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Summary of Contents for Aqua Thermal X R Series
- Page 1 Revision 2 AUGUST 2019 Thermal X - R Series Owner’s Manual This guide applies to the following models: R150 to R4000. Aqua Cooler Pty Ltd www.aquacooler.com.au U14, 2-12 Knobel Court 1300 AQUA COOLER Shailer Park 4128 Qld 1300 278 286...
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Page 2: Table Of Contents
CHLF12-40 ..........................11 CDMF20-4 ........................... 11 CDMF32-30 ..........................12 Aqua Cooler Controller ........................12 Unlocking the Keypad on the Aqua Cooler Controller ..............12 Operational Logic of Controller ......................13 Start Up ............................13 Temperature Control-Set Point ....................... 13 Temperature Control-Max and Min Set Point ................13 Temperature Control-High and Low Temperature Alarm Stop............ - Page 3 Close Tolerance..........................15 Full Setting List ..........................19 Advanced Controller Functions ......................21 Downloading Data Log ........................21 Calibration of Sensors-Aqua Cooler Controller................22 Updating Software .......................... 23 Controller Input and Output Schematic ..................24 Poor Heat Dissipation ........................26 Low Refrigerant ..........................
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Page 4: Introduction
INTRODUCTION Thank you for choosing an Aqua Cooler chiller. In order to use this chiller correctly and efficiently, please read the following instructions in detail. This manual is designed to explain the installation, operation and the basic maintenance of the product. It is recommended that for service issues Aqua Cooler Pty Ltd be contacted before any work commences. -
Page 5: Safety
Safety 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. The unit and the Product Manual have markings, warning and instructions on the safe operation of the unit and they should be adhered to. -
Page 6: First Aid
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 7: Installation Of The Water Path
At least 800mm should be left around the unit (Rear: 1400mm) to allow for proper ventilation of the condenser. The unit should not be installed in a closed-off room. Preferably there should be no obstructions above the chiller, with a minimum of 2000mm clearance permitted in other circumstances. -
Page 8: Water Connection Fittings By Model (Male Bspt)
Water Connection Fittings by Model (Male BSPT) Models: R150 R420 R1330 R3000 R180 R540 R1500 R4000 R230 R670 R2000 R300 R830 R2500 R330 R1000 R1200 1” 1” 1½” 2½” Water Out: 1” 1” 1½” 2½” Water In: 1” 1” 1” 1”... -
Page 9: Operating Sequence
Before starting up the chiller have the following installation requirements been carried out 1. The power supply voltage and phase should be in accordance with the specifications listed on the chiller’s marking place. 2. Check the ventilation of the unit. 3. -
Page 10: Chlf2-60
PUMP MODEL PUMP CURVES BY CHILLER Chiller Model Pump Model R150, R180, R230, R300, R330 CHLF2-60 R420, R540, R670, R830, R1000, R1200, R1330 CHLF4-60 R1500, R2000, R2500 CHLF12-40 R3000 CDMF20-4 R4000 CDMF32-30 CHLF2-60 /ℎ) Driving Motor Model Q(�� ( ���� ) (ℎ��) H ( ��... -
Page 11: Chlf12-40
CHLF12-40 /ℎ) Model Driving Motor Q(�� ( ���� ) (ℎ��) H ( �� ) CHLF12-40 43.5 41.5 39.5 37.5 31.5 27.5 CDMF20-4 /ℎ) Model Driving Motor Q(�� ( ���� ) (ℎ��) H ( �� ) 55.5 52.5 48.5 41.5 31.5 CHLF12-40 User Manual Thermal X - R Series Chillers Page 11... -
Page 12: Cdmf32-30
The chiller unit features an interface panel with LCD display and input buttons to configure certain functions of the unit. Unlocking the Keypad on the Aqua Cooler Controller The key pad on the smart controller will lock out after 10 minutes of non-use. To unlock the key pad... -
Page 13: Operational Logic Of Controller
OPERATIONAL LOGIC OF CONTROLLER Start Up Pump ON, Ball Valve OPEN (if fitted), 10 second delay and then flow readings are taken to check pump is running normally. After compressor hold time and water temperature is above the set point plus hysteresis, COMP1 ON. -
Page 14: High/Low Pressure Control
It will do these 3 times in a 24-hour period before shutting the chiller down permanently. HP/LP Warning R134A R407C Pressure Pressure Aqua Cooler - PCB 2300kPa 2750kPa 80kPa [170kPa] 200kPa [400kPa] The chiller can only be restarted once pressure is back to a reasonable pressure [__kPa]. Water Flow/Pump Control The system monitors flow rates and will send a warning if a flow rate is breached and shut the chiller down if the flow alarm point is breached. -
Page 15: Pump Delay Time
Note: This does not turn the unit off and the electrical circuitry inside the electrical box will still be live. Chiller achieves close tolerance control by using Aqua Cooler PCB to collect high pressure and low pressure data. PCB uses collected data to calculate suitable hot gas amount and send signal to hot gas solenoid valve. - Page 16 CHANGING THE CONTROLLERS PARAMETERS By opening the electrical box the programmable circuit board controller can be seen mounted on the door. The four small red buttons next to the display are the buttons used for changing the parameters in the programming. The two buttons on the left are the up and down scroll buttons. The button top right is the OK button and the last button is the ESC.
