Aqua Cooler R Series User manual

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

R Series Manual –R150 to R2500
2
Terms and Conditions of Sale
Listed below are some basic operational and installation conditions that must be adhered
to for Aqua Coolers warranty to remain valid and more importantly for trouble free chiller
operation. These are also the conditions under which Aqua Cooler will provide the
purchaser with products
Operation
The units are sophisticated pieces of equipment and must be operated in accordance with
the manner in which they are manufactured. Aqua Cooler warrants these products if they
are installed, commissioned, operated and serviced in a manner consistent with the
guidelines set out in this document. Aqua Cooler will not be liable for products
·Where the minimum flow rate specified in the manual is not maintained through the
units at all times. 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.
·Where the operational settings on the controller are altered without first consulting
Aqua Cooler in writing
·Where the temperature cut out set point is set below 5°C without first consulting
Aqua Cooler in writing
·Where the water bypass in the chiller is set to be fully closed without first consulting
Aqua Cooler in writing
·Where the chiller is not installed on level surface
·Where the chiller has not been powered up for at least 4 hours before starting the
chiller to allow for the sump heater to warm the compressor oil.
·Where the pressure in the sealed refrigeration system has not been checked by a
refrigeration mechanic before starting the chiller to ensure that the pressure on the
suction side is at least 400kPa for R407c chillers and 200 kPa for R134a chillers
·Where the chiller is installed too close to either other chillers, too close to walls or
too close to a roof or awning to prevent proper ventilation of the cooling system.
·Where the information supplied to Aqua Cooler for specifying the chillers is incorrect
with regards to, but is not limited to, flow rates, ambient operating condition and
heat load
·Where the cooling medium used in the product causes corrosion to the product
Service
·Aqua Cooler will not warrant product where service work is not carried out by Aqua
Cooler
·Aqua Cooler will only cover costs of refrigerant to the value of the specified charge
indicated on the marking plate of the unit
·Aqua Cooler will pass on extra cost associated with service work carried out on
chillers where neat access to facilitate servicing in a manner that is compliant with
safe work practices is not provided. This also includes additional charges will apply
for sites where access to the chiller is unsafe or restricted
·Aqua Cooler takes no responsibility for repairs carried out on the chiller by un-
authorised service agents or if parts are installed that are not from Aqua Coolers
approved supplier list

R Series Manual –R150 to R2500
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
not be covered by Aqua Cooler
Delivery and payment
·Upon the receipt of the delivery, the products should be inspected and any defects
reported to Aqua Cooler promptly without delay in writing. At all times, to the
extent of the relevant laws, title to the products shall remain with Aqua Cooler until
Aqua Cooler has received payment in full.
·Aqua Cooler will not be liable for products that are mishandled after delivery
FOREWARD
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 and work commences. A comprehensive service manual is available to be down
loaded from the website.
CONTACT DETAILS
Aqua Cooler Pty Ltd
161 Orchard Road
Chester Hill NSW 2162
Australia
Toll Free 1800649233 or [phone]
Fax + 612 9721 9344
www.aquacooler.com.au
Aqua Cooler Refrigeration Trading Authorisation number is AU12165

R Series Manual –R150 to R2500
4
CONTENTS
Safety
3
Marking
8
Certification
8
Warranty
9
General Information
9
Intended Use
9
Water
Circuit
10
Te
chnical Data
11
Cooling Syst
em Schematic
14
Dimensions
16
Transport and Storage
19
Installation
–
electrical, water connection, water treatment
, control circuit
and final
checks
19
Operation 31
Control 31
Service and Maintenance 35
Wiring Tandem Set Up 46
Pump Curves 46
Critical Spares 47
Data Sheets 47
Trouble Shooting 49
Wiring Diagram 50
Release Notes 51
Commissioning 52
Site Inspection 55

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.
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
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.

R Series Manual –R150 to R2500
6
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.
R407c
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.

R Series Manual –R150 to R2500
7
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. The compressor contains oil that must not be dumped.
Manual Handling
The chillers are very heavy; do not try to move the units manually. The unit can be lifted with
a crane (the centre of gravity is towards the front of the unit), a forklift or a pallet jack.

R Series Manual –R150 to R2500
8
MARKING
The units have various markings on them. There is a marking plate on the unit, an example is
shown below giving regulatory requirements. There will be a wiring diagram as shown in the
wiring diagram section of this document provided in a larger scale for ease of maintenance.
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
below outlined the available options
CERTIFICATION
All the electrical components in the chiller have certification for electrical safety. The electrical
box and all the exposed components are rated to IP66 against weather ingress.

