2.2.2.3 Vibration Isolators and Pipe support3 Vibration Isolators and Pipe support3 Vibration Isolators and Pipe support3 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.Figure 2.2 Airflow2 Airflow2 Airflow2 Airflow



See space requirements listed in Section 2.3 below to plan the location of

the R1600.

The R1600 requires free vertical discharge space above the chiller. Ensure

no eaves, overhangs, or any other obstructions are present to restrict the air

space above the chiller. 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. 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 the R1600 chiller with Refrigeration Service Contractor’s

name and/or contact information. The only labels permitted on the

interior or exterior of the R1600 come supplied by the factory.

2.32.32.32.3 Space RequirementsSpace RequirementsSpace RequirementsSpace Requirements

R1600 Dimensions

67’’W* x 67’’D* x 75’’ H (170cm W* x 170cm D* x 191 cm H* **** Add 4” (10.2cm) for Mounting Flange

Required Minimum Clearances for Service

Front: 36” (91.5cm) Left: 36” (91.5cm)

Back: 36” (91.5cm) Right: 36” (91.5cm)

!!!!



Bolted to Skid (Typ.)

Figure 2.Figure 2.Figure 2.Figure 2.4 R1600 on skid4 R1600 on skid4 R1600 on skid4 R1600 on skid

Remove this panel for access to compressor A and the panel on the opposite side to access

compressor B

2.42.42.42.4 Unpacking and HandlingUnpacking and HandlingUnpacking and HandlingUnpacking 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 chiller to its proper location. Insert

the forks fully past the center of the base.

21” Center21” Center21” Center21” Center

Fork Opening 8”W x 4”H (Typ.)



Glycol Solution Supply Line

Glycol Solution Return Line

2.52.52.52.5 Electrical Electrical Electrical Electrical RequirementsRequirementsRequirementsRequirements

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.

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 area in which your Haskris system

will be located. DO NOT mount or support any electrical service

disconnect directly to R1600 chiller.

Figure 2.6 above illustrates the exact location of the unit power box.

A terminal block is provided in the box for R1600 power

connection.

Figure 2.6Figure 2.6Figure 2.6Figure 2.6

Unit Power Box

!!!!



Termination point on electrical block

PLEASE NOTE: The 1½” pilot hole is for electrical power pass-through

only. DO NOT TERMINATE CONDUIT OR USE 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.

2.5.1 Phase Monitor:

Haskris Model R1600 is furnished with a three-phase

loss/reversal monitor as shown in Figure 2.8. This

phase monitor provides three-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 disconnect switch is turned on, there will be a 3

minute delay before the unit starts.

Figure 2.7 High Voltage PanelFigure 2.7 High Voltage PanelFigure 2.7 High Voltage PanelFigure 2.7 High Voltage Panel

Figure 2.8Figure 2.8Figure 2.8Figure 2.8

Main Power Termination Point on Electrical Block Torque Field Line Connection:

120 INCH-LBS -AND-

Field Ground Connection:

40 INCH-LB (6-10 AWG) –OR-

50 INCH-LB (2-4 AWG)

!!!!



2222....6666 CCCChiller hiller hiller hiller WaterWaterWaterWater

((((Glycol Solution from Haskris R1600Glycol Solution from Haskris R1600Glycol Solution from Haskris R1600Glycol Solution from Haskris R1600 to the Haskris to the Haskris to the Haskris to the Haskris WW4WW4WW4WW4))))

All interconnecting piping should be run per HMSA Standard Details.

2.6.1 Piping Installation

Install all water piping runs and components using the following

guidelines:

1. Excessive particles in the pumping system can reduce the

efficiency of the system or cause damage to components.

Care should be taken to maintain the internal cleanliness of

the piping. If flux is used during the soldering of any

connection, Haskris 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 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.

5. Install air vents at all high points in the system to eliminate air from the system.

6. Properly support all piping where required. Do NOT attach any form of piping support directly to R1600 chiller.

7. Install heat trace on all piping exposed to low ambient

temperatures (34°F [1°C] or below) and cover with a suitable

thickness of closed-cell, UV resistant insulation. Route power

for heat trace from a separately fused disconnect. Identify

disconnect as heat trace power source with a warning that



power must not be turned off except when unit is being

serviced.

8. Properly label supply and return lines over the insulation with

either a flow arrow or the words ‘SUPPLY’ and ‘RETURN’.

9. Properly sleeve and insulate pipe penetrations through all roof

and/or wall penetrations to protect pipe from potential

damage.

10. Properly sleeve and insulate pipe penetrations through all roof

and/or wall penetrations to protect pipe from potential

damage.

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.

12. Provide and install a ball 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 temperature at the

WW4 heat exchanger.

14. Provide a pressure gauge (0-100psig) on the supply side

between the ball valve and indoor WW4 heat exchanger to

measure supply pressure at the WW4 heat exchanger.

