OC VERHULST Aqua Cool 100 User manual

MANUAL
Aqua Cool 100
Rental Units v5.2 2022
For further documentation see:
http://www.oc-verhulst.nl/
OC Verhulst
Albert Einsteinweg 10
5151 DL Drunen
The Netherlands
Tel.: +31(0)416 – 672 200
Fax: +31(0)416 – 340 785
www.oc-verhulst.nl
OC Verhulst is a trade name of Verhulst Klimaattechniek
B.V., part of Orange Climate.

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Contents
Contents .............................................................................................................................................................2
1. Introduction .................................................................................................................................................5
2. Warranty .....................................................................................................................................................6
3. Description of the Aqua Cool......................................................................................................................7
3.1. Design types .......................................................................................................................................7
3.2. Aqua Cool system principle ................................................................................................................7
4. General maintenance / securing.................................................................................................................8
4.1. Maintenance of the Aqua Cool ...........................................................................................................8
5. Description of the components ...................................................................................................................9
5.1. Brief description of the cabinet layout. ...............................................................................................9
5.2. (Air control) dampers ..........................................................................................................................9
5.3. Filter ....................................................................................................................................................9
5.3.1. Filter maintenance ......................................................................................................................9
5.4. Cooling battery .................................................................................................................................10
5.4.1. Maintenance 5.4 & 5.5..............................................................................................................10
5.5. Drip tray ............................................................................................................................................10
5.5.1. Drip tray maintenance ..............................................................................................................10
5.6. Droplet eliminator/separator .............................................................................................................10
5.6.1. Droplet eliminator maintenance................................................................................................10
5.7. Siphon...............................................................................................................................................11
5.7.1. Siphon maintenance .................................................................................................................11
5.8. Fan....................................................................................................................................................11
5.8.1. Fan maintenance ......................................................................................................................12
5.9. Housing.............................................................................................................................................12
5.9.1. Maintenance of housing ...........................................................................................................12
5.10. Control panel ................................................................................................................................12
5.10.1. Control panel maintenance.......................................................................................................13
5.11. Switch panel .................................................................................................................................14
5.11.1. Maintenance of electrical equipment and switches ..................................................................14
6. Maintenance schedule for operating personnel + qualified personnel.....................................................15
6.1. Damaged or missing pictograms......................................................................................................16
7. Control Technology ..................................................................................................................................17
7.1. Air inlet temperature sensor: ............................................................................................................17
7.2. Supply air temperature (internal/external) sensor: ...........................................................................17
7.3. Fluid supply / return temperature sensor:.........................................................................................17
7.4. Dual position switch (start/stop):.......................................................................................................17

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7.5. Control panel: ...................................................................................................................................17
7.6. Fans:.................................................................................................................................................17
7.7. Three-way valve: ..............................................................................................................................17
7.8. Defrosting cycle: ...............................................................................................................................18
7.9. tERA Portal: ......................................................................................................................................18
7.10. Control Technology error messages: ...........................................................................................18
7.10.1. Dirty filter message | not urgent:...............................................................................................18
7.10.2. Error message: .........................................................................................................................18
7.10.3. Status message: .......................................................................................................................18
7.10.4. Defrosting cycle active:.............................................................................................................19
8. Set-up and installation ..............................................................................................................................19
8.1. Preparations .....................................................................................................................................19
8.2. Delivery and transport ......................................................................................................................19
8.2.1. Vertical transport.......................................................................................................................19
8.2.2. Horizontal transport ..................................................................................................................20
8.3. Temporary storage ...........................................................................................................................20
8.4. Final placement ................................................................................................................................21
8.5. Installation.........................................................................................................................................21
8.6. Commissioning .................................................................................................................................22
8.7. Pre-commissioning check.................................................................................................................22
9. Starting .....................................................................................................................................................23
9.1. Decommissioning .............................................................................................................................23
10. Safety....................................................................................................................................................24
10.1. General safety instructions ...........................................................................................................24
10.2. Statutory requirements .................................................................................................................24
10.3. Safety measures...........................................................................................................................24
11. Display instruction ................................................................................................................................26
11.1. Graphical operating display .........................................................................................................26
11.2. Display and operating buttons ......................................................................................................26
11.3. P&ID diagram ...............................................................................................................................28
11.4. IO list C.PCOe Mini.......................................................................................................................29
11.5. User interface with display............................................................................................................30
11.5.1. Function keys............................................................................................................................30
11.5.2. Adjusting the contrast ...............................................................................................................30
11.5.3. Alarm messages .......................................................................................................................30
11.6. Selection of menus .......................................................................................................................31
11.7. Main menu and start-up................................................................................................................32
11.8. Switching on/Switching off the unit ...............................................................................................33

