Cornelius Chiller ("CH" Series) CH 250 User's Manual
Contents
1. 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 620914801 COMPRESSOR L cs 115 1 60 q OVERLOAD l o 3 8 9 jx o e PUMP FAN av 2 7 ull S R Eu COMPRESSOR me 5 START START RELAY CAPACITOR ELECTRICAL WIRING DIAGRAM FIGURE 3 WIRING DIAGRAM 115V 7 620914801 H08716029 NVH9VIG SNIHIM 34N914 COMPRESSOR 1 3 5 6 c 2301 60 OVERLOAD 5 1 o 1 C o COMPRESSOR START START RELAY CAPACITOR N LIGHT POWER ON TEN ELECTRICAL WIRING DIAGRAM FIGURE 5 CABINET SECTION EXPLODED VIEW ke 10 11 12 13 14 15 16 17 18 620914801 WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workman2. 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 H250 H251 ooling Capacity BTU hr at 80 27 C and 3 000 879 3 000 879 70 F 21 C Liquid Temperature Pee ompressor Horsepower 25 2 kW 25 2 kW Electrical Data 115 1 60 230 1 60 Voltage Phase Hertz Amperage 7 5 Amps 3 8 Amps eee Refrigerant Type R134a R134a 38 Phvsical Dimensions Width X Depth 17 125 14 125 13 3 5 17 125 X 14 125 X 13 375 X Height 43 5 cm X 35 9 cm X 34cm 43 5 cm X 35 9 cm X 34cm tings ee Process Connections 1 2 FPT S S 1 2 FPT S S Opti
3. oc Rear ais 4 FAN MOTOR vz dou d DO diues 4 PUMP MOTOR innert 222 oT Pe TR Cn WIE e 4 CIRCULATION SYSTEM sssssesesse een ene teen eens 4 FIETERS STRAINERS he ad see cee alate era re haces 4 FLUID RECOMMENDATION 00 cece cece e eee eee eee ees 5 TROUBLESHOOTING B eo ea ee en eee aa 6 CHILLER DOES NOT OPERATE CONTROL POWER LIGHT OFF 6 PUMP DOES NOT OPERATE BUT POWER LIGHT IS 6 UNIT RUNS CONTINUOUSLY BUT IS NOT COOLING PROCESS WATER ENOUGEE as cur pert Ne OE ee BSE ae dae 6 WARRANTY us Bere Ha Hr I neh 9 FIGURE 1 SAMPLE DATA PLATE FIGURE 2 EXTERNAL RESERVOIR WATER LEVEL FIGURE 3 WIRING DIAGRAM 115V FIGURE 4 WIRING DIAGRAM 230V FIGURE 4 CABINET SECTION EXPLODED VIEW TABLE OF CONTENTS TABLE 1 DESIGN DATA 1 i 620914801 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
4. LAND 7 NEW ZEALAND 64 9 8200 357 FAX 64 9 8200 361 SINGAPORE 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA 763 421 6120 FAX 763 422 3255 LD004 4 21 98 620914801 10 CORNELIUS INC M M en CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 763 421 6120 800 238 3600 9 e 4801
5. QD IMI CORNELIUS REMCOR INC 500 REGENCY DRIVE GLENDALE HEIGHTS IL 60139 2268 Telephone 800 551 4423 Facsimile 800 519 4423 CHILLER 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 IMI CORNELIUS INC 1999 2002 PRINTED IN U S A TABLE OF CONTENTS Page GENERAL INFORMATION eeeeee enhn hh 1 INTRODUCTION 3 25 ohh Mean RUD UR Giu ed aie P RID 1 UNPACKING AND INSPECTION sssseee es 1 DESIGN tre cte al en he s i i erp d 1 DATA PLATE INFORMATION 0 0 0 RR RRRRRRRRRIRRRRRR RR IR IR In 1 CHILLER INSTALLATION sssene RR RRRRRRRRRRRIRRRRRRRRR IR 2 EOGATION OER GHIEEER aa de ale ra dda anes 2 ELECTRICAL CONNECTIONS ussesseseeses sara 2 START ns tecto ios a ics o aa doe a 2 PROCESS WATER FLOW UNITS WITH PUMP AND TANK STANDARD 2 PROCESS WATER FLOW UNITS WITHOUT RESERVOIR OPTIONAL 3 THERMOSTAT ADJUSTMENT 3 STANDARD THERMOSTAT 00 00 ccc eee ene ene n ene een eens 3 CHILLER MAINTENANCE 0 0 ccc RR RR RR n 4 CONDENSER t tee eee Ce oce i e ce
6. ators 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 WATER LEVEL EXTERNAL CHILLER RESERVOIR W O TANK CORRECT CHILLER CHILLER WATER LEVEL EXTERNAL EXTERNAL CHILLER WATER CHILLER RESERVOIR CHILLER RESERVOIR W O TANK LEVEL W O TANK W O TANK w u 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 3 620914801 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 t
