IMI CORNELIUS INC One Cornelius Place Anoka, MN 55303-6234 Telephone (800) 551–4423 Facsimile (800) 519–4423 CHILLER Models: CH1500–CH7500 Operator’s Manual Part No. 91961 July, 1997 Revised: August 9, 2002 Revision D THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC; 1997–2002 PRINTED IN U.S.
TABLE OF CONTENTS Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES FIGURE 1. INSTALLATION DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION) . . . . . . . . . 5 FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION) 5 FIGURE 5.
GENERAL INFORMATION INTRODUCTION Remcor “CH” Series Refrigerated Recirculating Water Chillers are designed to provide a continuous flow of clean cooling water at a constant temperature and to handle a variety of closed loop and tank cooling applications. The CH consists of a refrigeration system with associated operating controls housed in a sturdy sheet metal cabinet. A standard pump and reservoir package provides a complete self-contained water cooling and circulating system.
INSTALLATION LOCATION Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 40 F or rise above 110 F. To obtain optimum cooling capacity, the ambient temperature should be 80 F or below. Standard CH Chiller have air-cooled condensers. On air-cooled units it is important that the air intake and discharge are not obstructed. Avoid hot air discharge from other equipment or enclosed areas where heat build-up could cause a significant rise in ambient temperatures.
ELECTRICAL 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.
Chiller with Reservoir The reservoir can be filled by removing the water fill cap located on the upper rear of the Chiller (See Fluid Recommendations page). After ensuring that the drain valve is closed, fill the reservoir via the full port with clean water until the water level sight glass on the front of the unit indicates “FULL” the fill cap should then be reinstalled before operation begins.
RESERVOIR LOW TEMP. CONTROL FROM PROCESS EVAPORATOR CHILLER INLET TO PROCESS PUMP BYPASS VALVE CHILLER OUTLET FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD) FROM PROCESS CHILLER INLET LOW TEMP. CONTROL EVAPORATOR BYPASS VALVE CHILLER OUTLET TO PROCESS FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION) FROM PROCESS CHILLER INLET TO PROCESS LOW TEMP. CONTROL CHILLER OUTLET EVAPORATOR FIGURE 4.
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START UP WATER FLOW START-UP Chiller with Pump It is important to check the pump rotation on the three phase units. Remove the lower side panel to expose the pump. Turn the pump power switch to the “ON” position for a few seconds. Observe the motor shaft to ensure that it is turning in the direction indicated by the arrow located on the pump housing. If the rotation is incorrect, reverse two of the three incoming power supply leads at the terminal strip. After changing the leads, check the pump rotation.
Differential Thermostat Option If the Chiller is equipped with a DIFFERENTIAL THERMOSTAT, the air probe will need to be located where ambient temperature is to be monitored. The set-point will be the temperature sensed by this probe. This setpoint can be check by pushing the “SET-POINT” button located on the upper right of the digital display. Releasing this button will display the system water temperature.
MAINTENANCE CAUTION: Disconnect electrical power before performing any of the following maintenance procedures. The Chiller will require very little normal maintenance. 1. On AIR-COOLED Chillers, the condenser fins should be cleaned by blowing compressed air through the condenser from the fan side as required to eliminate any dirt or debris that may accumulate over time. This can severely reduce the performance of the Chiller. Cleanable air filters are available as an option.
FLUID RECOMMENDATION Remcor Chillers are designed to operate with water to provide maximum performance for temperatures of 40 F–100 F.
TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit. Trouble CHILLER DOES NOT OPERATE. CONTROL POWER LIGHT “OFF” PUMP DOES NOT OPERATE. PUMP POWER LIGHT “OFF” PUMP DOES NOT OPERATE. PUMP POWER LIGHT “ON”. CHILLER DOES NOT COOL. COOLING LIGHT “OFF”. Probable Cause Remedy A. Control power switch “off”. A.
Trouble HIGH PRESSURE ALARM LIGHT “ON”. LOW TEMPERATURE ALARM 91961 Probable Cause Remedy D. Refrigerant loss. D. Check the sight glass. If bubbles are seen flowing through it, the Chiller needs to be leak checked and recharged with refrigerant. E. Water bypass valve failed. E. Consult technical service department. F. Defective pump. F. Replace pump. A. Restricted condenser airflow. A. Clean the fins of the condenser and ensure that the air flow is not restricted. B.
SERVICE 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 information is found on the Data Plate along with the model number, voltage requirements and refrigerant information. The Serial Number is also needed when replacement parts are being ordered or for any warranty claims. See CHILLER WARRANTY PAGE. MADE IN U.
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SAFETY CONTROLS Each Chiller is provided with three standard safety controls. These controls are arranged in series in the control circuit to automatically shut down the unit in the event that a condition exists which could be harmful to the refrigeration system components. This section includes a brief description of each control, its location and some troubleshooting hints that may be helpful.
LIQUID LINE SOL. VALVE SIGHT GLASS FILTER/DRIER TXV LIQUID RECEIVER EVAPORATOR HOT GAS BYPASS VALVE TXV EQUALIZER LINE CONDENSER TXV SENSING BULB COMPRESSOR LOW PRESSURE SWITCH HIGH PRESSURE SWITCH FIGURE 6. REFRIGERATION PIPING SCHEMATIC WITH HOT GAS BYPASS SIGHT GLASS FILTER/DRIER TXV LIQUID RECEIVER TXV EQUALIZER LINE EVAPORATOR CONDENSER TXV SENSING BULB COMPRESSOR LOW PRESSURE SWITCH 91961 HIGH PRESSURE SWITCH FIGURE 7.
4 8 23 12 18 24 6 13 7 14 25 15 11 20 17 16 3 21 19 9 22 10 5 1 4 26 10 FIGURE 8. CHILLER PARTS BREAKDOWN Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Index No. Description 1/2” FPT Coupling Thermowell, Low Temp.
3 5 2 1 4 FIGURE 9. PUMP AND TANK COMPONENTS Index No. 1 2 3 91961 Description Thermowell, Temperature Control Temperature Probe Tank Assembly Index No. 4 5 Description Pump Pump Relief Valve ** Call the Remcor Service Department for proper pump identification.
4 5 1 2 6 7 3 FIGURE 10. ELECTRICAL BOX COMPONENTS Index No. 1 2 3 4 5 Index No. Description Low Temperature Thermostat Control Transformer Contactor, Compressor High pressure Control Low Pressure Control 6 7 19 Description Contactor, Pump Overload Relay, 1.0 to 1.6A Overload Relay, 1.4 to 2.0A Overload Relay, 2.0 to 3.0A Overload Relay, 2.8 to 4.4A Overload Relay, 4.0 to 6.
WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, 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 P.O.
IMI CORNELIUS INC.
