Aqua Cooler G Series User manual

Installation Guide for G Series Chillers Page 1
Revision 3
APRIL 2018
G Series
Owner’s Manual
This guide applies to the following models: R-GAXXX and R-GWXXX.
Aqua Cooler Pty Ltd
U14, 2-12 Knobel Court
Shailer Park 4128 Qld
www.aquacooler.com.au
1300 AQUA COOLER
1300 278 286

Installation Guide for G Series Chillers Page 2
TABLE OF CONTENTS
Table of contents ................................................................................................................................................................ 2
Introduction ........................................................................................................................................................................ 4
Safety .................................................................................................................................................................................. 4
First Aid ........................................................................................................................................................................... 5
Installation Requirements ................................................................................................................................................... 6
Installation of the Water Path.......................................................................................................................................... 7
Water Connection Fittings by Model (Male BSPT).......................................................................................................... 7
Electrical Installation........................................................................................................................................................ 7
Preparations For Starting the Chiller .................................................................................................................................. 8
Operating sequence........................................................................................................................................................ 8
Operating Precautions........................................................................................................................................................ 9
Operation Panel.................................................................................................................................................................. 9
Commonly Used Interfaces ........................................................................................................................................... 10
Main Interface............................................................................................................................................................ 10
Alarm Interface .......................................................................................................................................................... 10
Function Menu........................................................................................................................................................... 11
Manufacturer Menu ................................................................................................................................................... 11
Starting the Chiller..................................................................................................................................................... 11
Setting the Temperature ........................................................................................................................................... 11
Shut Down the Chiller................................................................................................................................................ 12
Chiller SETTINGS .............................................................................................................................................................. 12
User Settings ................................................................................................................................................................. 12
Manufacturer Settings................................................................................................................................................... 12
Fault Details ...................................................................................................................................................................... 16
Troubleshooting................................................................................................................................................................ 17
Poor Heat Dissipation.................................................................................................................................................... 18
Low Refrigerant Level.................................................................................................................................................... 18
Normal Low and High Pressure..................................................................................................................................... 19
Compressor Not Starting .............................................................................................................................................. 19
Maintenance ..................................................................................................................................................................... 19
Recommended preventative maintenance program ................................................................................................. 19
Warranty ........................................................................................................................................................................... 20
General information.......................................................................................................................................................... 20
Typical Controller Block Diagram ..................................................................................................................................... 21
Installation Sketch Map of Air Cooled Chiller................................................................................................................... 22
Installation Sketch Map of Water Cooled Chiller.............................................................................................................. 23
Internal Structure Sketch Map of Air Cooled Chiller ........................................................................................................ 24
Internal Structure Sketch Map of Water Cooled Chiller ................................................................................................... 25

Installation Guide for G Series Chillers Page 3
COMMISSIONING SHEET ................................................................................................................................................ 26
Pre-start checks ............................................................................................................................................................. 26
Electrical Connection .................................................................................................................................................... 27
Water Connection ......................................................................................................................................................... 27
Start Up ......................................................................................................................................................................... 27
Finishing Off .................................................................................................................................................................. 28
Notes ............................................................................................................................................................................... 29

Installation Guide for G Series Chillers Page 4
INTRODUCTION
Thanks 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.
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 has markings, warning and instructions on the safe
operation of the unit and they should be adhered to.
This unit is designed to be safe in the use for which it was planned provided that it is installed, started up and
maintained in accordance with the instructions contained in this manual.
The unit contains electrical components that operate at line voltage and contains moving parts. It therefore must be
isolated from the electrical supply before being worked on. All maintenance operations that require access to the unit
must be carried out by suitably qualified technicians who have a thorough understanding of all necessary precautions
associated with refrigeration and electrical machinery.
The liquids to be cooled must be compatible with the materials used in the constructions of this unit. These liquids can
be water or mixtures of glycol and water for example. The liquids to be cooled must not be flammable.
All panels must be re-installed after carrying out any maintenance work.
The unit is not to be used by the infirmed or children unless they are supervised by responsible persons qualified to
carry out the supervision.
The unit should be secured to prevent it from toppling over.
Always isolate power from the unit when working on it.
Minimum temperature setting is 5 degrees on the unit. Any lower than this may cause problems with the evaporator
icing up and potentially loss of refrigerant and potentially expensive service costs

