IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139–2268
Telephone (800) 551–4423
Facsimile (800) 519–4423
CHILLER (“CH” SERIES)
Models: CH 250
CH 251
Operator’s Manual
Part No. 620914801
February 16, 1999
Revised: August 12, 2002
Revision C
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
PRINTED IN U.S.A
IMI CORNELIUS INC; 1999–2002
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GENERAL INFORMATION
INTRODUCTION
The REMCOR ”CH” Series Recirculating Water Chiller is designed to provide an accurate, reliable, and user–
friendly system for cooling a continuous flow of water and keep it at a constant temperature in various closed
loop or tank cooling applications.
The ”CH” Series Chiller consists of an air–cooled refrigeration system housed in a sturdy sheet metal frame and
cabinet. A standard pump and insulated water reservoir package provides a complete liquid cooling and circu-
lating system.
The ”CH” Series Chiller is designed to operate in a clean laboratory or industrial environment where ambient
temperatures range from 40 to100° F (5 to 38° C). With proper installation, operation, and maintenance, the
”CH” Series Chiller will provide years of trouble free service.
UNPACKING AND INSPECTION
This unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it.
Any damage or irregularities should be noted at the time of delivery and immediately reported to the carrier. Re-
quest a written inspection report from the Claims Inspector to substantiate any necessary claims. In the event
that an immediate replacement is necessary, please contact REMCOR Chiller Sales at 1–800–551–4423.
DESIGN DATA
Table 1. Design Data
CH250
CH251
Cooling Capacity:
BTU/hr (W) at 80_ F(27_ C) and
70_ F (21_ C) Liquid Temperature.
3,000 (879)
3,000 (879)
Compressor Horsepower
.25 (.2 kW)
.25 (.2 kW)
Electrical Data:
Voltage/Phase/Hertz/Amperage
115/1/60
7.5 Amps
230/1/60
3.8 Amps
Refrigerant Type:
R134a
R134a
Physical Dimensions, Width X Depth
X Height
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34cm)
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34cm
Fittings:
Process Connections
Optimum Process Liquid Flow GPM
(Liters/Min)
1/2” FPT (S/S)
1/2I FPT (S/S)
0.6 (2.72)
0.6 (2.72)
Condenser Air Flow (CFM)
225
225
DATA PLATE INFORMATION
REMCOR PRODUCTS COMPANY
GLENDALE HEIGHTS, IL. 60139–2268
PART NO.
MODEL NO.
PH
SERIAL NO.
VOLTS
HZ
AMPS
R134A
BAR CODE
FIGURE 1. SAMPLE DATA PLATE
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When servicing a REMCOR Chiller, it is important to note the information contained on the data plate located in
the upper rear of the Unit.
If technical assistance is needed, the phone technician will need the Serial Number of your Chiller. That informa-
tion is found on the Data Plate along with the model number, voltage requirement, and refrigerant information.
The serial Number is also needed when replacement parts are being ordered or for warranty claims. See
CHILLER WARRANTY PAGE.
Be sure to include the serial number on any documentation or billing information.
CHILLER INSTALLATION
Location of Chiller
THE CHILLER MUST BE LOCATED NEAR A PROPERLY GROUNDED ELECTRICAL OUTLET. THE CIR-
CUIT SHOULD BE FUSED AND NO OTHER ELECTRICAL APPLIANCE SHOULD BE CONNECTED TO THE
CIRCUIT. ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL
CODES.
The Chiller must be located in a well ventilated, indoor area where ambient temperatures will remain above
40_ F (5_ C) and will never increase above 100_ F (38_ C). To obtain optimum cooling capacity, the ambient
temperature should be at or below 80_ F (27_ C).
It is very important that the air intake and discharge sides of the chiller are not obstructed by other free standing
objects. A minimum of two feet of space on all four sides of the chiller will be sufficient to prevent air flow ob-
structions.
It is also important to direct any hot air discharge from other equipment away from the air intake side of the chill-
er. Condenser air entering the “CH” unit should be below 100_ F (38_ C) .Condenser air temperatures above
100_ F (38_ C) can cause the high pressure safety control to shut down the unit.
Electrical Connections
(see Figure 3)
All wiring must conform to the National Electric Code and any applicable local codes. The Chiller must be
permanently wired by means of electrical conduit to a properly fused disconnect of proper amperage or wired to
a properly rated power cord and plugged into an outlet with the appropriate disconnect and amperage rating.
The electrical junction box, located on the back panel of the Chiller, includes a four terminal strip for power
supply connection.
The data plate, located next to the junction box, includes the actual voltage, phase, and amperage of the Chiller.
START UP
WARNING: Never operate the Chiller with it’s panels removed.
Always use the power switch to turn off the Chiller when it is not being used.
Always ensure that all air inlets and outlets are free from obstruction.
