Cornelius CH 551 User's Manual
Contents
1. gt REMCOR IMI CORNELIUS REMCOR INC 500 REGENCY DRIVE zi GLENDALE HEIGHTS IL 60139 2268 Telephone 800 551 4423 Facsimile 800 519 4423 Operator s Manual CHILLER CHILLER SERIES Models CH550 and CH 551 Part No 91272 Revised August 9 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 INTRODUGTION c coos eee erwarten Ra RR eee SPECIFICATIONS a enigen een INSTALLATION INSTRUCTIONS aaa anenun eee nn nn nn LOCATION zeeman 2 aaa are pn PLUMBING er en ELECTRICAL na ale START UP OPERATION sunan eaaa nu nennen nn nn nenn nenn MAINTENANCE on ennn nn aaa a ne SERVICE ant Snaren team rented ion E E en a ga aga ka oe REMOVING WRAPPER en REPLACING SWITCH eeen REPLACING STANDARD THERMOSTAT REPLACING ELECTRONIC DIFFERENTIAL THERMOSTAT REPLACING FAN BLADE AND OR MOTOR REPLACING PUMP aaa genah a aa gag EA an gah a d ka Na ak E da a aia FLUID RECOMMENDATIONS saenu nee eee eenen TROUBLESHOOTING GUIDE neee CHILLER DOES NOT OPERATE NO CIRCULATION OF CHILLED LIQUID INADEQUATE COOLI2. FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA 763 421 6120 FAX 763 422 3255 LD004 4 21 98 91272 8 REMCOR CORPORATE HEADQUARTERS Remcor Incorporated 500 Regency Drive Glendale Heights IL 60139
3. 1 Never operate the chiller with enclosure panels removed 2 Always use the illuminated switch to turn off the chiller when it is not being used 3 Always ensure that all air inlets and outlets are free of obstructions MAINTENANCE following maintenance procedures A WARNING Disconnect electrical power from the Unit before performing any of the The chiller requires very little normal maintenance The condenser fins should be cleaned by blowing com pressed air through the condenser from the fan side as required to prevent blockage of air flow by dirt and de bris that may accumulate over time The condenser fan motor should be lubricated every six months with a few drops of SAE 10 oil The positive displacement pump motor should be lubricated with thirty drops of SAE 20 oil once each year The circulation system should be drained and flushed periodically to avoid build up and pos sible restriction of flow contaminants Following these simple procedures will ensure many trouble free hours of chiller operation SERVICE Service of the chiller is limited to replacing the switch the thermostat the fan motor and the pump Charging and other refrigeration problems must be performed by a qualified refrigeration technician REMOVING WRAPPER 1 Disconnect electrical power from the Unit 2 Remove the seven screws from each side of the wrapper and the two screws that secure the wrapper to the front and back panels Retain all hardware
4. NG eens PARTS LIST 2234 22 2 2 22 ER nen WARRANTY senen eenen eene eee 00909 ARR EW WE O ONNENN N LIST OF FIGURES FIGURE 1 CH550 AND CH551 EXPLODED VIEW 7 i 91272 INTRODUCTION The REMCOR CH Series Water Chillers Models CH550 A and CH551 A are specifically designed to cool clean water before it is circulated to the cooling application The Unit includes a complete refrigeration system and associated controls housed in a sturdy sheet metal enclosure with perforated panels for air circulation Op tions include a reservoir and a choice of pumps and temperature controls to provide a self contained liquid cool ing circulation system tailored to a particular closed loop or tank application On closed loop systems the Unit is provided with a pump and reservoir for recirculation of water from the chiller to the process On tank cooling systems the Unit is provided without the reservoir and the pump is optional for recirculation of water from the chiller to the tank Control temperature is sensed on the outlet of the chiller for closed loop systems and it is sensed on the inlet of the chiller for tank cooling systems The temperature control options consist of a general purpose digital thermostat and an electronic differential thermostat to satisfy the temperature control requirements Both options include a digital thermometer for moni toring system temperature The pump options con