Installation Guide for G Series Chillers Page 5
WARNING
All wiring must be performed by qualified electricians. Improperly installed
wiring and grounding may result in electrocution and fire hazards
To avoid these hazards all wiring must be installed in accordance with all the
local relevant safety standards for wiring
WARNING
The chiller contains refrigerants under high pressure. The system also
contains oils under high pressure. Before the refrigeration circuit can be
opened, the refrigerant should be reclaimed to reduce pressure in the
system. Failure to recover the refrigerant to relieve pressure or the use of
refrigerants or refrigerant substitutes that are not specified for the unit may
result in system rupture and explosion.
Refrigerants have a narcotic effect when inhaled in high quantities. Should a leak occur of the refrigerants then the
room should be vacated and should only be re-entered after suitable ventilation.
Each model is offered with different refrigerant options. This is indicated by the model number containing either a “–
A” for R134a or “–C” for R407c . R134a and R407c have different refrigeration properties but both are similar
properties from a hazardous materials perspective.
First Aid
Eye Contact. Immediately flush with tepid water or sterile saline solution. Hold eyelids apart for 15 minutes while
irrigating. Seek medical attention.
Inhalation. Remove from area of exposure immediately and if you are assisting a victim avoid being exposed. Breathing
apparatus must be worn in the presence of high concentration of refrigerants. If victim is not breathing then apply
artificial respiration and seek urgent medical help. Give oxygen is available.
Skin Contact. Cold Burns. Remove contaminated clothing and gently flush affected area with warm water (30C) for 15
minutes. Apply sterile dressing and treat as for a thermal burn. For large burns immerse in water for 15 minutes. DO
NOT apply any form if direct heat. Seek medical attention.
Ingestion. For advice contact the poisons centre on 131126 in Australia. If swallowed do not induce vomiting. Ingestion
is considered unlikely due to product form.
Advice to Doctor. Use of adrenaline and other catacholamines may be contraindicted due to possible cardiac
sensation. Treatment for asphyxia.
R407 HazChem code 2RE
R407 is non –flammable.
R134a HazChem code 2RE
R134a is non –flammable.

Installation Guide for G Series Chillers Page 6
INSTALLATION REQUIREMENTS
Immediately upon receipt of the chiller, carefully inspect the chiller for any damage that may have occurred in transit.
Any such damage must be noted on the carrier’s delivery documents. It is the consignee’s responsibility to make any
subsequent claims upon the carrier or respective insurance company.
Any hidden damage should be reported to Aqua Cooler as soon as possible.
If the unit is to be stored before installation then care must be taken to ensure no foreign matter can get into the water
pipes. If the storage is for a prolonged period it is recommended that the water circuit be changed with nitrogen and
sealed.
A comprehensive commissioning program carried out by qualified refrigeration mechanics is available through Aqua
Cooler. For full details and conditions please contact Aqua Cooler. There is also a site inspection procedure at the end
of this manual.
The water fittings are on the standard unit are at the rear of the unit –that is the end as the unit away from the
electrical box and the unit should be positioned so this end is as close to the process as possible.
At least 1000mm should be left around the unit to allow for proper ventilation of the condensers –see diagram. The
unit should not be installed in a closed off room and if it is to be installed under anything then there should be a
minimum of 2 metres of clear air above the unit.
The unit has been designed to be lifted with a forklift or a crane. The standard unit is heavier towards the front looking
at the chiller side on and care must be taken when lifting with a crane that the strapping does not damage the side
panels. The units are also designed to be moved around with a pallet jack, some models also have castor wheels.
The commissioning section at the end of this manual has a site inspection check list designed to aid in checking that
the site for the chiller installation is suitable. 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. Failure to provide safe access to the chiller may lead to additional charges
should servicing be required.
When installing indoors it is important to understand that the chiller will impart a significant heat load into the
environment and it is essential to ensure a plentiful, unrestricted supply of ambient temperature air to the chiller.
Should you have concerns over the installation site then please contact Aqua Cooler for advice.
Note: Under no circumstances is ducting to be attached to the condenser fan outlet.
This chiller has been designed to draw air from each side and to exhaust vertically through the top of the unit (model
dependant). Preferably there should be no obstructions above the chiller, with a minimum of one metre clearance
permitted in other circumstances. In addition to ensuring sufficient space around the chiller for free air movement,
provision must be made around the chiller for service and regular maintenance. The chiller must be installed on a firm
and level foundation, of adequate strength to support the chiller’s full operating weight.

