Cornelius Remcor CH1500-A User manual

CHILLER (“CH”SERIES)
Operator’sManual
Models:CH 951-A
CH 1500-A
CH 1502-A
CH 1503-A
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1995--99Ó
IMICORNELIUSREMCORINC g500 REGENCYDRIVE gGLENDALEHEIGHTS, IL 60139--2268
Telephone [phone] Facsimile(800)519--4423
PartNo.92266
December5,1995
Revised:July,1999
Revision C
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i92266
TABLEOFCONTENTS
Page
GENERALINFORMATION1..................................................
INTRODUCTION1......................................................
UNPACKINGAND INSPECTION1........................................
DESIGN DATA1........................................................
CHILLERINSTALLATION1...............................................
LOCATIONOFCHILLER1..............................................
ELECTRICALCONNECTIONS2.........................................
PROCESS CONNECTIONS2...........................................
CHILLEROPERATION3................................................
PROCESS LIQUIDFLOW3.............................................
PHASE PROTECTION/3--PHASE MONITOROPTION3...................
PHASE PROTECTION/3--PHASE OPTIONADJUSTMENT3...............
COOLING OPERATION4................................................
TEMPERATUREINDICATOR/CONTROLLER(THERMOSTAT)4............
START--UP5...........................................................
THERMOSTATCONTROL 5.............................................
CHILLERMAINTENANCE5..............................................
CONDENSER5........................................................
FANMOTOR5.........................................................
PUMPMOTOR6.......................................................
CIRCULATIONSYSTEM6..............................................
FILTERS/STRAINERS6................................................
TROUBLESHOOTING7......................................................
CHILLER DOES NOTOPERATE,CONTROLPOWERLIGHT“OFF”7.........
PUMPDOES NOTOPERATE,BUTCOOLINGLIGHTIS”ON”.7..............
CHILLER DOES NOTCOOL,AND COOLINGLIGHTIS”OFF”.7.............
PUMPRUNS,COMPRESSOR”SHORTCYCLES”.7........................
UNITRUNSCONTINUOUSLY,BUTISNOTCOOLINGPROCESS LIQUID
ENOUGH.7............................................................
CHILLER DOES NOTOPERATE,BUTCOOLINGLIGHTIS“ON”AND SAFETY
LIGHTIS“ON”.8........................................................
WARRANTY14..............................................................
LISTOF FIGURES
FIGURE1.“CH”SERIES CHILLERS2.....................................
FIGURE2.CONTROLPANEL 4...........................................
FIGURE3.CH SERIES TEMPERATURECONTROLLER5...................
FIGURE4.CABINETSECTIONEXPLODEDVIEW9........................
FIGURE5.ELECTRICALBOX ASSEMBLY EXPLODEDVIEW11..............
FIGURE6.PUMP AND TANK ASSEMBLY12...............................
LISTOF TABLES
TABLE1.DESIGN DATA1...............................................

