INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS 1455 Kleppe Lane Sparks, NV 89431-6467 (775) 359-4712 Fax (775) 359-7424 E-mail: haws@hawsco.com Website: www.hawsco.com Model 8780 Tempering Skid General Area Classification & Class I Division 2 No. 0510000457(3) HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 1 of 20
IMPORTANT Read this installation manual completely to ensure proper installation, then file it with the owner or maintenance department. Compliance and conformity to drain requirements and other local codes and ordinances is the responsibility of the installer. Separate parts from packaging and make sure all parts are accounted for before discarding any packaging material. If any parts are missing, do not begin installation until you obtain the missing parts. Flush the water supply lines before beginning installation and after installation is complete. Test the unit for leaks and adequate water flow. Main water supply to the emergency fixture should be ON at all times. Provisions shall be made to prevent the unauthorized shutoff. Please refer to the enclosed instructions for flushing the unit prior to use. The ANSI Z358.1 standard requires an uninterrupted supply of flushing fluid. Haws plumbed emergency fixtures requires a minimum of 45-90 PSI flowing pressure. Flushing fluid should be tepid per ANSI Z358.1. The inspection and testing results of this equipment should be recorded weekly to verify proper operation. This equipment should be inspected annually to ensure compliance with ANSI Z358.1. Installation and maintenance of this system must be completed by a qualified plumber and electrician in accordance to the information contained in this installation manual and in compliance with all national and local codes. When making electrical connections be sure to follow all lockout-tag out safety procedures. It is recommended that all water supply and electrical connections be made at temperatures above freezing (32ºF (0ºC)). Failure to do so may result in major product and or property damage. For technical support, contact Haws' authorized service provider, Zevado (888) 508-8065 www.zevado.com HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 2 of 20
DESCRIPTION OF PRODUCT Haws Corporation Performance Series model 8780 tempered water system is situated upon a fiber reinforced skid. The bright yellow, fiber-reinforced membrane is waterproof, chemically resistant, and protected with UV inhibitors for a long lasting finish. This system includes a standard 480 voltage, 3 phase power circuit and has additional 5 voltage options available. The entire electrical system is designed for a wet/wash down area and can be NEMA or Class 1 Division 2 rated. Hot water, generated via 4kW or 6kW immersion heater (determined by tank size), is stored in a chosen tank size of 119, 120, 200 or 330 gallons. Hot and cold water are mixed with an engineered blending system to provide warm water for one or two, in the case of a 330 gallon tank, combination shower/eyewash unit(s) running at a maximum of 30 GPM. The blending system is a safe, prepackaged, fully engineered and tested system for mixing large volumes of hot and cold water specifically designed for emergency showers and eyewashes. The system provides multiple levels of protection to prevent scalding, including a high temperature shutoff valve. Also included is a pressure relief cold-water bypass that protects against constricted flow. There are no electrical components in the blending system. Dry contacts are provided for remote alarm hookup. SHIPPING, HANDLING AND STORAGE Performance Dimensions Dimensions Weight Description Weight Series Model W x L x H W x L x H (Crated) (Crated) 8780.21.3X 970 lbs. 1200 lbs. 8780.22.3X 970 lbs. 1200 lbs. Tempering Skid 60 x 60 x 102 69 x 69 x 106 8780.23.3X 1700 lbs. 2150 lbs. 8780.25.3X 1020 lbs. 1350 lbs. Recommended Equipment, Materials and Supplies to be provided by Installer: Concrete slab rated to support a minimum of 6,000 pound load requirement. (4) 3/4 minimum diameter by 1-1/2" minimum length anchor bolts with washers. A forklift capable of lifting 5,000 lbs. should be utilized to transport the unit from truck to site. The unit should be lifted from the rear or equipment end and low to the ground. Electrical Supply Materials (if applicable). Plumping Supply Materials (if applicable). Freeze protection equipment for the water supply leading up to the enclosure (if applicable). Storage The unit should be stored in a clean, dry place until ready for installation unless otherwise specified. WARNING: DO NOT connect power before plumbing and supply and drain lines. Connections should be performed by a certified electrician and plumber only. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 3 of 20