Installation Guide for G Series Chillers Page 7
Installation of the Water Path
Before connecting the make-up water, check the suction pressure on in the chiller is above 400kPa OR 200 kPa for
chillers with R134a refrigerant. A refrigeration mechanic can do this with gauges or if the unit has a smart controller the
pressure can be viewed on the display on the controller in the electrical box.
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. If the pressure is below this then it is recommended that the chiller be inspected by a
qualified refrigeration mechanic before filling the system with water.
All pipe work with refrigerated water running to and from the chiller should be fitted with a water resistant insulation
material to prevent sweating and maximise the efficiency of the chiller.
Water Connection Fittings by Model (Male BSPT)
Models
GA0.6
GA1
GA2
GA3
GA5
GA6
GA8
GA10
GA12
GA15
GA25
GA30
GA40
GA50
GA60
Water Out:
½”
1”
1”
1½”
2”
2½”
3”
Water In:
½”
1”
1”
1½”
2”
2½”
3”
Drain:
½”
½”
½”
1”
1”
1”
1”
Overflow:
1”
1”
1”
1”
1”
1”
Water Supply:
½”
½”
½”
½”
½”
½”
Electrical Installation
The chiller draws a large amount of current and it is important that the connection of the unit to the power supply must
be carried out in accordance with the local standards and only by a licensed electrician.
The power supply system on site and the circuit protection must be designed for the total current of the unit taking
into account the in rush current and the lock rotor amps of the compressor–see Technical Data. The circuit breaker
must be set no more than 125% of the units rated load current.
The power supply system on site and the fuses must be designed for the total current of the unit –see technical data.
Mains supply cables must be sized to ensure adequate voltage at the chiller under all load conditions. Three phase
power must be symmetrical, ensuring equal effective voltage and equal phase angle between consecutive phases. The
pump and the compressor rely on correct phase rotation. Ensure all electrical connections are tight prior to start up.

