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Aqua Cooler R Series Product Manual

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R Series Manual – R150 to R2500
Aqua Cooler Pty Limited
PRODUCT MANUAL
R SERIES WATER CHILLERS
001-D139
Client
Model
Serial No.
R150 R180 R230 R300 R330
R420 R540 R670 R830 R1000 R1200 R1330
R1500 R2000 R2500

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  • Page 1 R Series Manual – R150 to R2500 Aqua Cooler Pty Limited PRODUCT MANUAL R SERIES WATER CHILLERS 001-D139 Client Model Serial No. R150 R180 R230 R300 R330 R420 R540 R670 R830 R1000 R1200 R1330 R1500 R2000 R2500...
  • Page 2 This applied to units not supplied with a pump. · Where the commissioning data is not returned to Aqua Cooler or at the very least be retained for the warranty period of the product to be accessible in the event of a fault developing with the product.
  • Page 3 Terms and Conditions of Sale General Conditions · It is not Aqua Cooler’s responsibility to connect the chiller to the BMS unless agreed to before delivery of the chiller · Costs for installations where a crane lift is required to undertake major repairs will...

  • Page 4: Table Of Contents

    R Series Manual – R150 to R2500 CONTENTS Safety Marking Certification Warranty General Information Intended Use Water Circuit Technical Data Cooling System Schematic Dimensions Transport and Storage Installation – electrical, water connection, water treatment, control circuit and final checks Operation...

  • Page 5: Safety

    R Series Manual – R150 to R2500 SAFETY THE UNIT IS DESIGNED FOR OUTDOOR USE. WARNING The unit is only to be installed, operated, maintained and serviced by qualified persons only. Operation of units such as these can be hazardous and should be serviced by persons with the proper training and qualifications.
  • Page 6 R Series Manual – R150 to R2500 SAFETY The R150 to R330 unit have R134a refrigerant – the R420 to the R2500 has R407c refrigerant. They have different refrigeration properties but both are similar properties from a hazardous materials perspective.
  • Page 7 R Series Manual – R150 to R2500 SAFETY A full material safety data sheet for R134a refrigerant gas is available at http://www.refrigerants.com/msds/r134a.pdf Disposal The unit must be disposed of in a proper fashion. The refrigerants in the system must be reclaimed by a qualified refrigeration mechanic and disposed of in accordance with the statutory requirements.

  • Page 8: Marking

    A four digit serial number sticker will also be placed under the marking plate. With this number Aqua Cooler can trace the date of manufacture of the product and details on the unit. The wiring diagram will show the model of the unit and the options installed. The designation...

  • Page 9: Warranty

    Aqua Cooler Pty Ltd for consideration. This warranty is given by Aqua Cooler Pty Ltd, ABN 13 245 994 351, of 161 Orchard Rd, Chester Hill, NSW 2162 – ph 02 9721 9310.

  • Page 10: Water Circuit

    R Series Manual – R150 to R2500 CHILLED WATER CIRCUIT The chiller can be installed to feed a remote buffer tank or be a closed loop system. Whichever installation id required MUST be specified at the time of order. The chilled water circuit consists of 1.

  • Page 11: Technical Data

    For the R420 to the R2500 if R134a is used then reduce power consumption by approximately 30%. The power consumption of the unit will also change for units supplied with R404 or R410a. Contact Aqua Cooler for accurate data on non-standard chillers R SERIES I – R150 to R330...
  • Page 12 R Series Manual – R150 to R2500 TECHNICAL DATA ELECTRICAL DATA Model R150 R180 R230 R300 R330 Power requirements – 240V 50 Hz Single Phase Not readily available in single phase single phase Maximum current draw A/ Ph 17.1 22.1 –...
  • Page 13 R Series Manual – R150 to R2500 TECHNICAL DATA R420 to R1330 PERFORMANCE DATA – R134a Model R420 R540 R670 R830 R1000 R1200 R1330 Compressor horsepower Cooling capacity 0° supply 11.1 14.8 16.8 18.1 Power input – 45 Ambient 10.6 Power input –...
  • Page 14 R Series Manual – R150 to R2500 TECHNICAL DATA R SERIES III – R1500 TO R2500 PERFORMANCE DATA – R407c Refrigerant R1500 R2000 R2500 Cooling Capacity 5° supply 30.8 36.5 49.5 Power input – 45 ambient 15.4 22.9 27.6 Power input – 35 Ambient 13.7...
  • Page 15 R Series Manual – R150 to R2500 TECHNICAL DATA GENERAL DATA – R1500 to R2500 Model All Models 80 – reset High pressure safety cutout Low pressure safety cut out 2300 pressure – R134a pressure – R134a at 170 170 – reset High pressure safety cut out Low pressure safety cut out –...