15. Provide an in-line flow meter (5-25gpm) on the return side

between the ball valve and indoor WW4 heat exchanger to

measure return flow at the WW4 heat exchanger. Haskris

recommends Blue-White Series F-420N Variable Area Flow

Meter sized to match the piping line size. Provide a

moveable sleeve over the flow meter to prevent exposure to

light when flow meter is not being read. Any prolonged

exposure to light may promote biological growth in the water

lines.



Return Pressure Gage

Supply Pressure Gage

2.6.2 Piping Line Flush

1. 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).

A ¾” 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 CloseFigure 2.9 Valve CloseFigure 2.9 Valve CloseFigure 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 Position)ups (All Valves Illustrated in the CLOSED Position)

Supply Side Isolation Valve

Supply Side Flush Valve Return

Side Flush Valve

Return Side Isolation Valve



2. Open both supply and return side flush valves and begin to flush piping with city

water until stream becomes clear. (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.

Figure Figure Figure Figure 2.10 Valve Positions for Flushing2.10 Valve Positions for Flushing2.10 Valve Positions for Flushing2.10 Valve Positions for Flushing

Supply Side Isolation Valve Not Illustrated but CLOSED Supply Side

Flush Valve with ¾’’GHT CLOSED

Return Side Flush Valve with ¾’’ GHT CLOSED

Return Side Isolation Valve CLOSED



DO NOT OPEN ISOLATION VALVES DURING PROCESS OF FLUSHING THE

PIPING LINES.

2.6.3 Piping Leak Check

Close return side flush valve and perform leak check for a minimum of 30

minutes at city water pressure. Examine all piping connections for leaks. If

a leak is found, isolate and eliminate the leak. Repeat piping flush (see

Section 2.6.2) if required after repair is performed.

2.6.4 Piping Line Purge

Once a successful leak check has been performed, all water must be

drained from the piping lines. Open all drains (including drains installed

at the base of every rise) and drain all piping runs. Compressed 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 a De-Ionization filter. See Table 1 below for approved

glycol vendors. The optimum level of propylene glycol in the system is 35%

by volume.

DO NOT OPERATE OUTSIDE THE ALLOWABLE GLYCOL PERCENTAGE

RANGE. Percent glycol solution below the allowable range may lead to

the rupture of piping lines and damage to the pump. Percent glycol solution

above the allowable range may inhibit proper pumping ability which could

lead to damage to the pump. DO NOT USE AUTOMOTIVE ANTIFREEZE.

USE OF AUTOMOTIVE ANTIFREEZE MAY DAMAGE SYSTEM.

!!!!

!!!!



Tank Drain Tank Drain Tank Drain Tank Drain ValveValveValveValve

Table 1Table 1Table 1Table 1 Approved Propylene Glycol VendorsApproved Propylene Glycol VendorsApproved Propylene Glycol VendorsApproved Propylene Glycol Vendors

SUPPLIER PROPYLENE

GLYCOL PHONE

PRIMARY Dow Chemical DowFrost 800-447-4369

ALTERNATES Houghton Chemical Safe-T-Therm 800-777-2466 Interstate Chemical Co. Intercool NFP 800-422-2436

Huntsman Petrochemical Jeffcool P-155 281-719-6000

Noble Company NoBurst-100 800-878-5788

Fill Reservoir

1. Close supply and 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 ¾” 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 the level of glycol solution has reached the tank full level

Tank Fill ValveTank Fill ValveTank Fill ValveTank Fill Valve

Full TankFull TankFull TankFull Tank

Tank LowTank LowTank LowTank Low Fill LED will be Fill LED will be Fill LED will be Fill LED will be on at this level.on at this level.on at this level.on at this level.

Figure 2.11 Glycol Tank FillingFigure 2.11 Glycol Tank FillingFigure 2.11 Glycol Tank FillingFigure 2.11 Glycol Tank Filling



6. After the level of glycol solution in the tank has reached the full level, close fill

valve as shown in Figure 2.10 and install the protective cap back on the ¾”

GHT connection.

• Fill Piping

1. Close supply and return side isolation valves as shown in

Figure 2.9 of Section 2.6.2.

2. Remove protective cap from the supply side flush valve and

connect hose to the ¾” GHT connections (as shown in Figure

2.9).

3. Remove protective cap from the return side flush valve and

connect hose to the ¾” 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 and fill the piping with 35%

glycol solution. The use of an external pump may be required

to properly fill the system with glycol solution. See Table 2

below for approximate volume in gallons per 100 feet of

piping.

DO NOT USE THE CIRCULATING PUMP IN THE R1600 TO FILL

PIPING.

!!!!



Table 2 Approximate Volume of Pipe RunsTable 2 Approximate Volume of Pipe RunsTable 2 Approximate Volume of Pipe RunsTable 2 Approximate Volume of Pipe Runs

NOM. SIZE VOLUME (INCHES) (GALLONS

PER/100FT) 2 16.75 2-1/2 26 3 36.5

5. Vent air at pipe rises during the fill process.

6. Stop filling piping when glycol solution begins to drain.

7. Close both the return and supply side flush valves and install the

protective caps back on the ¾” GHT connections.