Installation Guide for G Series Chillers Page 8
PREPARATIONS FOR STARTING THE CHILLER
For the initial operation of the chiller, please confirm the following:
1. The power supply voltage and phase should be in accordance with the specifications listed on the chiller’s
name place.
2. Check that the refrigerated pipe and the cooling pipe are connected properly and the valve is open. (Please
refer to the installation diagram for details)
3. Fill the refrigerate water tank with water or other secondary refrigerant before starting the water pump.
(Ensure you are using a suitable secondary refrigerant according to your requirements)
4. For water-cooled units, please pay attention to the moving direction of the water pump and confirm the tower
fans are not moving in the opposite direction. If the pump is three-phase, change any two relative phase lines
to reverse its direction. Then close the switch after connections have been made.
Before starting up the chiller have the following installation requirements been carried out
The power supply voltage and phase should be in accordance with the specifications listed on the chiller’s name
place.
Has the unit got proper ventillation
Was the pressure on the suction gauge above 300kPa before filling the unit with water
Is the bypass in the tank left open
Is the power supplied to the unit in accordance with the requirements
Has air been bled from the water path
Operating sequence
1. Open the valve of refrigerated pipe and cooling pipe and ensure the water way is unimpeded.
2. Turn the unit on with the master power switch.
3. Press the power button on the interface panel to start the controller.
4. Press the compressor start button on the interface panel to start the compressor.
5. Pressing the power button while the unit is running will power off the unit.
Before starting the chiller, ensure that the pressure on the suction pressure gauge on the front of the chiller is above
400kPa OR 200 kPa for chillers with R134a refrigerant. 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. If the pressure is below this then
it is recommended that the chiller be inspected before filling the tank with water.
The unit is ready to be started up. Once power is provided to the chiller, open the clear plastic guard over the
ON/OFF switch and turn the unit on and the unit will start automatically. The pump will start immediately and the
controller will start measuring the flow rate to check that the pump is running normally.
The water bypass on the chiller will be supplied fully open.
The compressors have a start delay. Once the compressors have cut in the watch the display to ensure that the water
temperature in coming down.
Operational parameters than are displayed on the screen. Any faults are indicated on the face of the control panel.
It is a good idea after the unit has been running for 5 minutes check that the water temperature is dropping and check
there are no bubbles in the sight glass (if fitted) –if these two things are happening then the unit is running properly.

Installation Guide for G Series Chillers Page 9
Give the system a final check to ensure that there are no water leaks. An amp meter can also be run over the wires
into the contactors to ensure that the compressor and the pump are drawing the right amount of amps according to
the technical data. Close the guard over the ON/OFF switch and screw into place to prevent passers by shutting down
the chiller.
OPERATING PRECAUTIONS
1. Chilled water pump cannot be started without water in the water tank.
a. All standard models are equipped with water level protection in the water tank (except for closed
water tanks). When the water level is too low, the unit will throw an alarm and the pump will not
operate.
2. Switching the operating switches frequently should be avoided.
3. When the refrigerated-water temperature reaches the set temperature, the compressor will stop.
4. In order to prevent the evaporator freezing, do not set temperature below 5 °C (Except for sub-zero models)
5. When the unit is not in use for long periods of time, drain the tank
6. To ensure the most efficient operation, please clean the condenser, evaporator, and the water filter (if fitted)
regularly.
OPERATION PANEL
The chiller unit features an interface panel with an LCD display and input buttons to configure certain functions of the
unit. Below is a sketch of the interface panel.

Installation Guide for G Series Chillers Page 10
Commonly Used Interfaces
Main Interface
When the [Fn] or [OK] icon is shown on the display, pressing the FUNCTION or OK button respectively will perform the
action shown alongside the icon.
Alarm Interface
When an alarm occurs, the interface will show a notification similar to the below diagram. To view the alarm details,
press the FUNCTION button.
The screen will then show the alarm details.
After the conditions which caused the fault have been corrected, you can reset the alarm by pressing the OK button.
The interface will then return to the main display and the unit operate normally.
Outlet temperature
Set temperature
Function button action