7. e 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 620914801 4 FLUID RECOMMENDATION Chillers are designed to operate with water to provide maximum performance for temperatures of 40 F 100 F Distilled Water De lonized Water 1 5 MEG OHMS De lonized Water 5 MEG OHMS Propylene Glycol Lab amp Industrial Grade Lab amp Industrial Grade Ethylene Glycol Mineral Hydraulic Oils Viscosity lt 50 Centistrokes Ethylene Glycol Commercial Automotive Antifreeze Acidic Basic Solutions Above 8 Below 6 PH Mineral Hydraulic Oils Viscosity gt 50 Centistrokes Acceptable Acceptable Acceptable with Stainless Steel amp PVC only No Copper or Brass Acceptable 30 Glycol 70 Water Applications with Temperatures below 40 F Acceptable 30 Glycol 70 Water Applications with Temperatures below 40 F Acceptable NOT Acceptable Silicate Rust Inhibitors in Automotive Commer cial Antifreeze will damage pump seals and housing which lead to failure Not Acceptable Not Acceptable 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 Corneli
8. h 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 620914801 2 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 radi
9. he 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 E SET DOWN N 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 b
10. mum Process Liquid Flow GPM 0 6 2 72 0 6 2 72 Liters Min ondenser Air Flow CFM 225 225 DATA PLATE INFORMATION REN COR gt gt GLENDALE HEIGHTS IL 60139 2268 PART NO MODEL NO SERIAL NO VOLTS HZ PH AMPS RI34A MADE IN U S A BAR CODE FIGURE 1 SAMPLE DATA PLATE 1 620914801 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 temperat
11. ship 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 210 RIVERWOOD NSW 2210 AUSTRALIA 61 2 533 3122 FAX 61 2 534 2166 AUSTRIA AM LANGEN FELDE 32 A 1222 VIENNA AUSTRIA 43 1 233 520 FAX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE B49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 FRANCE 71 ROUTE DE ST DENIS F 95170 DEUIL LA BARRE PARIS FRANCE 33 34 28 6200 FAX 33 1 34 28 6201 GERMANY CARL LEVERKUS STRASSE 15 D 4018 LANGENFELD GERMANY 49 2173 7930 FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE AGIA PARASKEVI 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 KOK CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES P O BOX 19 044 AVONDALE AUCK
12. ure 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 wit
13. us 800 648 3412 Dow Therm SRI available in 5 gallon 800 551 4423 111521000 5 gallons 5 620914801 TROUBLESHOOTING attempting any internal maintenance Only qualified personnel should service internal WARNING Disconnect electrical power to the Chiller to prevent personal injury before 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 CHILLER DOES NOT OPERATE CONTROL POWER LIGHT OFF PUMP DOES NOT OPERATE BUT POWER LIGHT IS ON UNIT RUNS CONTINUOUSLY BUT IS NOT COOLING PROCESS WATER ENOUGH PROBABLE CAUSE No Power To Unit Defective Control Power Switch Defective Control Transformer Wrong Voltage Supplied to Unit Line to or from Chiller is restricted Internal or external filter is blocked with debris Pump Contactor is defective Damaged pump motor or impeller Condenser is restricted Unit low on refrigerant Inefficient compressor Unit is undersized for application REMEDY Check Main disconnect fuses wiring and power lead to unit Replace Switch Replace Transformer Supplied Voltage Must be within t 1095 nameplate rating Inspect lines and remove any obstructions Remove and clean strainer then replace Replace Contactor Replace pump motor or impeller Clean condenser Call Service Call Service Call REMCOR
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