Be sure that the reservoir is filled with fluid prior to powering up the unit (see Fluid
Recommendations page).
Process Water Flow, Units with Pump and Tank (Standard)
Follow standard plumbing practices and local codes in making water connections. The Chiller inlet and outlet
connections are 3/4”. Flexible hose and fittings are recommended for plumbing the system. A No. 20 mesh
strainer should be installed on the Chiller inlet to prevent foreign particles from entering the system and should
be cleaned monthly. Lines should be routed with as few bends as possible. Prevent lines from running near
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radiators, hot water pipes, etc. Any lengths of tubing that are exposed to high ambient temperatures should be
insulated to prevent condensation and/or significant liquid heat loss.
After ensuring that the system is free from the obstruction, that all valves are open, and the reservoir when avail-
able is full, push the CONTROL POWER switch to the “ON” position. The pump should now be operating.
Process Water Flow, Units Without Reservoir (Optional)
Follow standard plumbing practices and local codes in making water connections. The Chiller inlet and outlet
connections are 3/4”. Flexible hose and fittings are recommended for plumbing the system. A No. 20 mesh
strainer should be installed on the Chiller inlet to prevent foreign particles from entering the system and should
be cleaned monthly. Lines should be routed with as few bends as possible. Prevent lines from running near
radiators, hot water pipes, etc. Any lengths of tubing that are exposed to high ambient temperatures should be
insulated to prevent condensation and/or significant water heat loss.
Proper priming of the water lines is essential to prevent pump cavitation. Be certain all air has been purged from
the lines before operating the pump for an extended period of time. Be sure to remove any loops in the lines that
may trap air. The pump must have a supply of water with the level of the water above the inlet of the Chiller.
The supply tank must feed the Chiller from the side of the tank below the water level (see Figure 2).
CHILLER
INLET
WATER
LINE
LEVEL
EXTERNAL
RESERVOIR
CHILLER
W/O TANK
CORRECT
CHILLER
INLET
LINE
CHILLER
INLET
LINE
CHILLER
INLET
LINE
WATER
LEVEL
WATER
LEVEL
EXTERNAL
RESERVOIR
EXTERNAL
RESERVOIR
WATER
LEVEL
CHILLER
W/O TANK
CHILLER
W/O TANK
CHILLER
W/O TANK
EXTERNAL
RESERVOIR
WATER LEVEL IS
AIR CAN BE TRAPPED IN
WATER FEEDING FROM
BELOW CHILLER INLET
CHILLER INLET
TOP OF TANK
INCORRECT
INCORRECT
INCORRECT
FIGURE 2. EXTERNAL RESERVOIR WATER LEVEL
THERMOSTAT ADJUSTMENT
Standard Thermostat
The following procedure should be followed to adjust the standard thermostat:
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1. Push the “SET” button located to the right of the digital display. The current set-point will be displayed.
2. Push the “UP” or “DOWN” button until the desired set-point is displayed.
3. After approximately 3 seconds, the display will show the system water temperature. The set-point can be
viewed at any time by pressing the “SET” button.
The thermostat has a range that has been pre-set at the factory. The range is 40° F (5° C) to 100° F (38° C). If
operation outside of this range is required, please contact the Remcor Technical Service Department.
UP
5
F
DOWN
SET
CHILLER MAINTENANCE
WARNING: Disconnect electrical power to the Chiller to prevent personal injury before
attempting any internal maintenance. Only qualified personnel should service the internal
components or electrical wiring.
Condenser
On air–cooled Chillers, the CONDENSER FINS should be cleaned by blowing compressed air through the con-
denser from the fan side. Dirt and debris accumulate on the condenser fins over time, and this build up can se-
verely reduce the performance of the Chiller. Cleaning of the CONDENSER COIL FINS should be done
approximately every three months, depending upon cleanliness of your application.
Fan Motor
On air–cooled Chillers, the condenser FAN MOTOR should be lubricated every 6 months with a few drops of
SAE 10 oil.
Pump Motor
The PUMP MOTOR should be lubricated with thirty drops of SAE 20 oil once a year.
Circulation System
The CIRCULATION SYSTEM should be drained and flushed periodically to avoid build up and a possible flow
restriction caused by contaminants.
Filters/Strainers
The STRAINER at the Chiller inlet should be removed and cleaned monthly.
The “Y” STRAINER, located inside the unit at the inlet of the pump, should be cleaned periodically depending on
applications. If a reduction in flow or cavitation of the pump occurs, remove the strainer, flush it out with water,
then replace.
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FLUID RECOMMENDATION
Remcor Chillers are designed to operate with water to provide maximum performance for
temperatures of 40_F–100_F.