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Function Menu
When on the main screen, pressing the FUNCTION button will open the function menu.
From the function menu, you can navigate with the UP and DOWN button, return to previous page with the BACK
button, and enter the selected item with the OK button.
There are 5 sub-menus in the function menu:
1. User setting –This menu contains user-configurable settings. Please refer to the Chiller Settings section of
this manual for more information.
2. Unit status –This menu provides information about the current state of the unit.
3. History list –This menu provides a list of past alarms.
4. Equipment efficiency –This menu provides information about the units total run time.
5. Version information –This menu provides the unit’s model number and software version.
Manufacturer Menu
Manufacturer settings should only be modified by trained personnel and any unauthorised modification to these
settings may result in damage to the unit and void of warranty.
1. While on the main screen of the operation panel, press the UP and OK button at the same time.
2. Enter the password by pressing the UP, DOWN, and FUNCTION buttons.
3. Press the OK button
The manufacturer menu contains 3 sub-menus:
1. Manufacturer settings –This menu contains manufacturer-configurable settings. Please refer to the Chiller
Settings section of this manual for more information.
2. Manufacturer debug –This menu contains troubleshooting tools for technicians such as three-phase test tool.
3. Configuration Guide –This menu provides a configuration wizard for setting up a new unit.
Starting the Chiller
1. Turn on the air switch inside the electric tank of the chiller.
2. Turn on the power to the chiller.
3. After power has been supplied, press the RUN button on the operation panel.
4. The cooling pump will start to run and the RUN button indicator will illuminate.
5. Press the COMPRESSOR button on the operation panel.
6. The COMPRESSOR button indicator will begin to blink.
7. When the conditions are present for the compressor to run, the COMRESSOR button indicator will turn solid.
Setting the Temperature
1. Press the UP and DOWN buttons on the operation panel to adjust the set point temperature.
2. Press the OK button to confirm the new set point temperature.

Installation Guide for G Series Chillers Page 12
Shut Down the Chiller
1. Press the RUN button on the operation panel.
2. The RUN button indicator will blink to indicate the shutdown command is being performed.
3. Once the chiller has performed the proper shutdown sequence (this can take up to a minute), the RUN button
indicator will be quenched.
CHILLER SETTINGS
Please refer to the Operation Panel section of this manual for information on how to modify these parameters.
User Settings
User settings are modifiable through the “User setting” function sub-menu.
Parameter Name
Default
Setting Range
Remark
Lock Temperature
No
Yes or No
When set to yes, the temperature setting
function will be disabled.
Setting Temperature
12.0 °C
-30 –99.9 °C
The temperature set point.
Adjust the Contrast
32
20 –44
Adjust the LCD screen contrast.
Start and Stop
Local
Local or Remote
Set to remote to allow a remote signal to start
the unit. See block diagram for details.
Screen Saver Time
0
0 –255 mins
Time until screen goes into screen saver more.
Set to zero to disable.
Language
English
English or Chinese
Select display language.
Manufacturer Settings
Manufacturer settings should only be modified by trained personnel and any unauthorised modification to these
settings may result in damage to the unit and void of warranty.
Setting Menu
Parameter Name
Default
Setting Range
Remark
Control Settings
One-Button Start
Off
On or Off
When enabled, the unit will start up
by pressing the RUN button only.
The COMPRESSOR button will be
ignored.
Power On Auto-Start
Off
On or Off
When enabled, the unit will
remember its on/off status after a
power failure and will return to this
state when power is resupplied.
Alarm Output Mode
Fault On
Output
Fault Output or
Do Not Output
After Noise
Erasure
Fault Output: faults will be output
by the relay.
Do Not Output After Noise
Erasure: faults will not be output
after noise erasure.