8. Open supply and return side isolation valves shown in Figure 2.8

of Section 2.6.2.

2222....7 7 7 7 Install ChecklistInstall ChecklistInstall ChecklistInstall 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 R1600 No Load Start-Up date. Haskris will notify the Installer of the Haskris Authorized Start-Up Agent. Installer will contact Haskris Authorized Start-Up Agent at least 2 business days in advance. No Load Start-Up subject to Technician availability. Start-Up will be done during normal working hours. Installer will issue a Credit Card Purchase Order to Haskris Start-Up Agent if any items are found incomplete and resulting in delay of system start-up.

!!!!

Section 3: Start-Up


3.13.13.13.1 RemovRemovRemovRemove e e e Liquid RefrigerantLiquid RefrigerantLiquid RefrigerantLiquid Refrigerant Prior to Compressor Start UpPrior to Compressor Start UpPrior to Compressor Start UpPrior 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

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 for some reason the crankcase heater cannot be energized for 12

hours prior to the no-load start-up, the Cooling Mode – Stop - Pump

Only Mode switch (See Section 4) may be toggled between the center

position (Stop) and the left position (Cooling Mode) rapidly 3 or 4 times,

before switching the system ON permanently. Use this method only as a

last resort.

Haskris recommends leaving main power to the R1600 on at all times.

!!!!

Section 3: Start-Up


3.23.23.23.2 No Load Start UpNo Load Start UpNo Load Start UpNo Load Start Up

NO LOAD START-UP SHOULD BE PERFORMED IN THE PRESENCE OF A HASKRIS AUTHORIZED REPRESENTATIVE.

• 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. See R1600 Control Panel description at the beginning of Section 4 for more details.

• When the service 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). 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 maintain tank full level. Fill system to tank full level as viewed on the liquid level indicator (See Figure 2.11).

• Check to make sure all external piping is leak-tight and that the system is operating satisfactorily.

• Clean Blow-Off Wye Strainer (See Section 5.2) • Replace all sheet metal panels except outer panel at R1600 Control Panel. • Complete No Load Start-Up Data Log

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 the fans begin to run at full speed.

!!!!

Section 3: Start-Up


2. 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 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 R1600.

Section 3: Start-Up


3.33.33.33.3 Full Load Full Load Full Load Full Load System CheckSystem CheckSystem CheckSystem Check

FULL LOAD SYSTEM CHECK MUST BE PERFORMED WITH OASIS MRI SYSTEM IN OPERATION. SCHEDULING OF FULL LOAD SYSTEM CHECK SHOULD BE COORDINATED WITH HMSA INSTALLATION TEAM. FULL LOAD SYSTEM CHECK SHOULD BE PERFORMED IN THE PRESENCE OF A HASKRIS AUTHORIZED REPRESENTATIVE AND ONLY AFTER A SUCCESSFUL NO LOAD START-UP PER SECTION 3.2.

• 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. See R1600 Control Panel description at the beginning of Section 4 for more details.

• When the service 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 Load System Check 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 maintain tank full level. Fill system to tank full level as viewed on the liquid level indicator (See Figure 2.11).

• Check to make sure all external piping is leak-tight and that the system is operating satisfactorily.

• Complete No Load Start-Up Data Log (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:

!!!!

Section 3: Start-Up


1. On the Head Pressure Display (See Section 4), press and hold

the key repeatedly to lower the head pressure value until the fans begin to run at full speed.





• System should remain on and operational under load. • Remove refrigerant manifold gauge.

• Close control box and replace all sheet metal panels on the R120

Section 4: Operating Features & Functions


4.04.04.04.0 Operating Features and FunctionsOperating Features and FunctionsOperating Features and FunctionsOperating Features and Functions

1) Fan A 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 PanelFigure 4.0 R1600 Control PanelFigure 4.0 R1600 Control PanelFigure 4.0 R1600 Control Panel

7

8

9



5) Head Pressure Display B

Indicates refrigerant head B pressure set value (SV) and current head B pressure

process value (PV).

6) Pump Only Mode – Standby – Normal Operation

This 3 position switch determines the operation mode of the R1600.

Right –Powers display panel and pump only. (Pump Only Mode - Service)

Center – Powers display panel only. (Standby)

Left – Switch is in this position during magnet operation. (Normal Operation

Mode)

7) Fill LED

LED is lit when tank is at the maximum operating level.

8) Low liquid LED

Liquid level latch. If this light is on the compressor and pump 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.

4444.1.1.1.1 Temperature ControlTemperature ControlTemperature ControlTemperature Control

4.1.1 Notes

1. Temperature is Factory Pre-Set Haskris has pre-set the glycol solution temperature to 14°C (57.2°F). On initial start-up, apply the actual heat load and wait 30-40 minutes for the temperature to stabilize.

2. Allowable Adjustments: The following procedures are intended for glycol solution temperature adjustments only. All other control parameters are factory set for optimum performance and should not be adjusted. If it appears that “tuning” is required, please contact Haskris for further information.