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11.9. Setpoint.........................................................................................................................................34
11.9.1. Setpoint temperature ................................................................................................................34
11.9.2. Setpoint speed..........................................................................................................................34
11.9.3. Setpoint voltage ........................................................................................................................34
11.9.4. Defrosting setting......................................................................................................................34
11.9.5. Manual mode ............................................................................................................................35
11.10. Information....................................................................................................................................36
11.11. Table of alarm messages .............................................................................................................38
11.12. Other functions .............................................................................................................................40
11.12.1. Indicator lights connected to digital output ...........................................................................40
11.12.2. Supply air sensor - Automatic selection ...............................................................................40
11.13. Menu settings <<Programming>> ................................................................................................40
11.13.1. Fan........................................................................................................................................40
11.13.2. Belimo...................................................................................................................................40
11.13.3. Belimo...................................................................................................................................41
11.13.4. Configuring the unit ..............................................................................................................41
11.13.5. Alarm ....................................................................................................................................41

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1. Introduction
Read this manual carefully before putting the Aqua Cool into operation. Familiarise yourself with the operation
and handling of the machine and strictly follow the instructions provided.
This manual contains important information on the commissioning of your Aqua Cool. It also contains
instructions intended to protect you from possible accidents when using the unit and to prevent damage to the
unit. In addition, information regarding the maintenance of the Aqua Cool is included in order to promote
trouble-free operation.
For clarity, important items are indicated in bold along with the text 'CAUTION'. These are important
instructions that protect you from danger or refer to the risk of damage to the unit. Please bear all these
comments in mind.
If you have any questions or would like further clarification on specific issues relating to the unit, please do not
hesitate to contact one of our team in the Repair & Maintenance department on [phone].
The data published in this manual are based on the latest information. They may be subject to subsequent
amendments. OC Verhulst reserves the right to change the construction and/or design of our Aqua Cool
without prior notice at any time or to modify previously made deliveries accordingly.
The Aqua Cool comes in one version: Aqua Cool 100.

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2. Warranty
The warranty on the Aqua Cool is subject to the general terms and conditions of the NVKL.
The warranty lapses immediately and automatically if:
•Service and maintenance are not carried out strictly in accordance with the instructions, repairs are
not carried out by OC Verhulst personnel or are carried out without the prior written permission of OC
Verhulst.
•Changes to the equipment have been made without the prior written permission of OC Verhulst.
•Settings and/or safeguards have been changed without the prior written permission of OC Verhulst.
•Non-original parts or refrigerants or lubricants other than those prescribed are used.
•The equipment has not been placed and/or connected in accordance with the placement and
installation instructions.
•The equipment is used improperly, incorrectly, negligently or not in accordance with its type and/or
intended purpose.
In the aforementioned cases, OC Verhulst is indemnified against any product liability claims. In case of a
warranty claim, the order number of the respective unit must always be provided.

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3. Description of the Aqua Cool
The Aqua Cool is an air supply unit with a cold water coil. This unit was specially developed for supplying fresh
(outside) air into marquees and for temporary cooling in laboratories, for example. The Aqua Cool uses an
external cooling unit. The Aqua Cool converts the cold water into fresh, cool air.
The Aqua Cool can be used in environments up to 50°C.
The Aqua Cool has primarily cold water connections, but can also be equipped with hot water connections for
defrosting the cooling battery, for example. The Aqua Cool can be connected with an electric plug.
Aqua Cool 100
16A
3P
3.1. Design types
The Aqua Cool 100 has a nominal output of 100 kW, maximum cooling capacity at 12,500 m3/h and is suitable
for both indoor and outdoor installation.
3.2. Aqua Cool system principle
Aqua Cool 100
D01
Outside air inlet damper (manually operated)
TT01
Outside air inlet temperature
ΔP
Delta - P dirty filter switch
Filter
Filter
Coil
Battery
MV01
Belimo 3-way valve
TT04
Return water temperature
TT05
Supply water temperature
TT02
Supply air temperature (internal)
TT03
Supply air temperature (external)
F01 & F02
Fans 2 pcs (Aqua Cool 100)
D02
Supply air damper (manually operated)

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4. General maintenance / securing
A warning label is attached to your Aqua Cool stating: "secure unit before opening". This means that before
opening the unit for service or maintenance work, switch off the unit using the main switch and lock the main
switch in the "off" position using a padlock. In this way you can avoid a dangerous situation during the
maintenance, should the unit be switched back on. Switching off and locking the main switch prevents this kind
of risk.
4.1. Maintenance of the Aqua Cool
Regular and careful maintenance of your Aqua Cool is essential for long-term, efficient and trouble-free
operation. A number of maintenance tasks can be caried out by the operating personel, see chapter 6.
Maintenance must be carried out by authorised and qualified personnel, see chapter 6. For maintenance, you
can use the service organisation of OC Verhulst, which offers you a maintenance contract for this. If you notice
any defects and/or deviations, please report this to our service organisation immediately. When reporting, it is
important to mention the order number of the unit (this number is indicated on the model plate of the unit). If
necessary, consult the wiring diagram during the inspection work.
The inspection schedules in these operating instructions have been compiled as a guideline for maintenance
work. OC Verhulst does not guarantee the completeness of this information and can therefore not accept
liability for any inaccuracies!
! CAUTION:
The main switch of the unit must be switched off and locked at all times when handling or
working on the unit!
! CAUTION:
If a unit is installed on a roof, the effect of gusts of wind must be taken into account when
opening and closing service doors.

