Cornelius CH 551 Operator`s manual

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:
Operator’s Manual
CH 1001-A
CH 1501-A
CH 1502-A
CH 1503-A
Part No. 620914301
August 9, 2002
Revision D
Control Code A
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
DATA PLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
CHILLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
LOCATION OF CHILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHILLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
PROCESS WATER FLOW, UNITS WITH PUMP AND TANK (STANDARD) . . 4
PROCESS WATER FLOW, UNITS WITHOUT RESERVOIR (OPTIONAL) . . . 5
TEMPERATURE CONTROLLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
7
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FILTERS/STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 LIQUID
ENOUGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER DOES NOT OPERATE, BUT POWER LIGHT IS “ON” AND RED
SAFETY LIGHT IS “ON”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
10
10
10
10
11
19
LIST OF FIGURES
FIGURE 1. SAMPLE DATA PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. CH SERIES TEMPERATURE CONTROLLER . . . . . . . . . . . . . . . . . . .
FIGURE 5. EXTERNAL RESERVOIR WATER LEVEL . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. PROCESS WATER FLOW SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. REFRIGERATION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 8. WIRING DIAGRAM (CH 1001-A, 1501-A, 230/1/60) . . . . . . . . . . . . . .
FIGURE 9. WIRING DIAGRAM (CH 1001 230/1/60 FLOW SWITCH HIGH TEMP.
INTERLOCK, LOW LEVEL SWITCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 10. WIRING DIAGRAM (CH 1501 230/3/60, 460/3/60
FLOW SWITCH HIGH TEMP INTERLOCK, LOW LEVEL ALARM) . . . . . . . . . . .
FIGURE 11. CABINET SECTION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 12. ELECTRICAL BOX ASS’Y EXPLODED VIEW . . . . . . . . . . . . . . . . . .
1
2
3
3
5
12
12
13
14
15
16
18
LIST OF TABLES
TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
1
620914301
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 pure liquid and keep that liquid 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 water cooling and circulating 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. Request 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
CH1001–A
CH1501–A
Cooling Capacity:
BTU/hr (W) at 80_ F(27_ C) and
70_ F (21_ C) Liquid Temperature.
CH1502–A
CH1503–A
12,000 (3,515)
18,000 (5,272)
18,000 (5,272)
18,000 (5,272)
Compressor Horsepower
1 (.746 kW)
1 1/2 (1.12 kW)
1 1/2 (1.12 kW)
1 1/2 (1.12 kW)
Electrical Data:
Voltage/Phase/Hertz/Amperage
230/1/60
11.0 Amps
230/1/60
13.0 Amps
230/3/60
16.4 Amps
460/3/60
10.0 Amps
R134a
R22
R22
R22
Refrigerant Type:
Reservoir Capacity
6.0 gallons (22.7 6.0 gallons (22.7 6.0 gallons (22.7 6.0 gallons (22.7
liters)
liters)
liters)
liters)
Physical Dimensions, Width Depth 22I 26.5XI Height:
38.25I
(56cm 67cm
97cm)
Fittings:
Process Connections
3/4” FPT (S/S)
Optimum Process Liquid Flow GPM
2.4 (9.0)
(Liters/Min)
Condenser Air Flow (CFM)
712
22I 26.5XI 38.25I
(56cm 67cm
97cm)
22I 26.5XI 38.25I
(56cm 67cm
97cm)
22I 26.5XI 38.25I
(56cm 67cm
97cm)
3/4I FPT (S/S)
3.6 (13.6)
3/4I FPT (S/S)
3.6 (13.6)
3/4I FPT (S/S)
3.6 (13.6
1050
1050
1050
DATA PLATE INFORMATION
REMCOR PRODUCTS COMPANY
GLENDALE HEIGHTS, IL. 60139–2268
MADE IN U.S.A.
PART NO.
VOLTS
MODEL NO.
HZ
PH
SERIAL NO.
AMPS
R134A
BAR CODE
FIGURE 1. SAMPLE DATA PLATE
1
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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 information 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
(see Figure 2)
THE CHILLER MUST BE LOCATED NEAR A PROPERLY GROUNDED ELECTRICAL OUTLET. THE CIRCUIT 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
obstructions.