Distilled Water
Acceptable
Acceptable
De–Ionized Water
(1–5 MEG/OHMS)
De–Ionized Water
(5+MEG/OHMS)
Acceptable with Stainless Steel & PVC only
*No Copper or Brass
Propylene Glycol
(Lab & Industrial Grade)
Acceptable – 30% Glycol/70% Water
*For Applications with Temperatures below 40_F
Acceptable – 30% Glycol/70% Water
*For Applications with Temperatures below 40_F
Acceptable
Lab & Industrial Grade Ethylene Glycol
Mineral/Hydraulic Oils
(Viscosity<50 Centistrokes)
Ethylene Glycol
NOT Acceptable
(Commercial/Automotive Antifreeze)
*Silicate Rust Inhibitors in Automotive/Commer-
cial Antifreeze will damage pump seals and
housing which lead to failure.
Acidic/Basic Solutions
(Above 8/Below 6 PH)
Not Acceptable
Mineral/Hydraulic Oils
Not Acceptable
(Viscosity>50 Centistrokes)
For questions regarding special or other fluids contact IMI Cornelius Remcor at
800–551–4423.
To Purchase Lab or Industrial Glycol contact:
Hubbard Hall
IMI Cornelius
(800) 648–3412 – Dow Therm SR1 available in 5 gallon
(800) 551–4423 – Part# 111521000 5 gallons
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TROUBLESHOOTING
WARNING: Disconnect electrical power to the Chiller to prevent personal injury before
attempting any internal maintenance. Only qualified personnel should service internal
components or electrical wiring.
If repairs to the Chiller must be made, disconnect electrical power to the unit, then shut off the
water source.
TROUBLE
PROBABLE CAUSE
A. No Power To Unit.
REMEDY
CHILLER DOES NOT
OPERATE, CONTROL
POWER LIGHT “OFF”
A. Check Main disconnect fuses,
wiring, and power lead to unit.
B. Defective Control Power
Switch.
B. Replace Switch
C. Defective Control Transformer. C. Replace Transformer
D. Wrong Voltage Supplied to
Unit.
D. Supplied Voltage Must be within
± 10% of nameplate rating.
PUMP DOES NOT OPERATE, A. Line to or from Chiller is
A. Inspect lines and remove any
obstructions.
BUT POWER LIGHT IS “ON”.
restricted.
B. Internal or external filter is
blocked with debris.
B. Remove and clean strainer, then
replace.
C. Pump Contactor is
defective.
C. Replace Contactor.
D. Damaged pump motor or
impeller.
D. Replace pump motor or impeller.
A. Clean condenser.
UNIT RUNS CONTINUOUSLY, A. Condenser is restricted.
BUT IS NOT COOLING
PROCESS WATER ENOUGH.
B. Unit low on refrigerant.
C. Inefficient compressor.
B. Call Service.
C. Call Service.
D. Unit is undersized for
application.
D. Call REMCOR Chiller Sales Rep.
NOTE: When servicing a REMCOR Chiller, it is important to note all information provided on the DATA
PLATE located in the upper rear of the unit. If technical assistance is needed, the REMCOR Service
Technician will need this information along with any description of the problem(s) you are
encountering. The serial number and other information will also be required when ordering
replacement parts and any other Warranty Claims.
6
620914801
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COMPRESSOR
1
C
3
M
OVERLOAD
115/1/60
5
8
1
9
M
6
115V
24V
PUMP
FAN
7
M
4
S
R
M
COMPRESSOR
START
CAPACITOR
START RELAY
ELECTRICAL WIRING DIAGRAM
LIGHT, POWER ON
FIGURE 3. WIRING DIAGRAM (115V)
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COMPRESSOR
1
2
3
C
M
OVERLOAD
230/1/60
1
5
8
9
M
6
PUMP
FAN
230V
24V
7
M
4
S
R
M
COMPRESSOR
START
CAPACITOR
START RELAY
LIGHT, POWER ON
ELECTRICAL WIRING DIAGRAM
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4
17
2
16
1
6
3
14
15
7
5
8
10
18
11
12
13
9
FIGURE 5. CABINET SECTION EXPLODED VIEW
Item
Item
No.
Part No.
Name
No.
10
11
Part No.
Name
1
2
3
4
5
6
7
8
9
32386
TemperatureController
Power Switch
Evaporator
31962
Fan Motor
Fan Blade
31934
31488
61014
12
13
14
15
16
17
18
620023503
60576
Panel, Right Side
Condenser
620023502
51882
Wrapper Panel
Priming Reservoir Ass’y
Panel, Left Side
Compressor
33082
Relay
24388
32378
Transformer
60992
32588
Temperature Probe
Panel, Front
31955
Pump
620023504
24389
24390R
Base Ass’y
Shroud, Condenser
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WARRANTY
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un-
der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod-
uct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the
equipment model number, serial number and the date of purchase.
IMI Cornelius Offices
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552
D
FAX (32) 3 665 2307
BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829
ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644
FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201
GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (763) 421-6120 D FAX (763) 422-3255
LD004
4/21/98
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IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600
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