3. Adjust While System is Running:

Make all glycol solution temperature adjustments while the system is running with the actual heat load.

4. Permissible Temperature Settings: Permissible glycol solution temperature range is 10°C - 22°C (50°F - 71.6°F). If a temperature setting outside of this range is required, please contact Haskris.

5. Response Time for 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 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).



Figure 4.2 Bypass ValveFigure 4.2 Bypass ValveFigure 4.2 Bypass ValveFigure 4.2 Bypass Valve

4444....2222 Water Pressure Water Pressure Water Pressure Water Pressure

Bypass/Relief ValveBypass/Relief ValveBypass/Relief ValveBypass/Relief Valve

The Bypass/Relief valve

modulates. The valve does not

snap open and closed. The

valve serves two basic functions:

1. Divert Water Pump Discharge Flow

Its primary function is to divert the water pump discharge flow whenever

the pump pressure reaches the bypass pressure setting. The glycol solution

is diverted through the bypass line, through the 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, the valve can be used for partial-flow diversion.

If the flow characteristics of the pump cause excessive pressure drop

through the heat exchanger on the equipment being cooled, this valve can

be adjusted to bypass some of the excess glycol solution. This reduces the

flow through the equipment, thereby reducing the pressure required to

complete the circuit.

4.2.1 Bypass/Relief Valve Adjustment Procedure:

Figure 4.1 Electronic ControllerFigure 4.1 Electronic ControllerFigure 4.1 Electronic ControllerFigure 4.1 Electronic Controller



The valve has been preset for a maximum operating pressure of 50psi. For

installations with high head pressure loss due to long piping runs or multiple

elbows, the water pressure bypass/relief valve setting may need to be increased.

An adjustment screw is located under the brass cap on top of the valve.

• Open needle valve at inlet to pressure gauge. If this is already open, close the

supply valve isolation valve. Page 12, fig 2.10.

• Remove brass valve stem cap.

• Loosen the locking nut.

• Turn the screw inward (clockwise) to increase the pressure required to bypass

water

-OR-

Turn the screw 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

4444.3.3.3.3 Refrigerant Sight Glass/Moisture Indicator Refrigerant Sight Glass/Moisture Indicator Refrigerant Sight Glass/Moisture Indicator Refrigerant Sight Glass/Moisture Indicator

There are two liquid-line sight glass/moisture indicators that have

been installed to help you identify when the system is low on

refrigerant, and to assist the refrigeration mechanic when recharging

the system.

The sight glass/moisture indicator is located behind the front panel,

near the bottom of the midpoint of the frame. The sight glass/moisture



Sight Glasses

indicator is visible when the front service panel is removed. 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. The sight glasses should

be clear when the system is continuously running.

Figure 4.3 Sight GlassesFigure 4.3 Sight GlassesFigure 4.3 Sight GlassesFigure 4.3 Sight Glasses



4444.4.4.4.4 High and Low Refrigerant Pressure Controls High and Low Refrigerant Pressure Controls High and Low Refrigerant Pressure Controls High and Low Refrigerant Pressure Controls

The refrigerant pressure controls (Figure 4.4) are located in front of each

compressor on both sides of the unit. The pressure controls prevent the compressors

from operating at unsafe pressures. The controls should only be adjusted by a

Haskris Approved Technician. This technician should install refrigerant pressure

gauges on the high and low-side of the refrigeration 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 Cut-Out.

Model R1600 includes a high-refrigerant pressure safety cutout with manualmanualmanualmanual reset.

The high-pressure cutout will shut down the compressors when there is insufficient

air flow through the air-cooled condenser.

PRESSURE CONTROL REGULATES THE PERFORMANCE OF THE REFRIGERATION

COMPRESSORS: If one or both of the compressors are not operating or if the

Figure 4.4 Pressure ControlFigure 4.4 Pressure ControlFigure 4.4 Pressure ControlFigure 4.4 Pressure Control

!!!!



compressors will not come on at all when cooling is required, it is likely that it is

controlled by the safety control board. (See item number section 4.0 Operating

Features and Functions page 22 or 23). To restart the compressors, confirm that

there is water circulation and then reset the system by flipping the reset switch

down and back up. Contact Haskris if you have any questions about these features

or require assistance.

4444.5.5.5.5 Low Liquid Level Indicator LightLow Liquid Level Indicator LightLow Liquid Level Indicator LightLow 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 LIGHT IS

ONONONON.

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).

Refill according to the instructions in Section 2.6.5 of this manual. Cycle the reset

switch to restart the unit.

!!!!

Section 5: Maintenance Recommendations


5555.1.1.1.1 Frequency of Glycol Solution ChangesFrequency of Glycol Solution ChangesFrequency of Glycol Solution ChangesFrequency of Glycol Solution Changes

The frequency of required propylene glycol solution changes varies according to

the condition of the glycol solution at your individual environment. A minimum

replacement of once a year is recommended. The two factors to consider in

determining whether the glycol solution needs to be changed or adjusted sooner

are pH and percentage of glycol solution.