Installation Guide for G Series Chillers Page 13
Setting Menu
Parameter Name
Default
Setting Range
Remark
Water Level Low Stop
Pump
Stop
Stop or Do Not
Stop
Stop: when there is a low water
level fault, the pump will stop.
Do Not Stop: the pump will not
stop on a low water fault.
Current Detection
Off
On or Off
Whether the unit features a current
detection module or not.
Compressor Rated
Current
0.3 A
0 –35.0 A
Used in conjunction with the
Current Detection parameter. Not
shown if Current Detection module
is not installed.
Frozen Rated Current
0.3 A
0 –25.0 A
Cooling Rated Current
0.3 A
0 –25.0 A
Three-Phase Power
Test
Off
On or Off
When enabled, the unit will detect
power phase lacking and anti-
phase fault.
Anti-Freeze / Cooling
Over Load
Cooling
Overload
Anti-Freeze or
Cooling Over
Load
Input function selection for switch
DI1
Compressor Number
2
1 –2
Number of compressors in this unit
Type Selection
Water
Cooled
Water
Water Cooled Air,
Water Cooled
Water, Air Cooled
Water, or Air
Cooled Air
Chiller type selection.
Temperature
Settings
Loading Deviation
1.0 °C
0 –10.0 °C
Temperature deviation of open
compressor.
Unloading Deviation
1.0 °C
0 –10.0 °C
Temperature deviation of closed
compressor.
Temperature Set Point
Upper Limit
50.0 °C
12.0 –100.0 °C
The upper limit of the set point
temperature.
Temperature Set Point
Lower Limit
5.0 °C
-30.0 –12.0 °C
The lower limit of the set point
temperature.
Temperature
Compensation
0.0 °C
-9.9 –9.9 °C
Compensation value for the outlet
water temperature.
Low Temperature
Protection
3.0 °C
-30.0 –99.9 °C
The outlet water temperature at
which a low temperature warning
will be thrown.

Installation Guide for G Series Chillers Page 14
Setting Menu
Parameter Name
Default
Setting Range
Remark
Over Temperature
Warning
50.0 °C
0 –99.9 °C
The outlet water temperature at
which an over temperature alarm
will be thrown.
Over Temperature
Alarm
60.0 °C
0 –99.9 °C
The outlet water temperature at
which a shutdown over
temperature alarm will be thrown.
Over Temperature
Reset Temperature
Difference
5.0 °C
0 –99.9 °C
The difference in outlet water
temperature at which the over
temperature warning will be reset.
Time Settings
Delay of Frozen Start
10 s
0 –255 s
Frozen pump delay for when the
unit is shutting down.
Delay of Cooling Start
10 s
0 –255 s
Cooling delay for when the unit is
shutting down.
Energy Regulation
Cycle
5 s
0 –255 s
Energy regulation cycle.
Compressor Protect
60 s
0 –255 s
The delay time between
compressor start and stop
commands. Used to protect the
compressor from frequent cycling.
General Failure
Disappears Shake
2 s
0 –255 s
Time for a condition to be present
before considering it a fault.
Water Shortage
Disappears Shake
10 s
0 –255 s
Time for water shortage to be
present before throwing a fault.
Water Level
Disappears Shake
10 s
0 –255 s
Time for water level to be at fault
level before throwing a fault.
Low Pressure Testing
Delay
60 s
0 –255 s
Time delay between compressor
running and checking for low
pressure fault.
Low Pressure
Disappears Shake
5 s
0 -255 s
Time for pressure to be at low fault
level before throwing a fault.
Compressor Use Time
0 h
0 –9999 h
The unit will not start when
compressor accumulated running
time is larger than this value.
Compressor Switching
Time
#1 Compressor Start
Time
#2 Compressor Start
Time

Installation Guide for G Series Chillers Page 15
Setting Menu
Parameter Name
Default
Setting Range
Remark
Open & Close
Setting
Compressor High
Pressure
Normally
Closed
Normally Closed
or Normally Open
Whether the fault signals are
normally open or closed.
Compressor Low
Pressure
Compressor Overload
Water Level Switch
Water Flow Switch
Freezing Overload
Cooling Overload
Loading Range Control
Three-Phase Power
Failure