It is also important to direct any hot air discharge from other equipment away from the air intake side of the chiller. 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.
PRESS
GAUGE
FILL PORT
JUNCTION BOX
INLET
OUTLET
26–13/16
CONTROL
PANEL
37–11/16
37–5/16
30–1/2
19–7/16
21–15/16
FRONT VIEW
RESERVOIR
LEVEL
INDICATOR
DRAIN VALVE AND
PLUG (BEHIND PANEL)
SIDE VIEW
FIGURE 2. INSTALLATION
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2
REAR VIEW
Electrical Connections
(see Figure 2 and 8)
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.
CAUTION: On three-phase applications, it is important that the rotation of the pump, when
supplied , is correct. Operating the pump in reverse for more than a few seconds will result
in permanent pump damage. When the pump is operating, the shaft rotation must match the
direction indicated on the pump housing. If the rotation is incorrect, reverse two of the three
incoming power leads.
CHILLER OPERATION
CONTROL PANEL
(see Figure 3)
BLUE INDICATOR
POWER SWITCH
BYPASS
CONTROL
POWER
SAFETY
TEMPERATURE
CONTROLLER
RED INDICATOR
PRESS GAUGE
FIGURE 3. CONTROL PANEL
1. TEMPERATURE CONTROLLER (see Figure 4)
The TEMPERATURE CONTROLLER uses a PID control algorithm to precisely monitor and control the process set point temperature. The Unit has a large LED READOUT that displays temperature. For adjusting
set point and programming options, see section on TEMPERATURE CONTROLLER OPERATION.
70
FIGURE 4. CH SERIES TEMPERATURE CONTROLLER
3
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2. CONTROL POWER SWITCH/LIGHT (see Figure 3)
A lighted ON/OFF push button switch is used to switch power to the 24 VAC control circuit. The switch
lights up to indicate that the Chiller power is present.
3. BYPASS LIGHT (BLUE) (see Figure 3)
A blue light is used to indicate when the system is operating at a reduced capacity. The light will cycle on
and off in response to the Temperature Controller when the system temporarily requires less cooling.
4. SAFETY LIGHT (RED) (see Figure 3)
A red light is used to indicate that a fault has occurred in the Chiller operation. The following conditions will
illuminate the safety light.
A.
High refrigerant pressure.
B.
Low process water temperature.
C.
Low process water flow (optional, see OPTIONAL EQUIPMENT section).
5. HIGH–PRESSURE SAFETY (see Figure 3)
The high-pressure safety will shut down the compressor and pump when the refrigerant head pressure
reaches 240-PSIG for R–134A refrigerant units and 350–PSIG for R–22 refrigerant units. The high pressure switch must be reset manually. The switch is located in the electrical box which must be accessed by
removing the Chiller lid. The high-pressure switch can be re-set by depressing the reset button through the
opening in the electrical box cover. If the control opens again, check the setting with a set of refrigeration
gauges. If the setting is correct, contact the Remcor Technical Service Department.
LOW–TEMPERATURE SAFETY
The low–temperature safety will shut down the compressor and the pump when the process water temperature drops below 35_ F (1.7_ C). The switch will automatically reset when the water temperature is restored to 38_ F (3.3_ C). The low temperature control is located in the electrical box.
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 (see Fluid
Recommendations page).
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.
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
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 available is full, push the CONTROL POWER switch to the “ON” position. The pump should now be operating.
On three–phase units such as the CH1502–A and the CH1503–A, it is important to check the pump rotation.
Remove the left–side panel. Momentarily push the POWER button in and observe the motor shaft. Make sure
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4
that the shaft is rotating in the direction of the arrow indicated on the pump housing. If the rotation is incorrect,
reverse two of the three incoming power supply leads at the terminal strip.
NOTE: Operating the pump in reverse for more than a few seconds will result in permanent pump damage.
All Chillers with pumps and tank are supplied with a pressure regulating valve on the pump discharge. This
valve is preset at the factory to ensure that system pressure does not exceed the capabilities of the pump motor
and/or piping. If this valve requires adjustment, please contact the REMCOR Service Group for the proper setting procedure and pressures.
Process water flow can be adjusted VIA a throttling valve and flow meter installed in the Chiller outlet line.
Once the flow has been established, the thermostat can be programmed to the desired set–point.
