Aqua Cooler S Series User manual

Models
Models - S150, S200, S275, S400
A Q U A
COOLER
Aqua Cooler Pty Limited
PRODUCT MANUAL
S SERIES
WATER CHILLER
001-D081 ISS I
Customer
Model
Plant Serial Number

S Series Manual
2
CUSTOMER
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

S Series Manual
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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

S Series Manual
4
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 any
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
CONTENTS
Safety 3
Marking 5
Certification 5
Warranty 5
General Information 5
Intended Use 5
Water Circuit 6
Technical Data 6
Cooling System Schematic 7
Dimensions 7
Transport and Storage 8
Installation –electrical, water connection, water treatment, control circuit and final checks 8
Operation 9
Control 9
Service and Maintenance 12
Wiring Tandem Set Up N/A
Pump Curves 14
Critical Spares 16
Data Sheets 16
Trouble Shooting 17
Wiring Diagram 18
Release Notes 20
Commissioning 21

S Series Manual
5
SAFETY
THE INDOOR RANGE OF CHILLERS CANNOT BE USED OUTDOORS
- This chiller 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 chiller contains electrical components that operate at mains voltage. It therefore must
be isolated from the electrical supply before being worked on. All maintenance operations
that require access to the chiller must be carried out by suitably qualified technicians who
have a thorough understanding of all necessary precautions associated with servicing the
chiller.
- The liquids to be used in the appliance must be compatible the materials used in the
construction of the appliance. The appliance is designed to dispense chiller water only.
- All panels must be re-installed after carrying out any maintenance work.
- The chiller 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 or rolling.
- Where the above symbol is shown there are live electrical parts and the utmost care
should be taken.
- Work should be carried out by qualified electricians only.
- Electrical connection should be in accordance with all the local relevant safety standards
for wiring safety.
- Always isolate power from the unit when working on it.
- All the components in the chiller are 240V.
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.

S Series Manual
6
SAFETY
Refrigerants
The unit is charged with r134a gas
Product name 1,1,1,2-Tetrafluoroethane, R134a
Inhalation
In low concentrations may cause narcotic effects. Symptoms may include dizziness, headache,
nausea and loss of co-ordination. In high concentrations may cause asphyxiation. Symptoms may
include loss of mobility/ consciousness. Victim may not be aware of asphyxiation.
Remove victim to uncontaminated area wearing self contained breathing apparatus. Keep victim
warm and rested. Call a doctor. Apply artificial respiration if breathing stopped.
Skin/ Eye Contact
In case of frost bite spray with water for at least 15 minutes. Apply a sterile dressing. Immediately
flush eyes thoroughly with water for at least 15 minutes. Obtain medical assistance
Ingestion
Ingestion is not considered a potential route of exposure.
ACCIDENTAL RELEASE MEASURES
Personal precautions
·Evacuate area.
·Wear self-contained breathing apparatus when entering area unless atmosphere
is proved to be safe.
·Ensure adequate air ventilation.
Environmental precautions
·Try to stop release.
·Prevent from entering sewers, basements and workpits, or any place where its
accumulation can be dangerous.
Clean up methods
Ventilate area.
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 unit weights approximately 40kg dry. Always keep in mind safe manual handling procedures
when moving the unit. The unit is on rollers to help move it into place once the it is near its final
position.

S Series Manual
7
MARKING
The unit will have serial number sticker on the rear panel of the chiller.
There is an alpha-numeric number under the bar code and this number should be quoted in the
case of a service call. It will tell Aqua cooler the model number and the production date.
Units without a buffer tank will have the high and low water mark indicated next to the level
indicator on the rear of the unit. It is important that the chiller is not over filled.
CERTIFICATION
All the electrical components in the chiller have been certified for electrical safety.
The unit is not designed to be connected to the mains water supply, nor is it certified to be used
for food preparation or drinking water. Contact Aqua Cooler for advice on using the chiller for food
preparation or for potable water applications.
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.

S Series Manual
8
GENERAL INFORMATION
The chiller is designed to refrigerate and circulate water to a heat developing process to aid in
keeping that process cool. Water is circulated out of the unit via a pump. It is designed to easily
install with a standard house electrical cable and be used in an indoor environment. The standard
unit is not designed to dispense drinking water or for food preparation.
INTENDED USE
The chiller is designed to deliver refrigerated water to a heat developing process in an indoor or
weatherproof environment. Any use beyond this is not deemed as intended.
CHILLED WATER CIRCUIT
The chilled water circuit consists of
1. Plate heat exchanger or copper evaporator - optional
2. HDPE buffer tank or stainless steel evaporator - optional
3. Pump
4. Solenoid valve –optional
5. Plastic, silicon and copper tubing
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 and silicon rubber

S Series Manual
9
TECHNICAL DATA
Model S50 S150 S200 S275 \S400
Cooling Capacity @ 5 Dg
Supply
Watts 20 Ambient 300 600 900 1100 1400
45 Ambient 200 400 500 600 900
Cooling Capacity @ 10 Dg
Supply
Watts 20 Ambient 360 900 1200 1600 2100
45 Ambient 240 600 800 1000 1300
Cooling Capacity @ 15 Dg
Supply
Watts 20 Ambient 425 1100 1600 2100 2700
45 Ambient 290 800 1000 1400 1800
Cooling Capacity @ 20 Dg
Supply
Watts 20 Ambient 500 1500 2100 2800 3600
45 Ambient 350 1000 1400 1800 2400
Cooling Capacity @ 25 Dg
Supply
Watts 20 Ambient 1800 2500 3500 4400
45 Ambient 1200 1800 2300 2900
Buffer
Tank Capacity
Litres .5
Indoor chillers
-
6
Outdoor chillers - 25
Dry Weight Kg 15 40 45
Power Requirements
240V 50 Hz Single Phase
Total Amps A 3 4.6 5.6 6.3 7.2

S Series Manual
10
COOLING SYSTEM SCHEMATIC
Cooling Schematic –Standrd Unit
Cooling Schematic –Instantaneous Unit
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