5. and lift the wrapper off the Unit REPLACING SWITCH 1 Remove the wrapper as specified in REMOVING WRAPPER Remove the spade lugs from the existing switch and note connection points 2 3 Remove the switch from the front panel 4 Install the new switch in the front panel and connect the leads to the new switch 5 Install the wrapper REPLACING STANDARD THERMOSTAT 1 Remove the wrapper as specified in REMOVING WRAPPER 2 Loosen the screw terminals securing the wires at the rear of the thermostat Note connection points and remove the wires 3 91272 nl Od ON rte lt 0 Remove the screw securing the mounting bracket to the back of the thermostat Remove the thermostat from the front panel Install the new thermostat in the front panel and secure it with the mounting bracket Reconnect the wires at back of the thermostat Install the wrapper REPLACING ELECTRONIC DIFFERENTIAL THERMOSTAT 1 2 Remove the wrapper as specified in REMOVING WRAPPER Remove the two screws securing the thermostat cover and remove the cover Loosen the screw terminals securing all wires to the thermostat Note connection points and remove the wires If the Unit is provided with a digital display the ribbon cable should be removed from the thermostat The display can be replaced by depressing the plastic clips and removing it from the front panel Remove the two screws securing the thermostat to the fan shroud and remove the thermostat Se
6. ate of purchase IMI Cornelius Offices AUSTRALIA P O 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 B 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA 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 1 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 e VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES P O BOX 19 044 AVONDALE AUCKLAND 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 e BARCELONA SPAIN 34 3 640 2839
7. cure new thermostat to the fan shroud then re connect all wires and ribbon cable Replace cover Install the wrapper REPLACING FAN BLADE AND OR MOTOR 1 2 3 4 5 6 7 Remove the wrapper as specified in REMOVING WRAPPER Remove the screws securing the fan guard to the fan shroud Remove the conduit connection at the back of the motor and disconnect the wire leads Remove the bolts securing the fan mounting bracket to the base and remove the fan motor assembly Separate the fan blade from the motor and install the new blade or motor Re install the fan mounting bracket and fan guard Re connect the wire leads and conduit connection Install the wrapper REPLACING PUMP 1 SMO ON a ID Remove the wrapper as specified in REMOVING WRAPPER Remove the clamps and hoses from the suction and discharge of the pump Remove the screws securing the pump to the base Disconnect the wire leads from the pump motor and remove the pump Remove all fittings from the pump and install them on the new pump Install the pump and re connect wire leads and hoses Install the wrapper 91272 4 FLUID RECOMMENDATION Remcor 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 Oi
8. justed to the proper setpoint Set the standard digital thermostat to the desired setpoint as follows 1 Push the Set button located to the right of the digital display The current setpoint will show on the display 2 While the current setpoint is displayed push the Up or Down buttons until the desired setpoint shows on the display 3 Release all buttons The display will show the system water temperature after a few seconds The setpoint can be viewed at any time by merely pushing the Set button If the Unit is provided with the electronic differential thermostat the air probe will need to be located where am bient temperature is to be monitored The setpoint will then be the temperature of the probe If this thermostat is provided with a digital display the setpoint can be checked by pushing the Setpoint button located on the dis play Releasing this button will display the system water temperature 91272 2 When the flow rate to the process is critical a flow meter and valve should be installed in the line in order to ob tain the proper flow rate On Units with optional bypass valve the aforementioned valve can be omitted and the flow can be adjusted with this valve Turning the valve clockwise increases the flow to the process whereas turning the valve counterclockwise decrease the flow to the process Once these start up procedures are complete the chiller is ready for standard operation NOTE