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GENERALINFORMATION
INTRODUCTION
The REMCOR”CH”SeriesRecirculating LiquidChillerisdesigned to provide an accurate,reliable,and user--
friendly systemforcoolingacontinuousflowofpureliquid and keep thatliquid ataconstant temperatureinvari-
ous closed loop ortank cooling applications.
The ”CH”SeriesChillerconsistsofan air--cooled refrigeration systemhoused in a sturdy sheetmetalframe and
cabinet. Astandard pump and insulated liquidreservoirpackage providesacompleteliquidcooling and circu-
lating system.
The ”CH”SeriesChillerisdesigned to operateinaclean laboratoryorindustrialenvironmentwhere ambient
temperaturesrange from40 to100° F(5to 38° C).With properinstallation,operation,and maintenance, the
”CH”SeriesChillerwill provide yearsof troublefree service.
UNPACKINGAND INSPECTION
Thisunitwasthoroughlyinspected beforeleaving the factoryand the carrierhasaccepted and signed forit.
Anydamage orirregularities should be noted at the time ofdeliveryand immediatelyreported tothe carrier.Re-
questawritten inspection report fromthe ClaimsInspectortosubstantiate anynecessary claims. Inthe event
thatan immediatereplacementisnecessary,pleasecontactREMCOR ChillerSalesat1--800--551--4423.
DESIGN DATA
Table 1.Design Data
CH951 CH1500 CH1502 CH1503
Cooling Capacity:
BTU/hr (W)at80_ F(27_ C)and
70_ F(21_C)LiquidTemperature.12,000 (3,515)18,000 (5,272)18,000 (5,272)18,000 (5,272)
CompressorHorsepower1(.746 kW)1 1/2(1.12 kW)1 1/2(1.12 kW)1 1/2(1.12 kW)
ElectricalData:
Voltage/Phase/Hertz/Amperage 230/1/60 11.0Amps230/1/60 13.0Amps230/3/60 16.4Amps460/3/60 10.0Amps
RefrigerantType:R134a R22 R22 R22
ReservoirCapacity6.0 gallons(22.7
liters)6.0 gallons(22.7 liters)6.0 gallons(22.7 liters)6.0 gallons(22.7 liters)
PhysicalDimensions,Width¢Depth
¢Height: 22I¢26.5XI¢ 38.25I
(56cm¢67cm
¢97cm)
22I¢26.5XI¢
38.25I
(56cm¢67cm
¢97cm)
22I¢26.5XI¢
38.25I
(56cm¢67cm
¢97cm)
22I¢26.5XI¢
38.25I
(56cm¢67cm
¢97cm)
Fittings:
Process Connections3/4”FPT(S/S)3/4IFPT(S/S)3/4IFPT(S/S)3/4IFPT(S/S)
CHILLERINSTALLATION
Location ofChiller
THECHILLERMUSTBELOCATED NEAR A PROPERLYGROUNDEDELECTRICALOUTLET.THECIR-
CUITSHOULD BEFUSED AND NO OTHERELECTRICALAPPLIANCE SHOULD BECONNECTEDTOTHE
CIRCUIT.ALL ELECTRICALWIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICAL
CODES.
The Chillermustbe located in a well ventilated,indoorarea where ambient temperatureswill remain above
40_ F(5_ C)and will neverincrease above 100_ F(38_ C).To obtain optimumcooling capacity, the ambient
temperatureshould be atorbelow80_ F(27_ C).

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It is veryimportant that the airintake and discharge sidesof the chillerare notobstructed byotherfree standing
objects.Aminimumof twofeetofspace on all foursidesof the chillerwill be sufficient to preventairflowob-
structions.
It isalsoimportant to directanyhotairdischarge fromotherequipmentawayfromthe airintakeside of the chill-
er.Condenserairentering the “CH”unitshould be below100_ F(38_ C).Condenserairtemperaturesabove
100_ F(38_ C)can causethe high pressuresafety controltoshutdownthe unit.
ElectricalConnections
All wiring mustconformtothe NationalElectricCode and anyapplicablelocalcodes.
The “CH”unitmustbe PERMANENTLYwired bymeansofelectricalconduit to a properlyfused disconnectof
properamperage OR wired to a properlyrated powercord and plugged into an outletwiththe appropriate dis-
connectand amperage rating.The electrical junction boxincludesafourterminalstripforpowersupply connec-
tions.The DATA PLATElocated beside the junction boxindicatesthe phase,voltage and amperage of the
chiller.
Process Connections
Followstandard plumbing practicesand localcodesinmaking liquidconnections.The Chillerinletand outlet
connectionsare 3/4”--inchFPTcouplings.Itisrecommended that3/4--inchI.D.orlargerflexible hose and tube
fittingsbe used asprocess connections.Lines shouldberouted with asfewbendsaspossible.Preventlines
fromrunning near radiators,hotwaterpipes,etc.Anylengthsof tubing thatare exposed to high ambient tem-
peratures shouldbeinsulated to preventcondensation and/orsignificantliquid heatgain.
Oncethe systemhasbeen properlyplumbed,itisimportant that the circulation systembe filled withliquid.The
reservoircan be filled byremoving the fill portcap located on top of the Chiller.Afterensuring that the drainis
closed, fill the reservoirviathe fill portwith pureliquid until the liquidlevelsightglass on the frontof the unitindi-
cates”FULL”.The fill portcap shouldthen be replaced priorto operation.
INTERLOCKSTRIP
(IFAPPLICABLE)
JUNCTIONBOX
DATA PLATE/SERIALNO.
OUTLET
TERMINALSTRIP
REAR
INLET
14.000
38.224
DRAIN
37.638 PRESSUREGAUGE
”FULL”
FRONT
35.138
21.963
RESERVOIRLEVELINDICATOR
FILL PORT
TEMPERATURECONTROLLER
CONTROLPANEL
FIGURE1.“CH”SERIES CHILLERS