R Series Manual –R150 to R2500
9
WARRANTY
Any claim under this warranty must be made within 12 months 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, ABN 13 245 994 351, of 161 Orchard Rd,
Chester Hill, NSW 2162 –ph 02 9721 9310.
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 or Aqua Cooler can
do the commissioning, otherwise the warranty will be voided.
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, an air cooled condenser and a scroll compressor to circulate the
refrigerant gas. Water is circulated out of the unit via a pump. The controller is available in two
options - either the Aqua Cooler proprietary microprocessor with high level control and high
level interface or a basic controller controlling the chillers basic functions. This must be
specified at the time of order.
INTENDED USE
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.

R Series Manual –R150 to R2500
10
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. Plate heat exchanger or copper evaporator
2. Flow meter - optional
3. One way valve –optional
4. Pump
5. Motorised Ball Valve –optional
6. Expansion tank –for closed loop systems
7. Pressure relief valve –feeds to drain in closed loop system
8. Filter pack –if ordered –0.5 micron
The chilled water path starts with the pump delivering the water through a one way valve and
to the process. The return water passes through a flow meter to monitor the flow rate, through
the evaporator and back to the pump.
The primary pump will run full time unless the system detects a drop in flow.
It is important to ensure that any water treatment is passive to the wetted parts of the system
which include
·Stainless Steel
·Copper
·High Density Polyethylene
·Brass
·ABS Plastic
·Nitrile Rubber

R Series Manual –R150 to R2500
11
TECHNICAL DATA
All power data, current draw and power consumption of the compressor and the chiller is based on the
prescribed refrigerant for each unit. 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
PERFORMANCE DATA
Model
R150
R180
R230
R300
R330
Compressor horsepower
hp
1.5
1.8
2.3
3
.0
3.3
Cooling
capacity
5°
C
supply
kW
2.2
2.8
3.7
4.5
5.1
Power input
–
45 Ambient
1.6
1.8
2.5
3.0
3.6
Power input
–
35 ambient
1.1
1.5
2.0
2.4
3.0
COP
–
45 Ambient
1.4
1.6
1.5
1.5
1.4
COP
–
35 Ambient
2.0
1.9
1.9
1.9
1.7
Current draw
–
45 ambient
Amps
2.
7
3.4
4.8
5.7
7.0
Current draw
–
35 Ambient
2.2
2.8
3.6
4.7
5.7
10°
C
supply
kW
2.5
3.3
4.4
5.5
6.3
Power input
–
45 Ambient
1.6
1.8
2.5
3.0
3.7
Power input
–
35 ambient
1.1
1.5
2.1
2.4
3.0
COP
–
45 Ambient
1.6
1.8
1.8
1.8
1.7
COP
–
35 Ambient
2.3
2.2
2.1
2.3
2.1
Current draw
–
45 ambient
Amps
2.7
3.5
4.9
5.8
7.1
Current draw
–
35 Ambient
2.2
2.8
3.6
4.7
5.8
15°C Supply
kW
3.1
4.1
5.5
6.6
8.0
Power input
–
45 Ambient
1.6
1.8
2.6
3.0
3.7
Power input
–
35 ambient
1.2
1.5
2.1
2.5
3.0
COP
–
45 Ambient
1.9
2.3
2.1
2.2
2.1
COP
–
35 Ambient
2.6
2.8
2.6
2.6
2.7
Current draw
–
45 ambient
Amps
2.8
3.5
5.0
5.9
7.2
Current draw
–
35 Ambient
2.3
2.9
3.6
4.8
5.8
20°
C S
upply
kW
3.9
5.1
6.8
8.1
9.7
Power input
–
45 Ambient
1.6
1.8
2.6
3.1
3
.7
Power input
–
35 ambient
1.2
1.5
2.1
2.5
3.0
COP
–
45 Ambient
2.4
2.8
2.6
2.6
2.6
COP
–
35 Ambient
3.3
3.4
3.2
3.2
3.2
Current draw
–
45 ambient
Amps
2.8
3.6
5.0
6.0
7.2
Current draw
–
35 Ambient
2.3
2.9
3.7
4.8
5.9
Power input figures and
current draw include the fan but not the pump if supplied