- Page 17 Maximum and Minimum Temperature Limits This set a minimum and Scroll to the PARAMETERS MENU then to the SET POINTS sub menu Scroll to “MIN TEMP LIMIT” or “MAX TEMP LIMIT” maximum temperature limit for the chiller and is there to Press “OK”...
- Page 18 Setting High Pressure (HP) Alarms and Warnings Scroll to “PARAMETER MENU” and to the SET POINTS sub menu Controller will send out and Scroll to “ HP Warn Press” warning at warning pressure and shut unit down at alarm pressure Press “OK”...
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Page 19: Full Setting List
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. Some of the setting may change. - Page 20 LOW RETURN TEMPERATYRE ALARM HYSTERESIS MIN TEMP LIMIT SUPPLY FLOW 0.1 L/s ALARM 1 MAX TEMP LIMIT SUPPLY FLOW Varies with pump supplied WARNING 1 SET PT AMB SET POINT TEMP Customer Specific OTEMP SENSOR MENU CCT1 SUCT PR 0-10 Bar SECONDARY See Procedure SIZE...
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Page 21: Advanced Controller Functions
ADVANCED CONTROLLER FUNCTIONS The units can use Modbus/BACnet via RS485 or TCP/IP using the Ethernet port. The default IP address of our chillers is 10.1.1.130. So you’ll need to configure a laptop or computer to be on the same subnet then open a web browser to the web interface at http://10.1.1.130:8076 Navigate to ‘Network’... -
Page 22: Calibration Of Sensors-Aqua Cooler Controller
4. The process has to be done twice – once for each file. 5. Putting the USB into a computer will show the folder labelled “AQUA” and inside this will be a excel data file. The excel file will have labels for all the data that has been logged – the newest data will be at the top. -
Page 23: Updating Software
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 24: Controller Input And Output Schematic
Controller Input and Output Schematic Connector Type Control Outputs – OUT1 to OUT12 24VDC 1 Compressors across the top of the board 2 Hot Gas/ Spray Cool 3 Pump 4 Ball Valve 5 Fan Bank 6 Master Fault 7 Master Run 8 Standby/ Tandem link enable/ Status 0-10 Volt out put 11 Variable Speed Compressor Control... - Page 25 TROUBLESHOOTING 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 Possible Causes Solutions Replace Pump ensuring new pump has been leak tested, phase wiring is around Faulty Pump the right way Check water flow is coming back through to chiller.
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Page 26: Poor Heat Dissipation
Check operation of safety switches (circuit that connects to input 2) Check Hp, Safety switch LP, water level switches are made. Fan/pump and compressor overloads are open made. Bridge out components one after the other and test to see when unit doesn’t trip. Work Around Faulty Fans Check operation of condenser fans. -
Page 27: Low And High Pressure Difference
A comprehensive preventative maintenance program is available through Aqua Cooler carried out by qualified refrigeration mechanics. If there is any fault or concern during daily operation, please contact Aqua Cooler to arrange a service call. -
Page 28: Recommended Preventative Maintenance Program
Aqua Cooler will pay your reasonable, direct expenses of claiming under this warranty. You may submit details and proof of your expense claim to Aqua Cooler Pty Ltd for consideration. This warranty is given by Aqua Cooler Pty Ltd, U14, 2-12 Knobel Court Shailer Park 4128 QLD. -
Page 29: Installation Sketch Map Of Air Cooled Chiller
Installation Sketch Map of Air Cooled Chiller User Manual Thermal X - R Series Chillers Page 29... -
Page 30: Installation Sketch Map Of Water Cooled Chiller
Installation Sketch Map of Water Cooled Chiller User Manual Thermal X - R Series Chillers Page 30... -
Page 31: Internal Structure Sketch Map Of Air Cooled Chiller
Internal Structure Sketch Map of Air Cooled Chiller User Manual Thermal X - R Series Chillers Page 31... -
Page 32: Internal Structure Sketch Map Of Water Cooled Chiller
Internal Structure Sketch Map of Water Cooled Chiller User Manual Thermal X - R Series Chillers Page 32... -
Page 33: Commissioning Sheet
COMMISSIONING SHEET It is important that the chiller is commissioned in accordance with the guidelines in the end of the manual 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 chillers. Please print out the table and check through it one by one. - Page 34 Chiller Water Circuit Requirements (YES/NO) Pipe Size: inch Pipe Insulation: Length: Height Difference: Balancing Valve: Isolation Valves: Water Treatment: Make Up Water: Treatment Used and Others Notes: Operation Testing: (YES/NO) C C Water Set Point: Ambient Temp: Temp Controller Fault Buzzer/Light Reading Check: Works: Unit Handles Heat...
- Page 35 Note regarding to water cycle and application: Completion: Aqua Cooler uses the information from this data sheet to confirm that the chiller is installed and operating correctly. Should any problems or issues be raised as a result of this preventative maintenance procedure 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.
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Page 36: Notes
Agent signature: Date: Customer representative print name: Customer representative signature: Filing – Aqua Cooler: Date: Print name: Signature: NOTES User Manual Thermal X - R Series Chillers Page 36...
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