INSTALLATION PROCEDURE a. Remove unit from crate. b. The unit should be secured on a level site, using the supplied brackets and suitable anchoring devices. Suggested anchoring devices are 3/4 minimum diameter by 3/4" minimum length anchor bolts with washers. c. If the skid is to be placed over a drain, the drain should be able to handle a flow of 35 GPM, otherwise, the slab should allow the water to drain out the sides and away from the booth. WARNING: Failure to allow water to drain may result in premature failure of booth and void of product warranty. d. The expansion tank should be pre-charged with compressed air to a pressure equal to the water supply pressure. An air fitting is accessible on the top of the expansion tank, under the plastic cap. e. The connection provided for the water supply is a 1-1/2 NPT union and 1-1/4 NPT union tempered water outlet. Supply lines are expected to be capable of supplying 30 GPM of potable water at a dynamic pressure of 45-90 psi. The water supply line should run for a few minutes to eliminate any debris before it enters the equipment. f. Electrical supply connection must be made to the disconnect switch junction box. CAUTION: Do not apply power to the unit until all water connections are made and the tank and piping are full of water. Applying power prematurely will damage the equipment. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 4 of 20
g. Once all water and power connections are made, open an emergency shower or eyewash valve to eliminate any air that may be in the lines, and allow water in the system to flow. Inspect plumbing for leaks and repair as necessary. During transit, some plumbing may have become loose, allowing water to leak from the threads. Once the plumbing has been checked, the shower should run for several minutes to evacuate any debris that might have entered the system. Turn shower off once water is clear of debris. h. At this point the power can be turned on. The tank water must be allowed to heat up before the blending system will function properly. Heating can take up to several hours, depending on supply water temperature, size of immersion heater and tank. CAUTION: Before turning on the power, close all electrical boxes. NOTE: The emergency shower or eyewash should be utilized for testing of the blending system. Refer to the Maintenance, Testing, and Repair section of the Blending System Manual document for proper adjustment and operation. i. Activate shower again to fill the system with as much tempered water as possible. As the warm water reaches the shower, it can be shut off. WARNING: System is not freeze protected without an energized electrical connection. It is recommended that installation be completed when ambient temperature is above freezing. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 5 of 20
CHECK LIST FOR START-UP Pre-connection Check Check all components for any connections or connectors that may have loosened during shipping. System Flush (All Electrical Power off for System Flush) Verify that a minimum of 45 psi and maximum 90 psi is supplied to the inlet of the hot water tank. Drain is able to handle a flow of 35 GPM (if applicable). System water supply is connected and all water supply valves opened. Water is clear and free of any contamination, particles or discoloration. Connections System is charged with water and all air is evacuated from the system. Connect remote monitoring via plant control system (if applicable). Applying Power to the System Verify that the proper voltage is present. Verify that equipment ground is properly connected. Apply power to the system. The tank heater set point is preset in the program. It may take 4 to 6 hours for the tank to reach the operating temperature. Once the tank has reached operating temperature for a minimum of 1 hour, press the arrow and record these values in the chart provided in the Tank Monitor section of the program narrative included in this manual. Shower and Eye/Facewash (if applicable) Flow water through an eyewash or shower. Blending Valve When shower is activated read the center temperature gauge directly above the blending valve to ensure to the readout is 85ºF (29ºC) ± 2º. Programmable Logic Controller Display Set the current time and date in the controller (see instructions on page 7). Complete OK Inspector Initials HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 6 of 20