  • Page 16: Cooling System Schematic

    R Series Manual – R150 to R2500 COOLING SYSTEM SCHEMATIC Immersed Copper Coil Evaporator Brazed Plate Heat Exchanger Evaporator Model...
  • Page 17 R Series Manual – R150 to R2500 COOLING SCHEMATIC Closed Loop Installation Cooling Schematic Symbols Air Cooled Pressure Liquid receiver Condenser transducer Pump One way valve Ball valve Compressor TX valve Flow meter Sight glass Drier Pressure gauge Low pressure switch...

  • Page 18: Dimensions

    R Series Manual – R150 to R2500 DIMENSIONS Standard Chillers R150 to R330 R420 to R1330 R1500 to R2500...
  • Page 19 R Series Manual – R150 to R2500 DIMENSIONS R420 to R1330 Remote Unit R1500 to R2500 Remote Unit Compact Chiller – no buffer tank – Model RTDPC25 – 25 to 50kW...
  • Page 20 R Series Manual – R150 to R2500 DIMENSIONS R1500 Remote Condenser R2000/ R2500 Condenser...

  • Page 21: Transport And Storage

    Aqua Cooler. There is also a site inspection procedure at the end of this manual. It is strongly recommended that Aqua Cooler or one of its agents carry out a site inspection to confirm that the installation site will not compromise the chillers performance.
  • Page 22 This should be filled out by someone experienced in chiller installation and returned to Aqua Cooler if there are any doubts about the installation. It is essential to ensure that adequate and safe service access to the chiller is provided.
  • Page 23 R Series Manual – R150 to R2500 INSTALLATION On the rear of the standard and the remote unit with the buffer tank and on the front of the refrigeration module of the remote condenser version, the supply and return connections will be marked next to the water fittings.
  • Page 24 R Series Manual – R150 to R2500 INSTALLATION For both models of display there is a 24VDC master run light (green) and a fault light (red). Both will need to be wired back to the electrical box using 2 wires for each light. The terminals for the fault light are 10/11 and the terminals for the master run light are 12/13 –...
  • Page 25 The chiller has programming to allow it to be connected to the internet for monitoring or to be monitored via high level SNMP interface. Aqua Cooler can install customer IP address prior to the unit being dispatched other wise see the service section of this document for instructions on changing the system settings.
  • Page 26 R Series Manual – R150 to R2500 INSTALLATION To connect the chiller to your network or use a laptop on site · Connect a CAT5 cable to the Ethernet port on the circuit board · Open a browser and enter http://10.1.1.130:8076...
  • Page 27 R Series Manual – R150 to R2500 INSTALLATION Without a valid xml mapping file uploaded into the controller, only the SNMP Agent will be operational. All SNMP OIDs have remained unchanged from previous Pump and Transfer firmware releases so that firmware containing the latest BACnet and Modbus interfaces will still be able to be accessed by an alternative, external SNMP to BACnet and Modbus gateway such as the Babel Buster.
  • Page 28 See wiring diagram. Remote Condenser Installation R Series Chillers can be ordered in configurations featuring the ability to remotely mount the condenser in order to permit maximum installation flexibility. When ordered with a remote condenser configuration we deliver the condenser and the chilling unit separately. Both the chiller and the condenser are pre-charged with refrigerant and fitted with isolation valves.
  • Page 29 For pipe runs longer than 20 meters an oil separator or trap may have to be installed – please contact Aqua Cooler for recommendation on installation on pipe runs longer than this. The condenser is fitted with a junction box switch into which the electrical supply from the chiller must be connected.
  • Page 30 R Series Manual – R150 to R2500 INSTALLATION Unit with interal buffer tank Once the refrigerant lines have been connected between the condenser and the chiller it is essential to pressurise the lines with nitrogen and check for leaks. Once cleared of leaks the the lines should be evacuated.
  • Page 31 R Series Manual – R150 to R2500 INSTALLATION Once this task has been completed the fan direction should be checked. It will be necessary to organize somebody to view the operation of the fans at the condenser. Gain access to the electrical enclosure by removing the panel above the water fitting on the refrigeration module.
  • Page 32 Standard Aqua Cooler chiller can be installed together in pairs and one of the chillers will act as the master and the other the slave and the master will duty cycle the chillers and keep a healthy.