5.1.1 pH Level

The pH level allowable range is 7 to 10. If the pH of the glycol solution is outside

the allowable range, change the glycol in the system accordingly. When the pH

level is below 7, a line flush should also be performed 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 stated in Section 5.1.2

above, the percentage may be raised or lowered by adding either propylene

glycol or potable distilled water. To increase remove some glycol solution from the

system. To add either glycol or potable distilled water to the system, see Fill

Reservoir in Section 2.6.5. Repeat both the pH and glycol solution percentage

tests when adjustments are complete.

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.

1. Drain Tank

• Turn off R1600 Chiller.



• Close supply and return side isolation valves as shown in Figure 2.8 of

Section 2.6.2.

• Locate the drain valve on the side of the glycol reservoir (see Figure 5.3

below).

• Remove protective cap from drain valve and connect hose to the ¾” GHT

connection (as shown in Figure 5.3 above).

Figure 5.3 Glycerol Reservoir Drain ValveFigure 5.3 Glycerol Reservoir Drain ValveFigure 5.3 Glycerol Reservoir Drain ValveFigure 5.3 Glycerol Reservoir Drain Valve

Tank Tank Tank Tank Drain Drain Drain Drain ValveValveValveValve

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 level)indicate level)indicate level)

Full TankFull TankFull TankFull Tank

Tank LowTank LowTank LowTank Low Fill LED will Fill LED will Fill LED will Fill LED will be on at this be on at this be on at this be on at this level.level.level.level.



• Place the other end of the hose in a large bucket or drum and open drain

valve. The level of glycol solution in the tank should drop as viewed

through the liquid level indicator.

• After tank is completely empty, close drain valve as shown in Figure 5.3

and install the protective cap back on the ¾” GHT connection.

2. Drain Piping

• Turn off R1600 Chiller.

• Close supply and return side isolation valves as shown in Figure 2.8 of

Section 2.6.2.

• Remove protective cap from flush valves and connect hose to each of the

¾” GHT connections (as shown in Figure 2.9).

• Place the other end of each hose in a large bucket or drum. Open the

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.

5555.2.2.2.2 BlowBlowBlowBlow----Off Wye StrainerOff Wye StrainerOff Wye StrainerOff 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”

male GHT connection. Any accumulated solids can be removed by use of the

blow-off valve without shutting off the R1600 or disassembling the strainer. Clean

the Wye Strainer every time the glycol solution is changed in the system or if the



Figure 4.4 Wye Figure 4.4 Wye Figure 4.4 Wye Figure 4.4 Wye StrainerStrainerStrainerStrainer

return pressure as indicated in the Return Pressure Gage has increased 10psi or

more from the original value at start-up.

1. Locate the Wye strainer with blow-off valve in the R1600 chiller

(see Figure 5.4 below).

2. Remove protective cap from blow-off valve and connect hose to the

¾” 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

¾” GHT connection.

5. Dispose of the glycol solution in the bucket with the balance of the

glycol that was removed during glycol change.

Wye StrainerWye StrainerWye StrainerWye Strainer

BlowBlowBlowBlow----Off ValveOff ValveOff ValveOff Valve Return Pressure Return Pressure Return Pressure Return Pressure GageGageGageGage



5555.3.3.3.3 AirAirAirAir----Cooled Condenser CleaningCooled Condenser CleaningCooled Condenser CleaningCooled Condenser Cleaning

The Haskris R1600 chiller includes two air-cooled condensers which draw a

substantial amount of air across the condenser fins and coil. As dust and debris

collect, heat transfer becomes less efficient, resulting in the loss of cooling

capacity. To remove the accumulation of debris, vacuum the condenser fins

thoroughly during regular services. Additional cleaning may be required in some

extreme environments. Nearby vegetation, such as cotton wood trees, etc. should

be avoided or removed if found to be problematic. A brush may be used to loosen

compacted debris being careful not to damage the fins or the condenser coil

coating. HASKRIS DOES NOT RECOMMEND THE USE OF A PRESSURE

WASHER AS THIS MAY DAMAGE THE FINS OR CONDENSER COIL COATING.

5555.4 .4 .4 .4 Finding the Pressure Setting of the Bypass ValveFinding the Pressure Setting of the Bypass ValveFinding the Pressure Setting of the Bypass ValveFinding 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 THIS SHOULD NOT BE DONE WHILE THE EQUIPEMENT ATTACHED TO THE THIS SHOULD NOT BE DONE WHILE THE EQUIPEMENT ATTACHED TO THE THIS SHOULD NOT BE DONE WHILE THE EQUIPEMENT ATTACHED TO THE

CHILLER IS IN OPERATION. CHILLER IS IN OPERATION. CHILLER IS IN OPERATION. CHILLER IS IN OPERATION. The pressure gauge will then indicate the valve set-

point. As noted above, the valve does not snap open and shut. It will crack open

approximately 16-18 psi (1.1-1.2 Bar) below its set-point, depending on the valve.