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5. Description of the components
5.1. Brief description of the cabinet layout.
Seen from the front to the back in the direction of airflow.
- Housing with 2 holes (500 mm)
oExternal air intake connection
oWater-side connection by means of Bauer coupling ball valve. (cold / hot water)
- 2x air control dampers
- Intake filter G4
- Three-way cold water system
- Cooling coil incl. defrosting heater
oplastic drip tray
odroplet eliminator
osiphons
- 2 fans
oDirectly driven with EC motors
oRemovable from the side
- 2x air control dampers
- Housing with 2x connections (500mm)
oFor attaching supply air hoses
- Control panel (behind plastic, transparent panel)
oAccessible from outside
- Switch panel behind closed door (CE)
oCan only be opened with special tools
The dampers of the Aqua Cool 100 are manually operated and can be locked. Electrical connection (16
ampere) Menneke plug, 5-pin without 0. In the following subchapters, all components are listed separately
and the required maintenance is indicated.
5.2. (Air control) dampers
The external air intake is equipped as standard with a volume control damper with manual operation and
locking device. The dampers in the air outlet are also manually operated with a locking device. The dampers
are standard contra-rotating dampers with aluminium housing, aluminium damper blades and plastic
maintenance-free actuator.
5.2.1. Damper maintenance
The volume control dampers must be checked regularly for proper functioning and wear.
5.3. Filter
The intake filter is a G4 filter consisting of pleated filter material with a metal frame. The filters are mounted
in a metal sliding profile.
5.3.1. Filter maintenance
The filters must be replaced when the specified final resistance is reached. A non-urgent fault message on
the display of the Aqua Cool indicates that the filters must be replaced. Replace the filters with new ones of
the same type, ensuring correct positioning and safe (working) conditions.
When changing the filters, you should also clean the filter section.
Check the existing pressure sensors for proper functioning.
! CAUTION:

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Be careful when changing filters. Chemical, biological or microbiological substances may
have collected in the filter. These substances can be hazardous to health. They may also end
up as residue at the bottom of the section. Always use personal protective equipment (safety
glasses, gloves and P2 dust mask), never throw filters around, pack the dirty filters before
moving them (in a box or bag). In very dry and dusty conditions, it may be desirable to
moisten the filters slightly before removing them. Always dispose of used filters as chemical
waste.
5.4. Cooling battery
A three-way cold water system is mounted on the front of the Aqua Cool. This system ensures that the
desired air supply conditions of the unit are achieved.
The three-way mixing system is suitable for water as a water/glycol mixture. This can be either hot or cold.
The flow rate can be regulated by means of valves via the unit control system.
CAUTION!
A water/glycol mixture should always be used when there is a risk of frost.
The three-way mixing valve of the cooling battery is controlled by PLC.
5.4.1. Maintenance 5.4 & 5.5
The cooling coil front (inlet) unit can be reached by removing the filters. You should check the coil annually
for contaminants, and clean the coil if necessary using a high pressure water jet or compressed air, avoiding
damage to the fins. Repair any damage with a so-called 'Fin comb'.
When servicing coils, be aware of the hazards of the medium used; a neutral temperature is desired and the
medium must be sufficiently cooled. Even after switching off the heater (or cooler), the coil may remain hot
(or cold) for some time.
CAUTION!
When disconnecting both the coil and the defrosting heater, the coil must be drained on the
water side or stored frost-free.
5.5. Drip tray
The drip tray below the cooler collects the condensation water that runs off the cooler, including dirt.
5.5.1. Drip tray maintenance
Dirt, possibly including substances of a biological or microbiological nature, collects in the drip trays of
coolers. These substances may pose a threat to health. Therefore, be careful when cleaning these drip
trays. The drip tray under the cooler must be checked for dirt and cleaned if necessary.
5.6. Droplet eliminator/separator
The droplet eliminator is mounted at the end of the drip tray to keep condensation away from the cooling
element. The droplet eliminator guides this to the drip tray.
5.6.1. Droplet eliminator maintenance
Check the droplet eliminator for contamination every six months, dismantle and clean if necessary.