R Series Manual –R150 to R2500
12
TECHNICAL DATA
ELECTRICAL DATA
Model
R150
R180
R230
R300
R330
Power requirements
–
single phase
240V 50 Hz Single Phase
Not readily available in
single phase
Maximum current d
raw
–single phase2
A
/ Ph
15
17.1
22.1
Maximum current draw
–3 phase
A
/ Ph
9.0
9.8
10.9
11.8
13.1
Maximum continuous
current –compressor
A
/ Ph
7.0
9.5
10
13
15
Locked rotor amps
–
compressor
A
/ Ph
30
45
45
60
70
Rated load amps
A
/ Ph
4.5
6.1
6.4
8
.3
9.6
Power requirements
–
3 phase
–
380/
415V 50 Hz 3 phase plus neutral (4A Max)
PUMP CURVES –the chillers are available with 3 pump flow/ pressure options

R Series Manual –R150 to R2500
13
TECHNICAL DATA
R420 to R1330
PERFORMANCE DATA –R134a
Model
R42
0
R540
R670
R830
R1000
R1200
R1330
Compressor horsepower
hp
4.2
5.4
6.7
8.3
10
12
13
Cooling capacity
0° supply
kW
5.8
7.7
9.6
11.1
14.8
16.8
18.1
Power input
–
45 Ambient
kW
4.1
4.8
5.6
6.9
7.5
8.8
10.6
Power input
–
35 Ambient
3.4
4.8
5.6
6.2
7.1
8.0
9.5
Current draw
–
45 Ambient
Amps
7.0
11.6
13.0
14.9
20.0
23.2
24.9
Current draw
–
35 Ambient
5.4
9.0
10.9
12.6
16.7
19.3
20.7
COP 45 Ambient
1.4
1.5
1.6
1.6
2.0
1.9
1.7
COP 35 Ambient
1.7
1.6
1.7
1.8
2.2
2.1
1.9
5° supply
kW
6.1
8.1
10.3
11.7
15.6
17.5
19.2
Power input
–
45 Ambient
kW
3.8
6.4
7.6
8.7
8.7
8.8
10.1
Power input
–
35 Ambient
3.4
4.8
5.7
6.2
6.6
8.0
9.1
Current draw
–
45 Ambient
Amps
7.1
11.7
13.0
14.9
20.0
23.2
25.0
Current draw
–
35 Ambient
7.0
10.9
12.0
12.5
16.7
19.3
20.7
COP 45 Ambient
1.6
1.7
1.8
1.8
2.2
2.1
1.9
COP 35 Ambient
1.8
1.9
2.0
2.1
2.5
2.5
2.4
10° supply
kW
7.5
9.7
12.5
14.2
18.8
21.2
24.4
Power input
–
45 Ambient
kW
3.8
6.4
7.6
8.7
8.7
8.8
10.1
Power input
–
35 Ambient
3.5
4.9
5
.8
6.2
6.7
8.1
9.2
Current draw
–
45 Ambient
Amps
7.2
11.7
13.1
14.9
20.3
23.4
25.6
Current draw
–
35 Ambient
7.0
11.0
12.1
12.6
16.8
19.4
20.8
Current draw
3.9
6.6
7.7
10.8
14.1
16.7
16.9
COP 45 Ambient
1.8
1.9
2.0
2.1
2.4
2.3
2.1
COP 35 Ambie
nt
2.1
2.0
2.2
2.3
2.6
2.6
2.4
ELECTRICAL DATA
Model
R420
R540
R670
R830
R1000
R1200
R1330
Maximum
continuous current –
compressor
A/ Ph
12.5
15.0
17.0
17.0
19.0
29.0
32.0
Locked rotor amps
–
compressor
A/ Ph
62
87
87.0
86
98
130
145
Rated load
amps
A/ Ph
8
9.6
11.0
12.1
13.6
20.7
22.9
Power requirements
–
3 phase
–
380/ 415V 50 Hz 3 phase plus neutral (4A Max)
PUMP CURVES –Standard Offerings

R Series Manual –R150 to R2500
14
TECHNICAL DATA
R SERIES III –R1500 TO R2500
PERFORMANCE DATA –R407c Refrigerant
R
150
0
R
2000
R
2500
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
18.4
22.5
COP
–
45 Ambient
2.0
1.6
1.8
COP
–
35 Ambient
2.2
2.0
2.2
Current draw
–
45 Ambient
Amps
26.5
37.2
45.2
Current draw
–
35 Ambient
24.3
31.1
38.0
10° supply
36.5
46.0
61.0
Power input
–
45 Ambient
15.4
23.2
28.1
Power input
–
35 Ambient
13.7
18.7
22.9
COP
–
45 Ambient
2.4
2.0
2.2
COP
–
35 Ambient
2.7
2.5
2.7
Current draw
–
45 Ambient
26.6
37.6
45.8
Current draw
–
35 Ambient
24.3
31.4
38.5
15° supply
41.0
55.5
68.5
Power input
–
45 Ambient
15.5
23.5
28.6
Power input
–
35 Ambient
13.8
18.9
23.3
COP
–
45 Ambient
2.6
2.4
2.4
COP
–
35 Ambient
3.0
2.9
2.9
Current draw
–
4
5 Ambient
26.7
38.1
46.2
Current draw
–
35 Ambient
24.4
31.7
39.0
Current draw numbers do not include the current draw of the chilled water supply pump
PUMP CURVES –STANDARD OFFERING