Installation Guide for G Series Chillers Page 16
FAULT DETAILS
Fault Name
Consequences
Remark
#1 Compressor High Pressure
Alarm.
Compressor 1 stop.
Delay stop cooling.
Check whether the input switch value is set correctly.
#1 Compressor Low Pressure
#1 Compressor Overload
#1 Compressor High Current
Check whether the compressor rated current setting
is reasonable.
#1 Compressor Low Current
Check whether the compressor circuit wiring is
normal.
#2 Compressor High Pressure
Alarm.
Compressor 2 stop.
Delay stop cooling.
Check whether the input switch value is set correctly.
#2 Compressor Low Pressure
#2 Compressor Overload
#2 Compressor High Current
Check whether the compressor rated current setting
is reasonable.
#2 Compressor Low Current
Check whether the compressor circuit wiring is
normal.
Temperature Too Low
Alarm.
Compressor stop.
These faults are raised when the relevant value is
outside the range allowed for in the Manufacturer
Settings section.
Check to make sure these values are set
appropriately.
Over Temperature Alarm
Alarm.
Compressor stop.
Over Temperature Warning
Alarm only.
Cooling Current Too Low
Alarm.
Compressor stop.
Frozen Pump High Current
Stop unit.
Frozen Pump Low Current
Frozen Pump Overload
Power Failure
Stop unit
Check whether the three-phase power is inverse
phase or lacking phase.
Current Fault
Stop unit.
Check that the Normally Open or Normally Closed
value is set correction in the Manufacturer Settings
section.
Water Level Fault
Stop unit.
Unit Needs Maintenance
Unit will not start.
Compressor accumulative total run time is higher
than the allowed value.
Parameter Abnormal
Unit will not start.
Check for an invalid parameter setting.

Installation Guide for G Series Chillers Page 17
TROUBLESHOOTING
Problem
Possible Causes
Possible Solution
Power supply is normal but the
unit will not start.
Temperature controller is
faulty
Change the temperature controller.
The unit trips when attempting
to power on.
Short circuit
Locate and correct the short circuit
Main circuit overload
Check each load and find the cause of the
overload. Eliminate the overload. If it is because
of small rated current of the broken circuit,
change the broken circuit.
Faulty breaker
Replace the faulty breaker
Three-phase power failure
Reverse phase
Swap any two phases of the power supply to
reverse the pump direction.
Missing phase
Test the three-phase source with a multimeter
to determine if the power supply is in good
condition.
High Pressure Alarm
Poor heat dissipation
Refer to “Poor Heat Dissipation” section.
Damaged high pressure
switch
Replace with working switch.
Input line fault
Check the input line and remove the fault.
Low Pressure Alarm
Refrigerant low
Refer to “Low Refrigerant Level” section.
Outlet water temperature and
evaporator temperature too
low
Check whether there is a lack of water in the
water tank and whether the circulating pump is
running well. If those are normal, reset the low
pressure switch or restart the unit. If the
evaporator is frozen, input warm water to melt
the ice. Do not attempt to break the ice off with
force.
Input circuit fault
Check the input circuit and remove the fault.
Overload Alarm
The voltage is incorrect
Check the three-phase source to determine if
the power supply is in good condition.
Bad cooling
Refer to “Poor Heat Dissipation” section.
Water pump flow or pressure
too high
Check the water way and adjust the water flow
to within the water pump’s rated flow rate.
The bearings of the
compressor, motor, or pump
are damaged
Replace the damaged bearing.