Setting Current Time and Date on the Controller Press the SHIFT and OK buttons to enter the menu. Press 4 to enter setup. Press 1 to set date or 2 to set time. After date or time is set, press the SHIFT and key to return to setup menu. The Time and Date can be verified by pressing the or keys while in the normal operating screen. NOTE: If the blending valve temperature reading is incorrect, adjust the blending valve by turning the socket head screw counterclockwise located on the bottom of the center section of the valve body. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 7 of 20
LOGIC DIAGRAM AND NARRATIVE The program allows for monitoring the tank temperature. When no faults are present the tank temperature, tank heater status, and flow status are displayed. There are several alarm points that are continuously monitored. These alarms are shown on the Display as long as the fault is active. Alarm conditions may also be monitored by connecting another control system via interposing relays and terminals provided. See electrical schematic for details. A fault history is also provided to assist in monitoring the system performance. Additionally, the tank heater performance can be monitored to assist in determining when maintenance is required. Accessing the different functions is accomplished by depressing the appropriate key(s) on the display. The table below lists the key functions: Key Function Display Fault History Display Tank Heater Monitor Display Current Time Display Current Date 0 Reset High Tank Temp Alarm 0 & 2 Local Alarm Light Function (Off)* 1 Reset High Booth Temp Alarm* 1 & 2 Start Summer Mode* 1 & 3 Local Alarm Light Function (On)* 3 & 4 Return from Summer to Normal Mode* *Not used on some models HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 8 of 20
The following table lists the inputs and outputs used in the system. NOTE: For model specific program, please contact Haws Corporation at 1-888-640-4297. Input Function Output Function I-00 Flow Switch Q-00 Tank Heater Contactor I-01 Horn Silence Button * Q-01 Space Heater Contactor * I-02 Level Switch Q-02 Alarm Light * I-03 Booth Thermostat * Q-03 Horn * AI-02 Tank Temperature Thermocouple Q-04 Customer Contact (Trouble) AI-03 Booth Temperature Thermocouple * Q-05 Customer Contact (Flow) *Not used on some models The program consists of a series of charts (sub-routines) that are grouped according to function. Each chart will be discussed in the following sections. Tank Control When the tank temperature is below 163 F (72 C) and 144ºF (62ºC) for the 200 gallon tank, the tank heater contactor will close and the heater elements will be energized. When the temperature rises above 166 F (74 C) and 146ºF (63º) for the 200 gallon tank, the contactor will open and the element will become deenergized. A low level condition or an over temperature condition (that has not been addressed) will prohibit the contactor from closing even if the temperature is below the set point. If the tank thermocouple falls to a point below 32 F (0 C) a potential thermocouple failure is present and the tank heater contactor will not close. The customer trouble alarm contacts are monitored in this section of the program. The following conditions will de-energize output Q-04 (customer contact trouble) when a potential fault is present: Low Tank Temperature under 155 F (68 C) High Tank Temperature over 168 F (76 C) High Tank Temperature over 175 F (79 C) REQUIRES MANUAL RESET Low Tank Level NOTE: The high temperature alarm for the tank is designed to give a warning by displaying a fault message and changing the state of the customer contacts before the temperature rises to a point that requires a manual reset of the heating equipment. Should the alarm not be addressed before reaching the high set point then the system will require additional attention and a manual reset. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 9 of 20
Messages The display messages are controlled in this chart. When no faults are present, the display will present the following conditions: Tank Heater On (when active) Tank Temperature When a single fault condition is present, the display will indicate which fault condition is present. If more than one fault condition exists, the display will cycle through each fault at 4 second intervals. Each message will automatically clear when the condition is no longer active or when the corrective action has been taken. This chart also records a message to the Fault History chart which will assign the time and date when the fault occurred. Timer counter (TC-05 in conjunction with TC-06) will keep track of the 4 second