Process Water Flow, Units Without Reservoir (Optional)
Follow standard plumbing practices and local codes in making liquid 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 liquid 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 5).
CHILLER
INLET
LINE
WATER
LEVEL
EXTERNAL
RESERVOIR
CHILLER
W/O TANK
CORRECT
CHILLER
INLET
LINE
CHILLER
INLET
LINE
WATER
LEVEL
CHILLER
W/O TANK
WATER
LEVEL
EXTERNAL
RESERVOIR
CHILLER
W/O TANK
CHILLER
INLET
LINE
CHILLER
W/O TANK
WATER
LEVEL
EXTERNAL
RESERVOIR
EXTERNAL
RESERVOIR
WATER LEVEL IS
BELOW CHILLER INLET
INCORRECT
AIR CAN BE TRAPPED IN
CHILLER INLET
INCORRECT
WATER FEEDING FROM
TOP OF TANK
INCORRECT
FIGURE 5. EXTERNAL RESERVOIR WATER LEVEL
5
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TEMPERATURE CONTROLLER OPERATION
(see Figure 4)
During normal operation, the process temperature will be displayed on the Controller. The following procedure
should be followed to adjust the Controller set point:
1. Push and hold the “ *” button located at the bottom left corner of the Controller. The set point will be displayed.
2. While holding the “ *” button, press
the desired value is displayed.
(“ UP” ) or
“ DOWN” button to raise or lower the set point until
3. Release the “ *” button. The display will again show the system liquid temperature. The set point can be
viewed at any time by pressing the “ *” button.
The Controller set point range has been preset at the factory. The range is 40_ F (5_ C) to 100_ F (38_ C). If
operation outside this range is required, contact the Remcor Technical Services Department.
OPTIONAL EQUIPMENT
LX Model–Is equipped with a low–level alarm and a high–temperature interlock as optional items.
EX Model–Is equipped with a low–level alarm, high–temperature interlock, low–flow interlock, and RS232 communications as optional items.
A detailed description of these options is as follows:
Low–Level Alarm–A float switch located in the water reservoir will activate an audible alarm when the tank level
drops below a critical level. It is important to note that this alarm will not shut down the system. The alarm will
sound until the unit reservoir has been refilled to the full line on the sight glass.
High–Temperature Interlock–A second output on the temperature controller will sense the process water temperature and energize a set of normally open terminals located inside the electrical junction box on the back of
the Chiller when the temperature exceeds a set limit above the set point. The high–temperature interlock is
preset at the Factory to activate at 25_ F (13.9_ C) above the process set point with a hysteresis of 3.6_ F (2.0_
C). If other values are required, please contact the Remcor Technical Services Department.
Low–Flow Interlock–A flow switch located in the Chiller water plumbing will sense when the process water flow
has dropped below 0.5 gpm. The flow switch will energize a set of normally open terminals located in the electrical junction box on back of the Chiller. The low flow condition will also shut down the compressor and pump coils
of the Chiller and illuminate the red fault indicator on the control panel. The Chiller will remain shut down and the
terminals open until full flow is restored to the Chiller.
NOTE: The interlock terminals should be connected to a load that is appropriate for the following:
1. High–Temperature Interlock uses a solid–state relay rated at 5 FLA, 30 LRA @ 240 VAC.
2. Low–Flow Interlock uses a mechanical relay rated at 6 FLA, 1/2 H.P. @ 277 VAC.
RS 232 Communications–Allows the Controller to be connected to a personal computer to monitor
and/or program the Controller from a remote location up to 50 feet (15 meters).
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.
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6
Condenser
On air–cooled Chillers, the CONDENSER FINS should be cleaned by blowing compressed air through the condenser from the fan side. Dirt and debris accumulate on the condenser fins over time, and this build up can severely 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
De–Ionized Water
(1–5 MEG/OHMS)
Acceptable
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
Lab & Industrial Grade Ethylene Glycol
Acceptable – 30% Glycol/70% Water
*For Applications with Temperatures below 40_F
Mineral/Hydraulic Oils
(Viscosity<50 Centistrokes)
Acceptable
Ethylene Glycol
(Commercial/Automotive Antifreeze)
NOT Acceptable
*Silicate Rust Inhibitors in Automotive/Commercial Antifreeze will damage pump seals and
housing which lead to failure.