Installation Guide for G Series Chillers Page 18
The overload relay is too small
or its regulating value is too
low
Replace the overload relay with a higher rated
one.
The joint of the circuit is not
good
Lock the line contact.
The fault indicator is not on, but
the compressor will not run.
The unit has disabled
compressor start up as a
precaution
Refer to “Compressor Not Starting” section.
Water in the tank is not cooled,
or the low pressure switch is
shut off by itself.
The cooling capacity is not
great enough
Expand the capacity of the unit.
Refrigerant low
Refer to “Low Refrigerant Level” section.
The water tank is chocked by
the refrigeration medium
Replace the choked part such as drier or
expansion valve and fill refrigerating medium in
the vacuum state.
The valve is broken
Change the compressor.
The temperature is set too
high
Adjust the temperature set point.
The temperature switch is
faulty
Replace the faulty switch.
Poor heat dissipation
Refer to “Poor Heat Dissipation” section.
The sensor is faulty
Replace the faulty sensor.
Lacking water and the water
flow is not enough.
Not enough water in the
water tank
Add more water to the water tank.
Pipe line water flow is too low
Check that each valve is fully open.
Poor Heat Dissipation
While the condenser heat dissipation is poor, the compressor will be inefficient and the operating current will be
increased. When the chiller reaches the high pressure value (set depending on the chiller type and refrigerant used),
the high pressure switch will trip an alarm and the unit will stop working. This can be caused by poor heat dissipation.
For water cooled units, check whether water in the cooling tower is circulating well, the temperature of the cooling
water is too high, the fan of the cooling tower and the water pump are running, and that the cooling water valve is fully
open. For air-cooled chillers, confirm that the condenser is not dirty or choked. Once the above conditions are checked
to be in normal condition, clear the alarm. If the high pressure alarm is frequently occurring, clean the condenser as
soon as possible.
Low Refrigerant Level
If the water temperature is over 5 °C and the pressure is below 200kpa, it may indicate a shortage of refrigerant. Any
leaks should be filled, the dryer filter should be changed, and it should be drawing a vacuum again. Refill the
refrigerant after the above has been performed.

Installation Guide for G Series Chillers Page 19
If the leaking part is within water, stop the chiller immediately and discharge the water in the water tank quickly. The
compressor can be damaged badly if it sucks in water.
Normal Low and High Pressure
While the compressor is running, if the difference between high pressure and low pressure is small, it may indicate the
valve of the compressor is damaged. If this is detected, the unit should be stopped immediately. It is normal for the
pressures to be similar if the compressor is not running.
Compressor Not Starting
If the fault indicator and the protection switch are normal, but the compressor will not start, please check the following:
1. The set temperature is too high or the temperature switch is damaged
2. The selector switch is damaged
3. The anti-freezing switch is damaged
4. The pressure switch is damaged
5. The overload protector of the compressor is damaged
6. The electromagnetic relay is damaged or the overload protector is damaged
7. The water level is too low
8. The refrigerating water protecting switch is damaged
MAINTENANCE
Warning: Always isolate the power from the chiller prior to working on the unit.
Warning: Always ensure that personnel have read and understood the SAFETY section of this manual prior to working
on the chiller.
Warning: When the mains controller is de-energised the power contactors are live, even if the components are not
operating. All maintenance must be carried out by qualified refrigeration mechanics.
These units have been designed for the minimum of maintenance. However to ensure optimum performance qualified
personnel should carry out regular 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
Frequency
Refrigerant Charge
6 Monthly
Electrical connections are tight
6 Monthly
Compressor amp draw
12 Monthly
Pump amp draw
12 Monthly
Condenser strainer cleaned
6 Monthly
A comprehensive preventative maintenance section is included in the back of this manual

Installation Guide for G Series Chillers Page 20
WARRANTY
Any claim under this warranty must be made within the discussed time period of the date of purchase of the
product. To make a claim under the warranty, return the product (with proof of purchase) to the supplier where you
purchased the product or contact Aqua Cooler regarding warranty conditions.
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.
This warranty is provided in addition to other rights and remedies you have under law: Our goods come with
guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund
for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have
the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major
failure.
Attached to this document is a comprehensive commissioning procedure. This must be carried out in accordance
with the procedure and returned to Aqua Cooler at s[email protected]. Aqua Cooler offers a
commissioning program and can arrange this for you. Failing to follow the commissioning procedure may void this
warranty.
GENERAL INFORMATION
The chiller is designed to refrigerate and circulate water to a heat developing process to aid in keeping that process
cool. They are supplied with an immersed coiled copper evaporator, or plate heat exchanger, or shell and tube
evaporator (model dependant) an air cooled condenser and a scroll compressor to circulate the refrigerant gas. Water
is circulated out of the unit via a pump. The chiller is design to be installed outdoors and refrigerate water for a heat
developing process –not for drinking or food preparation purposes. Any other use of this water chiller is a not as it is
intended.