timing intervals and advance the message display to the next active fault (if present). Fault History The fault history chart keeps track of the time and date of the last occurrence of each fault. When the left arrow key is depressed, the time and date of each fault will be listed on the display. There will be a 4 second delay before the first fault is displayed. Each fault will be listed for 4 seconds as long as the left arrow key is depressed. The time and date of each fault are stored in registers R-004 through R-021. Once the left arrow key is released the display will return to the normal condition display if no faults are present. If there are faults in the system, the display will return to the fault display when the left arrow key is released. Tank Monitor The tank monitor chart provides a means of monitoring the tank heater performance. This chart records the actual amount of time that the tank heater contactor is on via registers R-050 through R-052. Counter TC-14 cycles the chart through the last 3 on/off cycles of the tank heater contactor. TC-13 records the actual on time of the contactor. When the unit is initially placed in service and has reached operating temperature for several hours, the on/off cycles should be recorded in the table below. Pressing the up arrow key will display the last three cycles. Each cycle will be displayed for 4 seconds as long as the key is depressed. CYCLE ON/OFF TIME 1 2 3 These values can be checked on a routine basis. If the amount of time that the tank heater is on has increased, it may be an indication that the tank heater needs service or repair. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 10 of 20
Tank History This tank history chart controls the display messages recorded by the tank monitor chart. TC-15 sets the time that each message is displayed. TC-16 is used to increment from Heater on time 1 through Heater on time 3. PREVENTATIVE MAINTENANCE Weekly Verify the tank temperature readout on the display reads 165º F ± 2ºF (74ºC ± 1ºC). Verify area lights located inside and outside the booth are operational. Verify shower and eyewash flow per ANSI requirements. Verify temperature gauge on center pipe of blending valve reads 84ºF ± 2ºF (29ºC ± 1ºC). Monthly Verify eyewash flows. Verify shower flow. Verify correct operation of mixing valve. See Maintenance section. Quarterly Flush Y strainers (if installed) HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 11 of 20
Annually Check tank heater and tank for deposit buildup. Drain tank and clean/replace heater if necessary. All valves should be periodically tested; at least once a year, more often if water is dirty. Drain tank and verify level switch operation. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 12 of 20
MAINTENANCE, TESTING, REPAIR Blending Valve System The blending valve system should require minimal amount of maintenance. During scheduled testing, the temperature output should be checked for proper adjustment. For a complete test, the steps below should be followed. 1. Activate the shower to initiate flow. 2. Observe temperature on outlet. Temperature should be 84ºF ± 2 F (29ºC ± 1ºC). Let flow for 30 seconds to see if temperature remains stable. 3. Adjust mixing valve to a warmer setting until the temperature increases to roughly 88 F. This step ensures that the hot shut-off valve and by-pass valve are working properly. 4. Adjust valve back to 70 F (21ºC) by adjusting the mixing valve in the cooler direction. 5. Slowly return temperature in the warmer direction until a constant 84ºF ± 2 F (29ºC ± 1ºC) is maintained. Turn shower off. NOTE: For more information, refer to the Blending Valve System O&M manual. Y Strainers Y strainers should be blown out at the same time as scheduled testing of showers or monthly. For technical support, contact Haws' authorized service provider, Zevado (888) 508-8065 www.zevado.com HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 13 of 20
TROUBLESHOOTING TROUBLE Tank temperature too cold (set point 165 F (74ºC) and 145ºF (63ºC) for 200 gallon tank): REPAIR CHECKLIST a) Used recently? Full recovery for each tank and heater size below: 119 gallon/4kw, 10 hours 120 gallon/4kw, 10 hours 200 gallon/4kw, 14 hours 330 gallon/6kw, 18 hours b) Check controller setting (165 F/145ºF). Check for heater on display if below 165 F/145ºF. c) Check controller for alarms. d) Check heater circuit fuses F1. e) Check control voltage and power supply fuses PFU & CFU. Tank temperature too hot: a) Check controller setting. b) Check alarms on controller. Uneven water flow to eyewash (if applicable): a) Eyewash must be level. b) Clogged flow control. Clean or replace flow control in eyewash head. Insufficient water flow to eyewash or shower: a) Check water supply dynamic pressure (45-90 PSI). b) Check and clean Y strainers. c) Check ball valves. Must be open and unclogged. d) Clogged flow control. If there are any questions that cannot be answered here, please consult Haws Corporation at 1-888-640-4297. For technical support, contact Haws' authorized service provider, Zevado (888) 508-8065 www.zevado.com HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 14 of 20