Acidic/Basic Solutions
(Above 8/Below 6 PH)
Not Acceptable
Mineral/Hydraulic Oils
(Viscosity>50 Centistrokes)
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
(800) 648–3412 – Dow Therm SR1 available in 5 gallon
IMI Cornelius
(800) 551–4423 – Part# 111521000 5 gallons
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THIS PAGE LEFT BLANK INTENTIONALLY
9
620914301
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
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.
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PROBABLE CAUSE
REMEDY
A.
No Power To Unit.
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.
E.
3–Phase Monitor tripped.
E.
Check for correct voltage level on
each phase of incoming 3–phase
power. Check for correct phase
rotation.
F.
Blown Fuse.
F.
Replace Fuse (1 Amp).
A.
Line to or from Chiller is
restricted.
A.
Inspect lines and remove any
obstructions.
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.
Condenser is restricted.
A.
Clean condenser.
B.
Unit low on refrigerant.
B.
Call Service.
C.
Inefficient compressor.
C.
Call Service.
D.
Unit is undersized for
application.
D.
Call REMCOR Chiller Sales Rep.
E.
Bypass gas valve stuck open.
E.
Replace solenoid valve.
10
TROUBLE
CHILLER DOES NOT
OPERATE, BUT POWER
LIGHT IS “ON” AND RED
SAFETY LIGHT IS “ON”.
PROBABLE CAUSE
REMEDY
A.
Unit is operating under high
pressure conditions.
A.
Check for dirty condenser fins or
obstruction of chiller air intake.
Press high pressure manual reset
switch. If this problem persist,
contact Remcor Service
Department.
B.
Unit is operating under low
temperature conditions.
B.
Low or no process water flow.
Ensure that there is adequate flow
through system plumbing.
or
Process water is too cold, below
35_ F. Increase thermostat setting
or bypass valve stuck open.
Replace solenoid valve. Check for
proper voltage.
or
Defective thermostat, replace.
C.
Unit has experienced low flow
condition (LX and EX units).
C.
Check for obstruction in process
water line plumbing.
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.
11
620914301
PROCESS
RETURN
RESERVOIR
AUTO
BYPASS
T
F
PROCESS
SUPPLY
FLOW
SWITCH
(OPTIONAL)
EVAPORATOR
PROCESS CONTROL
TEMPERATURE SENSOR
T
LOW
TEMP
SAFETY
PUMP
FIGURE 6. PROCESS WATER FLOW SCHEMATIC
P
HIGH PRESSURE
CONTROL
COMPRESSOR
CONDENSER
FAN
EVAPORATOR
SIGHT
GLASS
FILTER/
DRYER
CONDENSER
COIL
TXV
HOT GAS
SOLENOID
F
FIGURE 7. REFRIGERATION SCHEMATIC
12
620914301
L1
L2
COND UNIT
M1
M1
GRN
M2
M2
PUMP
GRN
230V
24V
GRN
HOT GAS
6
Y
FUSE
1 AMP
OR
SOL
B
R
7
R
5
1
R
2
OR
Y
3
Y
LOW TEMP
SAFETY
4
V
5
V
6
W
M1
COMPRESSOR
COIL
V
HI PRESS
SAFETY
6
W
BL
6
W
M2
PUMP
BL
– BLUE INICATOR LIGHT
2
OR
R
– RED INICATOR LIGHT
W
– WHITE INICATOR LIGHT
6
W
POWER
LIGHT
2
OR
6
W
T
CONTROLLER
POWER
WIRE
COLOR CODING
B = BLACK
BL = BLUE
R = RED
OR = ORANGE
Y = YELLOW
G = GREEN
BR = BROWN
V = VIOLET
W = WHITE
W
8
2
R
B
A
6
W
AUD ALARM
LL SWITCH
NOTES:
1) CONDENSER FAN IS ONLY REQUIRED ON AIR COOLED UNITS.
2) THERMAL OVERLOADS ARE BUILT INTO THE COMPRESSORS.
3) SEE INSTRUCTION ON TRANSFORMER FOR HOOK UP.
4) LAST TERMINAL USED: 15
5) ITEMS IN
BOX ARE OPTIONAL.