  • Page 33: Operation

    R Series Manual – R150 to R2500 OPERATION Before starting the chiller, ensure that the pressure on the suction pressure gauge on the front of the chiller is above 400kPa. If the pressure is below this then there may be a leak in the refrigeration circuit and water may be drawn into the refrigeration circuit on start up.
  • Page 34 If the chiller is to be installed in redundancy – that is with another chiller in tandem or with multiple chillers and controlled by a BMS or the Aqua Cooler central control system, this feature will de-activated.
  • Page 35 The rest of the control settings and the default setting for the parameters outlined above are outlined below – it is recommended that they are not altered without consulting Aqua Cooler The settings below are the only ones that should be altered by the operator – the rest of the menu are for setting up the chiller and should not be altered.
  • Page 36 R Series Manual – R150 to R2500 CONTROL Close tolerance If the unit has been manufactured for close tolerance then the controller will attempt to keep the water temperature within the close tolerance number around the midpoint between the set point and the hysteresis.

  • Page 37: Service And Maintenance

    A comprehensive preventative maintenance program is available through Aqua Cooler carried out by qualified refrigeration mechanics. Should any faults be identified then please call Aqua Cooler to arrange a service call. Recommended preventative maintenance program Operation...
  • Page 38 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Accessing the electrical box – standard chiller Remove the bottom panel – it will be marked Behind this panel is the electrical enclosure. The key for the enclosure will be attached to the chiller with wire...
  • Page 39 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Download via USB – insert a USB key into the USB key on the rear of the circuit board controller. 1. Go to the PARAMETERS MENU and press OK and then scroll to MANAGE LOG DATA sub menu and press OK 2.
  • Page 40 Upload this file onto the USB stick making sure it is the only HEX file in the root directory of the USB stick. Insert the stick into the USB port on the rear of the Aqua Cooler controller – the controller will look for the file automatically and start the upload. The screen will confirm upload in progress and confirm when it is complete.
  • Page 41 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Open a browser with http://10.1.1.130:8076/mpfsupload OR if the controller has already been configured to a unique IP address then use this address. Use the BROWSE key to retrieve the BIN file saved to your computer or USB key. Once this is uploaded the page will show a tab with “Site Main Page”...
  • Page 42 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Maximum and Minimum Temperature Limits · This minimum Scroll to the PARAMETERS MENU then to the SET POINTS sub maximum temperature limit for menu · Scroll to “MIN TEMP LIMIT” or “MAX TEMP LIMIT”...
  • Page 43 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Setting fan speed control · Scroll to “PARAMETER MENU” and to the SET POINTS sub menu If fan speed controllers are · Scroll to “ Fan Min SP Pressure” installed the minimum run speed ·...
  • Page 44 THEY ARE NOT altered without a full understanding of the chillers programming or without checking with Aqua Cooler first. The settings reflect Aqua Cooler recommended setting for the installation ordered. If at a later time another chiller is installed in tandem or the chiller is added to a multiple chiller set them some of the setting may change.
  • Page 45 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Controller Input and Output Schematic Connector Type Control Outputs – 1 to 8 across the 24VDC 1 Compressors top of the board 2 Hot Gas/ Spray Cool 3 Pump 4 Ball Valve...
  • Page 46 The RE range of chiller will be running R143a refrigerant unless specified otherwise. The power inverter receives a 2-10V signal from the Aqua Cooler controller and is factory set to run between 40 and 75Hz – that is at 2 volts the drive will be running the compressor at 40...
  • Page 47 R Series Manual – R150 to R2500 SERVICE and MAINTENANCE Changing the filter cartridges If installed it is recommended that the cartridges be changed every 9 to 12 months. Remote Chiller On the remote condenser the filter pack can be accessed by removing the panel at the opposite end of the unit to the electrical enclosure.