SPARE PARTS Please call Haws Corporation to order spare parts: 1-888-640-4297 FUSES PRIMARY (PFU) AND CONTROLLER (CFU) VOLTAGE PFU CFU QTY P/N QTY P/N 208V, 1PH 2 0210000298 208V, 3PH 2 0210000298 240V, 1PH 2 0210000298 240V, 3PH 2 0210000298 1 0210000297 480V, 3PH 2 0210000070 600V, 3PH 2 0210000070 FUSES TANK HEATER (F1) 4KW TANK HEATER 6KW TANK HEATER VOLTAGE F1 F1 QTY P/N TYPE QTY P/N TYPE 208V, 1PH 2 0210000072 KTK-R-25 2 0210000292 JKS-40 208V, 3PH 3 0210000065 KTK-R-15 3 0210000072 KTK-R-25 240V, 1PH 2 0210000072 KTK-R-25 2 0210000293 JKS-35 240V, 3PH 3 0210000065 KTK-R-15 3 0210000164 KTK-R-20 480V, 3PH 3 0210000143 KTK-R-10 3 0210000143 KTK-R-10 600V, 3PH 3 0210000142 KTK-R-6 3 0210000143 KTK-R-10 CONTACTORS TANK HEATER (CON1) VOLTAGE CON1 QTY P/N SIZE 208V, 1PH 1 0210000196 24V, 40A 208V, 3PH 1 0210000335 24V, 21A 240V, 1PH 1 0210000196 24V, 40A 240V, 3PH 1 0210000335 24V, 21A 480V, 3PH 1 0210000335 24V, 21A 600V, 3PH 1 0210000335 24V, 21A HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 15 of 20
POWER SUPPLY POWER SUPPLY VOLTAGE P/N 208V, 1PH 0210000189 208V, 3PH 0210000189 240V, 1PH 0210000189 240V, 3PH 0210000189 480V, 3PH 0210000190 600V, 3PH 0210000190 HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 16 of 20
DRAWINGS NOTE: General drawing included. Please find specific drawings on website or contact Haws Corporation. a. Installation Drawing (8780.21.31-GA) HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 17 of 20
b. Electrical Schematic (8780.21.31-E) HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 18 of 20
c. Piping and Instrumentation Diagram (8780.21.31-PID) HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 19 of 20
LIMITED WARRANTY HAWS warrants that this specific product is guaranteed against defective material or poor workmanship for a period of one year from date of shipment. HAWS liability under this warranty shall be discharged by furnishing without charge F.O.B. HAWS Factory any goods, or part thereof, which shall appear to the Company upon inspection to be of defective material or not of first class workmanship, provided that claim is made in writing to Haws within a reasonable period after receipt of the product. Where claims for defects are made, the defective part or parts shall be delivered to the Company, prepaid, for inspection. HAWS will not be liable for the cost of repairs, alterations or replacements, or for any expense connected therewith made by the owner or his agents, except upon written authority from HAWS, Sparks, Nevada. HAWS will not be liable for any damages caused by defective materials or poor workmanship, except for replacements, as provided above. Buyer agrees that Haws has made no other warranties either expressed or implied in addition to those above stated, except that of title with respect to any of the products or equipment sold hereunder and that HAWS shall not be liable for general, special, or consequential damages claimed to arise under the contract of sale. The emergency equipment manufactured by HAWS is warranted to function if installation and maintenance instructions provided are adhered to. The units also must be used for the purpose for which they were intended. This product is intended to supplement first-aid treatment. Due to widely varying conditions, Haws cannot guarantee that the use of this emergency equipment will prevent serious injury or the aggravation of existing or prior injuries. NO OTHER WARRANTIES EXPRESSED OR IMPLIED ARE AUTHORIZED, PROVIDED OR GIVEN BY HAWS. SHOULD YOU EXPERIENCE DIFFICULTY WITH THE INSTALLATION OF THIS MODEL PLEASE CALL: TECHNICAL SUPPORT: 1-800-766-5612 FOR CUSTOMER SERVICE: 1-888-640-4297 For technical support, contact Haws' authorized service provider, Zevado (888) 508-8065 www.zevado.com For more information on Haws products, see our website: www.hawsco.com 2016 Haws Corporation All Rights Reserved HAWS and other trademarks used in these materials are the exclusive property of Haws Corporation. HAWS P/N 0510000457 Rev.3 11/16 Model 8780 Page 20 of 20