R Series Manual –R150 to R2500
15
TECHNICAL DATA
GENERAL DATA
–
R1500 to R2500
Model
All Models
High pressure safety cutout
pressure –R134a kPa 2300 Low pressure safety cut out pressure –R134a kPa
80
–
reset
at 170
High pressure safety cut out
pressure –R407c kPa 2850 Low pressure safety cut out – R407c kPa
170
–
reset
at 400
Noise rating at 5m –dB
dB
73
No. of fans
3
Fan speed control
Variable/
Automatic Hot air discharge Vertical
Fan type
Axial 4 pole 3
phase Capacity control 0-100%
Maximum air flow
16700m
3
/ hr
Fan wiring
Y Star
–
3 Phase
Overflow connection
2”FBSP
Chilled Water connection
1 ½”FBSP
Make up water connection
3/8”FBSP
Drain connection
2”FBSP
Buffer tank capacity 500L Buffer tank construction
HDPE with
polyurethane foam
insulation
No. of compressors
1
Compressor type
Scroll
–
hermetic
Compressor oil
POE
Liquid receiver volume
10.6 L
Refrigerant type
R407c
–
option
for R134a TX/ expansion valve type Mechanical expansion
Compressor start method
DOL
Compressor motor insulation
Class F
Controller
Standard unit
–
off the shelf
–
0.1C a
ccuracy
Microprocessor controller –Aqua Cooler
High level BMS connection
protocols
Bacnet, SNMP and Modbus as standard
LON works as an option
All BMS stacks are imbedded without the need for a gateway
Condenser construction
Expanded 7mm rifle bor
e copper tube with 0.12mm aluminum fins
Condenser coating
Hydrophobic epoxy coating
General unit construction
Electrostatic powder coated galvanized steel
Centre of gravity
Unit is 45/55 along the long axis of the machine
Unit is weighted 60/40 about the short centre line
Model
R1500
R2000
R2500
Approximate shipping weight
800 kg
900 kg
950 kg
Oil charge
6.2 kg
8.0 kg
8.0 kg
Refrigerant charge
9 kg
10 kg
10 kg
Minimum water flow across the
evaporator 1.8 l/s 2.3 l/s 3.0 l/s
Evaporator
Evaporator type
Plate heat
exchanger Cooling medium Water
Pressure drop across evaporator
at minimum flow rate kPa 50
Maximum design operating
pressure water side kPa 1000
Minimum flow rate through
evaporator
l/s
m3/h
83
301
Fouling factor –evaporator
m2C/kW 0.006
Evaporator options include
oImmersed coil for dirty environment/ low flow/ low water temperature applications
oStainless shell and tube for corrosive environments

R Series Manual –R150 to R2500
16
COOLING SYSTEM SCHEMATIC
Immersed Copper Coil Evaporator
Brazed Plate Heat Exchanger Evaporator Model

R Series Manual –R150 to R2500
17
COOLING SCHEMATIC
Closed Loop Installation
Cooling Schematic Symbols
Liquid receiver
Air Cooled
Condenser
Pressure
transducer
Pump One way valve Ball valve
Compressor TX valve Flow meter
Sight glass Drier Pressure gauge
Low pressure switch Drain Thermowell
Motorised ball valve Expansion tank
Water regulating
valve
Pressure relief valve Strainer
High pressure
switch
Hot gas bypass
valve
Isolation valve
Plate heat
exchanger

R Series Manual –R150 to R2500
18
DIMENSIONS
Standard Chillers
R150 to R330
R420 to R1330
R1500 to R2500

R Series Manual –R150 to R2500
19
DIMENSIONS
R420 to R1330 Remote Unit
R1500 to R2500 Remote Unit
Compact Chiller –no buffer tank –Model RTDPC25 –25 to 50kW

R Series Manual –R150 to R2500
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DIMENSIONS
R1500 Remote Condenser
R2000/ R2500 Condenser