9. k wiring Correct for loose or poor wire connection Replace ON OFF switch Allow compressor to cool then install new overload device replace compressor if necessary Replace relay Nominal voltage 10 is required Check tubing and remove kinks Ensure that tank is full Check for obstruction or binding impeller replace pump and or motor if necessary Blow dirt out of fins Lubricate and hand spin until fan rotates freely replace fan blade and or motor if necessary See NO CIRCULATION OF CHILLED WATER Charge system with refrigerant Replace thermostat 91272 1 2 3 4 7 PARTS LIST A 00 00 Of FIGURE 1 CH550 AND CH551 EXPLODED VIEW Switch Illuminated CH550 Switch Illuminated CH551 Motor Fan CH550 Motor Fan CH551 550 551 les o f z o 7 Pimp crear Bl fen CONTACT THE SERVICE DEPARTMENT FOR THE APPROPRI ATE PART NUMBERS 620909701 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 d
10. ls 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 For Applications with Temperatures below 40 F Acceptable 30 Glycol 70 Water For 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 Cornelius 800 648 3412 Dow Therm SR1 available in 5 gallon 800 551 4423 Part 111521000 5 gallons 91272 Trouble CHILLER DOES NOT OPERATE NO CIRCULATION OF CHILLED WATER INADEQUATE COOLING Probable Cause No power Loose or poor wire connection Inoperable ON OFF switch Overload device open Inoperable relay Low input voltage Vinyl tubing kinked Low water level Inoperable pump Condenser fins dirty Fan motor not operating freely Water not circulating Low refrigerant level Inoperative temperature control TROUBLESHOOTING GUIDE Remedy Check fuse or circuit breaker Chec
11. quid heat gain Hook up the outlet of the chiller but delay making the final connection to the inlet of the chiller until the system is filled with water see START UP OPERATION ELECTRICAL All wiring must conform to the National Electric Code and any applicable local codes The chiller must be 1 Permanently wired by means of conduit from the junction box in the rear of the chiller cabinet to a properly fused disconnect of proper amperage or 2 Wired to a properly rated power cord and plugged into an outlet with appropriate disconnect and amperage rating START UP OPERATION Before the Unit can be operated it is important that the circulating system be filled with water On systems with a reservoir ensure that the drain plug is in place and the plug is secure Fill the reservoir through the fill port with water The water level sight glass on the front panel will indicate Full when enough water has been added Once full make the final connection to the inlet and outlet of the chiller On system without a reservoir the pump should be primed before operation Attach a water source to the inlet of the chiller and fill the Unit with clean water The system is filled when the water can be seen flowing at the chiller outlet Once full make the final connection to the inlet of the chiller Turn the power switch to the On position The switch will light indicating power to the Unit and the pump will operate the thermostat can be ad
12. sist of a small magnetic drive pump as standard with a variety of magnetic drive and posi tive displacement pumps available for particular flow and pressure requirements An optional bypass valve is available for the pump circulation system This valve is standard on Units utilizing the positive displacement pumps This can be used to adjust pump flow and pressure to match process requirements This valve also allows internal recirculation within the chiller in the event the chiller outlet is obstructed SPECIFICATIONS Tama Condensing Unit Horse Power 1 2 1 2 Electrical Volts Phase Hz FLA Ames Reservoir Capacity Gal Refrigerant 134 A Lbs Stainless Steel Connections 1 2 inch FPT 1 2 inch FPT Operating Water Temperature Range 40 100 F 40 100 F Net Weight Lbs 125 125 Dimensions Depth inches Width inches Height inches 1 91272 INSTALLATION INSTRUCTIONS LOCATION Locate the chiller indoors in a well ventilated area with ambient temperatures in the range of 65 to 100 F Allow a minimum of six inches of clearance around the chiller for proper air circulation Avoid hot air discharge from other equipment or enclosed areas where heat could build up and cause a rise in ambient temperature PLUMBING Follow standard plumbing practices and local codes in making water connections Piping that is exposed to high ambient temperatures may need to be insulated to prevent condensation and or significant li
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