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Aqua Thermal X R Series User Manual

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User Manual Thermal X - R Series Chillers Page 1
Revision 2
AUGUST 2019
Thermal X - R Series
Owner’s Manual
This guide applies to the following models: R150 to R4000.
Aqua Cooler Pty Ltd
U14, 2-12 Knobel Court
Shailer Park 4128 Qld
www.aquacooler.com.au
1300 AQUA COOLER
1300 278 286
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Aqua Thermal X R Series Specifications

General IconGeneral
BrandAqua
ModelThermal X R Series
CategoryChiller
LanguageEnglish

Summary

Introduction

General Information

Describes the chiller's purpose, design, and intended use for cooling processes.

Denomination

Explains the model naming convention and its components.

Safety

General Safety Warnings

Provides critical warnings about installation, operation, and maintenance by qualified personnel only.

First Aid

Details immediate actions for eye contact, inhalation, skin contact, and ingestion of refrigerants or coolants.

Installation Requirements

Installation of the Water Path

Outlines requirements for water path installation, including pipe work insulation and pressure checks.

Water Connection Fittings by Model (Male BSPT)

Lists water connection sizes for different chiller models.

Electrical Installation

Specifies requirements for electrical connection by a licensed electrician according to Australian standards.

Preparations For Starting the Chiller

Operating Sequence

Step-by-step guide for starting the chiller unit and its components.

Operating Precautions

Lists essential precautions for safe and efficient chiller operation, including temperature limits.

Aqua Cooler Controller

Unlocking the Keypad on the Aqua Cooler Controller

Instructions to unlock the controller keypad after a period of inactivity.

Operational Logic of Controller

Start Up

Describes the sequence of operations during chiller start-up, including delays and compressor staging.

Temperature Control Set Points

Explains how the controller manages water temperature, including set points and hysteresis.

Temperature Control Alarms

Details high and low temperature alarm functions and their impact on chiller operation.

Fan Speed Control

Explains how fan speed is controlled based on discharge pressure, with optional settings.

Operational Logic of Controller (Continued)

High/Low Pressure Control

Monitors discharge pressure, providing warnings and shutdowns for high or low pressure conditions.

Water Flow/Pump Control

Manages water flow rates, issuing warnings and shutdowns for low flow conditions.

Compressor Hold Time

Specifies the delay before compressors restart after shutdown to prevent frequent cycling.

Alarm Acknowledge Delay

Defines the delay before alarms are flagged, allowing for system stabilization.

Operational Logic of Controller (Continued)

Pump Delay Time

Controls the delay before flow readings are taken, allowing valves to open.

Tandem Control

Explains how to configure chillers for master/slave operation in a tandem setup.

Close Tolerance Operation

Describes how the chiller maintains tight temperature control within a specified range.

Standby Mode Operation

Instructions for placing the unit into standby mode for short-term shutdowns.

Changing the Controllers Parameters

Water Supply Temperature Setting

How to set the water supply temperature at which the refrigeration system cuts out.

Temperature Hysteresis Setting

Defines the temperature band between compressor cut-in and cut-out to prevent short cycling.

Compressor Hold Time Setting

Sets the rest time for compressors after shutdown, recommended at 2 minutes.

Changing the Controllers Parameters (Continued)

Maximum and Minimum Temperature Limits

Sets limits to prevent operators from selecting supply temperatures outside the recommended range.

High and Low Temperature Stop Control

Configures the unit to enter standby mode if high or low temperature alarms are breached.

High and Low Temperature Alarm Configuration

Sets specific temperature thresholds for high and low temperature alarms.

Setting Water Flow Alarms

Configures warnings and shutdowns for chilled and condenser water flow rates.

Changing the Controllers Parameters (Continued)

Setting High Pressure Alarms and Warnings

Configures pressure thresholds for warnings and unit shutdowns.

Setting Fan Speed Control

Adjusts minimum and maximum fan speeds based on discharge pressures.

Setting Alarm Acknowledge Delay

Sets the delay before alarms are flagged, useful for system stabilization.

Tandem Installation and Role Assignment

Guides on setting up chillers in tandem and assigning master/slave roles.

Duty Cycle and Timer Settings

Configures duty cycle modes (off, test, weekly) for multiple chiller units.

Full Setting List

Parameter Menu Settings

Lists recommended settings for various parameters within the Parameter Menu.

Set Time Menu Settings

Details recommended settings for time-related parameters like alarm delay and hold times.

Set Point Menu Settings

Lists recommended settings for operational set points, including pressure and temperature limits.

Advanced Controller Functions

Network Configuration and IP Settings

Instructions for configuring network settings, IP addresses, and protocols like Modbus/BACnet.

Downloading Operational Data Log

Guides on how to download operational and event logs via USB or web interface for diagnostics.

Advanced Controller Functions (Continued)

Downloading Data Log via USB

Specific steps for downloading time and event logs onto a USB drive.

Sensor Calibration Procedure

Outlines the process for recalibrating temperature sensors for accurate operation.

Advanced Controller Functions (Continued)

Software Update Procedure

Instructions for updating chiller firmware via USB or Ethernet for new features or fixes.

Controller Input and Output Schematic

Input/Output Connector Mapping

Details the function and type of each input and output connector on the controller board.

Troubleshooting

Low Flow Alarm Issues

Lists causes and solutions for low flow alarms, including pump and flow meter checks.

Compressor Fault Troubleshooting

Addresses common compressor faults like high/low pressure trips and motor protection issues.

PCB Blank / No Power Issues

Provides steps to diagnose and resolve issues related to the PCB or lack of power.

Troubleshooting (Continued)

Fault Code Specific Issues

Explains troubleshooting for specific fault codes like C1 FLT, LP Fault, HP Fault, and water temp issues.

Poor Heat Dissipation Diagnosis

Identifies causes of poor heat dissipation and their impact on chiller performance and alarms.

Low Refrigerant Diagnosis

Describes how to identify and address low refrigerant charge issues.

Troubleshooting (Continued)

Low and High Pressure Difference Issues

Discusses diagnosing potential piston damage in compressors based on pressure differences.

Compressor Not Starting Causes

Lists potential reasons why the compressor might fail to start, including sensor and electrical issues.

Maintenance

Recommended Preventative Maintenance Program

Outlines a schedule for routine maintenance tasks like checking refrigerant charge and electrical connections.

Warranty

General Application

Installation Sketch Map of Air Cooled Chiller

Installation Sketch Map of Water Cooled Chiller

Internal Structure Sketch Map of Air Cooled Chiller

Internal Structure Sketch Map of Water Cooled Chiller

Commissioning Sheet

Customer and On Site Requirements

Checklist for site requirements including capacity, temperature, and customer details.

Machine Information and Gauges

Details for recording chiller model, serial number, program version, and pressure readings.

Pump and Fan Checks

Checklist items for verifying pump operation, water leaks, and fan performance.

Commissioning Sheet (Continued)

Chiller Water Circuit Requirements

Checklist for pipe size, insulation, water treatment, and isolation valves.

Operation Testing Parameters

Checks for ambient temperature, controller readings, sight glass clarity, and button functionality.

Operation Testing – Current Draw

Recording electrical current draws for the chiller, pumps, and fans during operation.

Commissioning Sheet (Continued)

Installation and Build Check

Verifies physical installation aspects like clearance, wiring, and panel security.

Commissioning Site Details

Fields for recording details of the installation site and personnel involved.

Notes

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