  • Page 48: Pump Curves

    R Series Manual – R150 to R2500 WIRING DIAGRAM – TANDEM INSTALLATION PUMP CURVES...
  • Page 49 R Series Manual – R150 to R2500 PUMP CURVES...

  • Page 50: Data Sheets

    R Series Manual – R150 to R2500 CRITICAL SPARE PARTS Electrical spare parts are listed on the wiring diagram – contact Aqua Cooler for the parts required for the model of chiller. To maintain the smooth operation of the chiller only quality suppliers should be used for spare parts.

  • Page 51: Trouble Shooting

    R Series Manual – R150 to R2500 TROUBLE SHOOTING In the event the chiller develops a fault then the fault is displayed on the screen readout on the control board. The faults displayed are comprehensive but not fully descriptive. Symptom...

  • Page 52: Wiring Diagram

    A wiring diagram unique to the chiller will be in the electrical box with this manual – if it has not been provided please contact Aqua Cooler to organise a copy. Legend for component marking in the electrical box/ wiring diagram...

  • Page 53: Release Notes

    R Series Manual – R150 to R2500 RELEASE NOTES RELEASE - SOFTWARE Date Issue Description 01/11/11 Document release as a generic manual Software to version P264_56_E00_009 01/01/12 Software to version P264_56_E00_010 13/03/12 Software to version P264_56_EB0_011 06/06/12 Software to version P264_56_EB0_13...

  • Page 54: Commissioning

    R Series Manual – R150 to R2500 COMMISSIONING It is important that the chiller is commissioned in accordance with the guidelines below in order to ensure proper and trouble free operation. Outlined below is a check list showing all the considerations that must be taken for the proper installation and operation of the chiller.
  • Page 55 R Series Manual – R150 to R2500 COMMISSIONING Water Connection Was the pressure on the suction gauge checked before the unit was filled with water – see Installation Open the mains make up water to the chiller – has all the air...
  • Page 56 R Series Manual – R150 to R2500 COMMISSIONING Tandem Installation Checks On the master chiller set the cycle time to “10 minute test” and after 10 minutes check that the chillers duty cycle. Fault the running chiller and check the other chiller starts and...

  • Page 57: Site Inspection

    R Series Manual – R150 to R2500 SITE INSPECTION Proposed Date Inspected: Chiller Model: Inspected By: Company: Contact Number: Business Name Of Installation Site: Installation Site Street Address: Installation Site Phone Number: Installation Site Facsimile Number: Installation Site Contact Name:...
  • Page 58 R Series Manual – R150 to R2500 SITE INSPECTION Chiller Installation – Clearances Mark out any condensing units or other possible heat sources that may effect the operation of the proposed chiller installation Highlight any walls/fixtures/items that encroach on the clearances required for the chiller installation.
  • Page 59 R Series Manual – R150 to R2500 SITE INSPECTION Chiller Water Circuit Requirements Notes: Pipe Size: Pipe Insulation: Length: Height Difference: Balancing Valve: YES/NO Isolation Valves: YES/NO Water YES/NO Make Up Water: YES/NO Treatment: Treatment Used: Supply Pressure: Flow Rate:...
  • Page 60 General Notes/Feedback Completion Aqua Cooler uses the information from this site inspection sheet to confirm that the chiller will be installed and operating correctly. Should any problems or issues be raised as a result of the site inspection process then Aqua Cooler will take steps to address them with the customer, ensuring that the chiller operates reliably and without compromise to the long service life we expect of our products.

This manual is also suitable for:

R150R420R330R540R670R180 ... Show all

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