The valve continues to open gradually, increasing the amount of bypass, as

pressure approaches the valve set-point. When the set-point is reached, all of the

flow from the pump is being bypassed. For this reason, the valve should be set a

minimum 20 psi (1.4 Bar) above the normal operating pressure to ensure full flow

of the pump through the closed loop.

Section 6: Standard Product Warranty


6.0 6.0 6.0 6.0 Standard Product WarrantyStandard Product WarrantyStandard Product WarrantyStandard Product Warranty

NOTE: Please complete and return the Owner’s Registration Card on the back

cover of this manual in order to register your Haskris system.

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.

Term & Conditions Provisions: Warranty extends for one (1) year from date

of 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 Provisions: Parts warranty does not include consumable items such as

filtration elements. Replacement parts furnished during the system warranty

are covered until the system warranty expires. Parts purchased after the

system warranty expires will be covered for a period of 90-days from the

date of shipment. Defective parts must be returned, transportation prepaid,

to Haskris Company. Normal outgoing surface transportation charges will

be paid by Haskris.

Additional Extended Warranties:

Additional warranty service may apply. Please contact HASKRIS for further

information. See section 1.4 for contact information.

Worksheet 1: Recommended Line Sizes


This worksheet is designed to provide guidance in selecting an appropriate nominal piping size between Haskris Model R1600 and Haskris Model WW4. This worksheet assumes:

• All municipal, local and state codes will be followed. • Type L copper piping will be furnished. • The loop of hose installed for WW4 is 1½” ID. • All piping internal to the R1600. • A 35% propylene glycol/water solution will be furnished.

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.

Begin calculations with 1-½”nominal piping. Increase to next larger nominal pipe size if baseline number (335) is exceeded, or re-configure piping run using 90º LR Elbows (Recommended).

Find total length of pipe run (Supply and Return):Find total length of pipe run (Supply and Return):Find total length of pipe run (Supply and Return):Find total length of pipe run (Supply and Return): Estimated pipe run (start with 1-½” nom. 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 (A) + (B) + (C) + (D) ______________ (E) Divide (E) by 100 Divide (E) by 100 Divide (E) by 100 Divide (E) by 100 (E/100)(E/100)(E/100)(E/100)==== ________________(F) Multiply (F) by Head loss (For 1Multiply (F) by Head loss (For 1Multiply (F) by Head loss (For 1Multiply (F) by Head loss (For 1----½”½”½”½”=5.61) =5.61) =5.61) =5.61) (F X HL)=(F X HL)=(F X HL)=(F X HL)= ______________ (G) Multiply (G) by 1.26Multiply (G) by 1.26Multiply (G) by 1.26Multiply (G) by 1.26 (glycol factor): <: <: <: <Maximum Value 17Maximum Value 17Maximum Value 17Maximum Value 175>5>5>5> _________ (I) If (I) is less than or equal to 175 then your pipe size is 1-1/2”. If not, repeat the calculations using the next larger nominal pipe size. Continue in this manner until (I) is less than or equal to 175 to find your recommended line size.

Equivalent length of pipe in feet

Nom. Pipe Size

Head Loss per 100’ (HL)

90º Standard (Close) Elbow

90º Long Radius (LR) Elbow

45º Elbow

1-½” 5.61 4.1 2.7 1.9

2” 1.57 5.2 3.5 2.4

2-½” 0.55 6.2 4.2 2.9

3” 0.246 7.7 5.2 3.6

Haskris Model R1600 Install Checklist


Installer’s Checklist for Haskris Installer’s Checklist for Haskris Installer’s Checklist for Haskris Installer’s Checklist for Haskris R1600, S/N HLR1600, S/N HLR1600, S/N HLR1600, S/N HL ____________________________________________________________________________________________________________________ Project Name ______________________________ Location _______________________________________

Note:Note:Note:Note: Checklist MUST be completed for “No Load” Start-up to be scheduled. R1600 cannot be started until completed checklist has been returned via fax to Haskris no less than 5 business days prior to no load start-up.

Directions:Directions:Directions:Directions: Fax completed checklist to Haskris (Fax#: 847-956-6595) 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. Installer will contact Haskris Authorized Start-Up Agent at least 2 business days in advance. No Load Start-Up subject to Technician availability. Start-Up will be done during normal working hours. Installer will issue a Credit Card Purchase Order to Haskris Start-Up Agent if any items are found incomplete and resulting in delay of system start-up. Checklist:Checklist: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 verifying the red ‘FAULT’ LED is NOT lit on phase monitor. (See Section 2.5.1) ___ Hard copper piping with vents/drains as required and properly supported. ___ Vibration Isolators installed at R1600 on both glycol supply and return lines. ___ Separately fused heat trace covered with suitable thickness of closed-cell, UV resistant insulation on

all 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 (0-100°F) and flow (10-50gpm) gauges provided at indoor heat exchanger. ___ All external piping flushed with water and dried per R1600 Instruction Manual. ___ Leak check performed and no leaks in external piping loop per R1600 Instruction Manual.