6) COMPONENTS SHOWN IN DE–ENERGIZED CONDITION, WITH
EMPTY RESERVOIR.
FIGURE 8. WIRING DIAGRAM (CH1001–A, CH1501–A, 230/1/60)
13
620914301
M1
R
L1
L2
COMPRESSOR
B
M2
230V
PUMP
TRANSFMR
24V
SVHG
CT
Y
6
5 VDC
+
–
FU1
15
14
7
R
FL
PB
1
R
2
OR
BL
5
V
R
M1
SSR
R
R
12
FS
13
R
SSR RATING
5 FLA, 30 LRA @ 240V
HI-TEMP INTERLOCK
11
10
BL
BL
HP
6
W
M3
6
W
J
4
V
6
W
TR
2
OR
6
W
W
2
OR
M3
3
Y
M2
5 V
2
R
LOW FLOW RELAY
1/3 H.P., 240V. 10A.
LT
9
R
6
W
CAL
B
LOW FLOW
INTERLOCK
SSR
W
2
R
LLS
PUMP
8
R
A
LEGEND
M1 – COMPRESSOR CONTACTOR
M2 – PUMP RELAY
M3 – LOW FLOW INTERLOCK
PB – PUSHBUTTON
FL – FAILURE LIGHT
BL
BLUE INDICATOR LIGHT
R RED INDICATOR
LIGHT
SVHG – SOLENOID VALVE HOT GAS
BL – HOT GAS LIGHT
TR – BYPASS TIMER
LT – LOW TEMP THERMOSTAT
W WHITE INDICATOR
LIGHT
HP – HIGH PRESSURE CONTROL
FS – FLOW SWITCH
J – JUMPER
CAL – CAL ELECTRONIC THERMOSTAT
LLS – LOW LEVEL SWITCH
A – AUDIO ALARM
FU1 – FUSE
HTI – HIGH TEMP INTERLOCK
CT – CAL C. THERMOSTAT
SSR – SOLID STATE RELAY
NOTES:
WIRE COLOR CODING
W = WHITE
V = VIOLET
BR = BROWN
G = GREEN
Y = YELLOW
OR = ORANGE
R = RED
BL =
BLUE
B=
BLACK
1) CONDENSER FAN IS ONLY REQUIRED ON AIR COOLED UNITS.
2) THERMAL OVERLOADS ARE BUILT INTO THE COMPRESSOR.
3) SEE INSTRUCTIONS ON TRANSFORMER FOR HOOK–UP.
4) LAST TERMINAL USED: 15
5) ITEMS IN
BOX ARE OPTIONAL.
6) COMPONENTS SHOWN IN DE–ENERGIZED CONDITION WITH
EMPTY RESERVOIR.
FIGURE 9. WIRING DIAGRAM (CH1001 230/1/60 FLOW SWITCH HIGH TEMP.
INTERLOCK, LOW LEVEL SWITCH
620914301
6
W
6
W
14
6
W
L1
L2
L3
M1
BL
R
COMPRESSOR
B
G
CCH
230V
460V
M2
PUMP
TRANSFMR
24V
5 V DC
_
+
15
14
PB
FUI
SSR
12
7
R
FL
1
2
R
OR
5
R
10
11
FS
BL
LOW FLOW
INTERLOCK
LT
9
R
R
3
HP
Y
LP
4
M3
V
6
6
W
6
W
6
W
5 V
6
TR
W
R
2
6
W
W
OR
M3
M1
V
M2
2
LOW FLOW RELAY
1/3 HP @ 230V 10A
6
W
BL
13
SSR RATING =
5 FLA, 30 LRA @240V
HI TEMP INTERLOCK
BL
SVHG
CT
Y
CAL
2
OR
6
B
SSR
W
W
2
LLS
R
LEGEND
M1 – COMPRESSOR CONTACTOR
M2 – PUMP RELAY
M3 – LOW FLOW INTERLOCK
PB – PUSHBUTTON
FL – FAILURE LIGHT
SVHG – SOLENOID VALVE HOT GAS
BL – HOT GAS LIGHT
TR – BYPASS TIMER
LT – LOW TEMP THERMOSTAT
HP – HIGH PRESSURE CONTROL
FS – FLOW SWITCH
CAL – CAL ELECTRONIC THERMOSTAT
LLS – LOW LEVEL SWITCH
A – AUDIO ALARM
FUI – FUSE LAMP
HTI – HIGH TEMP INTERLOCK
CT – CAL C THERMOSTAT
SSR – SOLID STATE RELAY
CCH– CRANK CASE HEATER
8
R
BL
A
6
W
BLUE INDICATOR LIGHT
WIRE COLOR CODING
R
RED INDICATOR LIGHT
W
WHITE INDICATOR LIGHT
B = BLACK
BL = BLUE
R = RED
OR = ORANGE
Y = YELLOW
G = GREEN
BR = BROWN
V = VIOLET
W = WHITE
NOTES:
1. CONDENSER FAN IS ONLY REQUIRED ON AIR COOLED UNITS
2. THERMAL OVERLOADS ARE BUILT INTO THE COMPRESSOR
3. SEE INSTRUCTIONS ON TRANSFORMER FOR HOOK–UP
4. LAST TERMINAL USED: 15
5. ITEMS IN –––––– – –––––– – –––––– BOX ARE OPTIONAL
6. COMPONENTS SHOWN IN DE–ENERGIZED CONDITION WITH
EMPTY RESERVOIR
FIGURE 10. WIRING DIAGRAM CH1501 230/3/60, 460/3/60 FLOW SWITCH HIGH TEMP.
INTERLOCK, LOW LEVEL ALARM
620914301
15
6
21
16
10
17
8
9
15
23
11
13
1
2
5
26
12
22
14
18
19
25
24 20
7
4
FIGURE 11. CABINET SECTION EXPLODED VIEW
620914301
16
3
CABINET SECTION
Item
No.
Part No.
Item
No.
Name
Part No.
Name
1
620028005
Base, Pump/Tank
10
620306708
Electrical Box Ass’y
2
620028001
Panel, Front
11
41331
Y-Strainer
3
31036
Electrical Junction Box (DX Unit)
12
61003
TXV (Model CH1001–A)
15696
Electrical Junction Box (EX AND LX
Units)
13
60686
Filter Dryer
14
60687
Sight Glass
620604501
Condensing Unit (Model CH1001–A)
15
620602503
Evaporator Ass’y (Model CH1001–A)
620604403
Condensing Unit (Model CH1501–A)
16
620603201
Foamed Reservoir
620604402
Condensing Unit (Model CH1502–A)
17
22870
Fill Port (3/4-In. SS Coupling)
620604401
Condensing Unit (Model CH1503–A)
18
32806
Switch, Power
5
620028003
Panel, Side
19
620602701
Controller, Temperature
6
620028004
Lid, Chiller
20
620701209
Gauge, Pressure
7
620604302
Accumulator
21
620028002
Panel, Rear
8
32357
Pump (Model CH1001–A, CH1501–A
and CH1502–A)
22
620602703
620602704
Solenoid Valve, Hot Gas
Solenoid Coil, Hot Gas
32385
Clamp (Model CH1001–A, CH1501–A
and CH1502A)
23
40646
Bypass Valve, Water
32382
Motor (Model CH1001–A, CH1501–A
and CH1502–A)
24
32807
Indicator, Red
25
620311607
Indicator, Blue
33311
Motor, Pump (Model CH1503–A)
26
620028007
Base, Refrigeration
4
9
17
620914301
2
3
4
5
7
5
9
10
8
11
1
8
6
FIGURE 12. ELECTRICAL BOX ASS’Y EXPLODED VIEW
Item
No.
Part No.
Item
No.
Name
Part No.
Name
1
620028012
Enclosure, Electrical Box
6
620305802
Relay, Overload (460V)
2
32829R
Transformer
7
620307501
3
31001
Safety, Low Temp
Solid State Relay, High Temperature
(LX, EX)
4
60501
Safety, High Pressure
8
620305902
Compressor/Pump (460V) Contactor
5
33082
Pump/Low Flow Relay
9
33339
Audible Alarm, Low Level (LX, EX)
10
31407
Fuse Block
11
620313801
Bypass Timer
620914301
18
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 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
19
620914301
THIS PAGE LEFT BLANK INTENTIONALLY
17
620914301
IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600