Nominal Power:Nominal Power:Nominal Power:Nominal Power: 480V-3Ø-60Hz,+5% / -10% MCA: 54.3A, MOCP 70A

Record Voltage at Disconnect

(V)

L1-L2

Confirm and Record Size of Time Delay Breaker (Fusing) Supplying

Chiller (A) L2-L3

L1-L3

!

Haskris Model R1600 Install Checklist


___ Glycol manufacturer_________________________Glycol type________________________________ ___ Fax copy of receipt or packing list for glycol ___ Water used for glycol mixture: _________Distilled _________De-Ionized ___ System (50 gallon tank and entire piping loop) is filled with gallons of glycol/distilled

water solution. ___ 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. ___ 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 Name: _________________________________________________ Title: __________________________

(Please Print)

Signature: ______________________________ Date: _________________

Requested Start-Up Date: __________________ Time: _________________

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: 847-956-6595 if you have any questions.

Haskris Model R1600 No Load Start-Up Checklist


No Load StartNo Load StartNo Load StartNo Load Start----UpUpUpUp Checklist for Haskris Checklist for Haskris Checklist for Haskris Checklist for Haskris R1600, S/N HLR1600, S/N HLR1600, S/N HLR1600, S/N HL ________________________________________________ Project Name ______________________________ Location ___________________________________

Note:Note:Note:Note: Checklist to be completed by Haskris Approved Service Agent. Checklist MUST be completed for “Full Load” Start-up to be scheduled.

Directions:Directions:Directions:Directions: Fax both pages of completed checklist to Haskris (Fax#: 847-956-6595)

Pre StartPre StartPre StartPre Start----Up Up Up Up Checklist:Checklist: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 compressor crankcase heater has been energized for a minimum of 12 hours. (See Section 3.1) ___ Confirm proper phase by verifying the red ‘FAULT’ LED is not lit on phase monitor. (See Section 2.5.1) ___ Hard copper piping with vents/drains as required and properly supported. ___ Vibration Isolators installed at R1600 on both glycol supply and return lines. ___ Separately fused heat trace covered with suitable thickness of closed-cell, UV resistant insulation on all 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 (0-100°F) and flow (10-50gpm) gauges provided at indoor heat exchanger. ___ Leak check performed and no leaks in external piping loop per R1600 Instruction Manual. ___ Preventative Maintenance (PM) Test Kit has been provided to Start-Up Agent. ___ System (50 gallon tank and entire piping loop) is filled with gallons of glycol/distilled water solution. ___ Reservoir is at tank full level. ___ Lines air purged per R1600 Instruction Manual. ___ Glycol solution % (Record actual measurement here). ___ Glycol solution pH level (Record actual measurement here).

___ Spare glycol manufacturer______________________Glycol type__________________________ ___ 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. ___ Confirm all isolation valves are open and all flush valves are closed. Note:Note:Note:Note: If any of the above items are found to be deficiencies, DO NOT CONTINUE WITH START-UP and notify Haskris immediately. Installer will issue a Credit Card Purchase Order to Haskris Start-Up Agent if any items are found incomplete and resulting in delay of system start-up. If no deficiencies are found, continue with Start-Up Checklist below. --Page 1 of 3—

(continued on next page)

Nominal Power:Nominal Power:Nominal Power:Nominal Power: 480V-3Ø-60Hz,+5% / -10% MCA: 54.3A, MOCP 70A

Record Voltage at Disconnect

(V)

L1-L2 Confirm and Record Size of Time Delay Breaker (Fusing) Supplying Chiller

(A) L2-L3

L1-L3

!

!



No LoadNo LoadNo LoadNo Load StartStartStartStart----UpUpUpUp Data LogData LogData LogData Log for Haskris for Haskris for Haskris for Haskris R1600, S/N HLR1600, S/N HLR1600, S/N HLR1600, S/N HL ________________________________________________ Project Name ______________________________ Location ___________________________________

No Load StartNo Load StartNo Load StartNo Load Start----Up Up Up Up Checklist:Checklist:Checklist:Checklist: Record Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To Stabilize

ElectricalElectricalElectricalElectrical 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)

FluidFluidFluidFluid 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 Valves Open / Closed Pump Flush Valves Open / Closed

RefrigerationRefrigerationRefrigerationRefrigeration Ambient Air Temperature (ºF) Gauge Suction Pressure (psi) A Gauge Suction Pressure (psi) B Gauge Head Pressure (psi) A Gauge Head Pressure (psi) B Head Pressure Display (psi) A (PV) (SV) Head Pressure Display (psi) B (PV) (SV) Refrigerant Sight Glass Clear A YES / NO Refrigerant Sight Glass Clear B YES / NO Refrigerant Moisture Indicator A Blue / Purple / Orange Refrigerant Moisture Indicator B Blue / Purple / Orange

--Page 2 of 3—



No Load StartNo Load StartNo Load StartNo Load Start----UpUpUpUp Completed By:Completed By:Completed By:Completed By:


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: 847-956-6595 if you have any questions.

--Page 3 of 3—

Haskris Model R1600 Full Load System Check


Full Load SysteFull Load SysteFull Load SysteFull Load System Checklist for Haskris R16m Checklist for Haskris R16m Checklist for Haskris R16m Checklist for Haskris R1600, S/N HB00, S/N HB00, S/N HB00, S/N HB ________________________________________________ Haskris WW4Haskris WW4Haskris WW4Haskris WW4, S/N HB, S/N HB, S/N HB, S/N HB__________ (Located in Equipment Room)__________ (Located in Equipment Room)__________ (Located in Equipment Room)__________ (Located in Equipment Room) Project Name ______________________________ Location ___________________________________ Note:Note:Note:Note: Checklist to be completed by Haskris Approved Service Agent.

Directions:Directions:Directions:Directions: Fax both 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 between connected to WW4. ___ Reservoir is at tank full level. ___ Glycol solution % (Record actual measurement here). ___ Glycol solution pH level (Record actual measurement here). ___ Confirm all isolation valves are open and all flush valves are closed. Note:Note:Note:Note: If any of the above items are found to be deficiencies, DO NOT CONTINUE WITH FULL LOAD SYSTEM CHECK and notify Haskris immediately. Installer will issue a Credit Card Purchase Order to Haskris Start-Up Agent if any items are found incomplete and resulting in delay of system start-up. If no deficiencies are found, continue with Full Load System Check below.

--Page 1 of 3— (continued on next page)

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Full Full Full Full Load System CheckLoad System CheckLoad System CheckLoad System Check for Haskris for Haskris for Haskris for Haskris R1600, S/N HLR1600, S/N HLR1600, S/N HLR1600, S/N HL ____________________________________________________________ Project Name ______________________________ Location ___________________________________

Full Load System Full Load System Full Load System Full Load System Check:Check:Check:Check: Record Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To Stabilize








--Page 2 of 3—



Full Load SystemFull Load SystemFull Load SystemFull Load System CCCCheckheckheckheck By:By:By:By:



Signature: ______________________________ Date: _________________


--Page 3 of 3—

Haskris Model R1600 Preventative Maintenance (PM)


PM System CheckPM System CheckPM System CheckPM System Check PM SYSTEM CHECK SHOULD BE PERFORMED BY A HASKRIS AUTHORIZED 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). See R1600 Control Panel description at the beginning of Section 4 for more details.

6. 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 PM System Check if both displays are not lit.

7.7.7.7. Check to make sure all external piping is leak-tight and that the system is operating 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 the fans begin to run at full speed.





9. System should remain on and operational under load. 10. Remove refrigerant manifold gauge. 11. Add glycol solution to the reservoir as necessary to maintain tank full level.

Fill system to tank full level as viewed on the liquid level indicator (See Figure 2.11).

12. Clean condenser coil, if required, as outlined in Section 5.3. 13. Close control box and replace all sheet metal panels on the R1600.

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14.14.14.14. Complete PM Data Log Sheet.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.

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 R1600R1600R1600R1600, S/N HB, S/N HB, S/N HB, S/N HB ________________________________________________________________________________________________________

!!!!



Project Name ______________________________ Location ___________________________________

Full Load System Full Load System Full Load System Full Load System Check:Check:Check:Check: Record Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To StabilizeRecord Values After System Has Run For 30 Minutes To Stabilize










PM SystemPM SystemPM SystemPM System CCCCheckheckheckheck By:By:By:By:



Signature: ______________________________ Date: _________________


Maintenance Notes


VFD A and B

controllers are

located in the

Electrical Control

Panel pull-out

Compartment of the

R1600

Display Display Display Display R1600R1600R1600R1600 VFD Fault SequenceVFD Fault SequenceVFD Fault SequenceVFD 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 flashing.

Figure M.1 VFD Location Figure M.1 VFD Location Figure M.1 VFD Location Figure M.1 VFD Location

Maintenance Notes


5. Press the enter key to view the most recent fault. Record the value on the display

screen in the following table. Then press the “esc” key to return to the previous

screen.

Display ParameterDisplay ParameterDisplay ParameterDisplay Parameter ErrorErrorErrorError Code VFD ACode VFD ACode VFD ACode VFD A Error Code VFD BError Code VFD BError Code VFD BError 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 faults.

• 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”

Table 3 Fault CodesTable 3 Fault CodesTable 3 Fault CodesTable 3 Fault Codes

After Installation and Service Support (HMSA)


CLEAR VFD FAULTS CLEAR VFD FAULTS CLEAR VFD FAULTS CLEAR VFD FAULTS

1. Press the down arrow key until is flashing on the display panel. No LEDS

should be lit indicating that the VFD is in programming mode.

2. Press enter and 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 end then return to the screen from figure 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.



Maintenance Action: Performed By: Date:



After Installation and After Installation and After Installation and After Installation and Service SupportService SupportService SupportService 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


• Website: www.hitachimed.com

Date post:	14-Oct-2020
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