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ChillerOperation
WARNING:NEVEROPERATETHECHILLERWITHTHE PANELSREMOVED.
ALWAYS USE THE POWERSWITCH TOTURN OFF THECHILLERWHENITISNOTBEING
USED.
ALWAYS ENSURETHATALL AIRINLETSAND OUTLETSAREFREE FROMOBSTRUCTION.
BE SURETHAT THERESERVOIRISFILLEDWITHFLUIDPRIORTOPOWERINGUPTHEUNIT.
Process Liquid Flow
Afterensuring that the systempiping isfree fromobstruction, thatall valvesare open,and the reservoirisfull,
pushthe CONTROLPOWERswitchtothe ”ON”position.The pumpshould nowbe operating.
Onthree phase units such asthe CH1502 and CH1503,itisimportant tocheck the pumprotation.Removethe
left side panel,pushthe POWERbutton in,and observethe motorshaft. Makesurethat the shaft isrotating in
the direction of the arrowindicated on the pump housing. If the rotation isincorrect, reversetwo of the three in-
coming powersupplyleadsat the terminalstrip.
NOTE:Running thepumpinreverse fortoo long will resultin permanentpump damage.ThePhase
Protection/3--Phase MonitorOption will prevent thepumpfromoperating backwards.See thefull de-
scription of theoption forcomplete explanation.
All Chillerswith pumpsaresupplied withapressureregulating valve on the pump discharge.This valveispre-
setat the factoryto ensurethatsystempressure doesnotexceed the capabilitiesof the pumpmotorand/orpip-
ing. If this valverequiresadjustment, pleasecontact the REMCORServiceGroup forthe propersetting
procedure and pressures.
Oncethe flowhasbeen established the thermostatcan be programmed tothe desired set--point.
Phase Protection /3--Phase MonitorOption
The 3--PhaseMonitordetectsphaseloss,lowvoltage,and phasereversalby continuouslymonitoring the
3--Phase powerlinesforabnormalconditions.When correctvoltage and phaserotation are applied, the internal
relaywill energize.Afaultcondition will de--energizethe relay.When the faultis corrected, the monitorwill auto-
maticallyreset. BothTripand Normcondition indicatorsare provided on the relayto aidin adjustmentand sys-
temtrouble--shooting.
This control islocated inthe enclosurelabeled “Monitor”on top of the electricalbox.
Phase Protection /3--Phase Option Adjustment
The following procedurewill allowthe 3--PhaseMonitorto achieve a trip pointjustbelowthe nominalphase-to-
phasevoltage,wherethe unitisapplied.
Rotatethe adjustmentcontrolfully clockwise,oruntil the red (Trip)indicatorilluminated.Slowlyrotatethe
adjustmentcontrol inacounter-clockwise direction,justuntil the green (Norm)indicatorilluminates.At thispoint,
the 3--PhaseMonitoristhe mostsensitivetoirregularpowerline conditions.Ifnuisancetripping occurs, turnthe
controlslightlyfurthercounter--clockwise.

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COOLING OPERATION
CONTROLPANEL
WHITEINDICATOR/PUSHBUTTON
GREENINDICATOR
REDINDICATOR
SAFETY
CONTROL
POWER
REMCORCHXXX SERIESCHILLER
COOLING
FIGURE2.CONTROLPANEL
TemperatureIndicator/Controller(Thermostat)
Combinesa precisetemperaturecontroland easy programmabilitywithaconvenientLEDtemperature
readout thatindicates systemliquidtemperature(2_ FDifferential).To adjust thermostat, see nextsection.
1.CONTROLPOWERSWITCH/LIGHT
AsimpleON/OFF push--button thatswitchespowertothe 24 voltcontrolcircuit. When the switchis
pressed, the whitelighton the push--button illuminatestoindicatethatChillerControlPowerispresent.
Lightisno longerilluminated when button isreturned to”OFF”position.
2.COOLINGLIGHT
Agreen light thatilluminatestoindicatethat the refrigeration systemisoperating.Thislightmay cycle on
and off inresponsetothe thermostatorinresponsetoHOTGAS BYPASS if the unitisequipped withthe
hot--gasbypass option.
3.SAFETYLIGHT
Ared light thatilluminatestoindicatethata problemispresentwiththe chiller.The safetylightwill illumi-
nate underthe following conditions:
A.High RefrigerantPressure
B.Low RefrigerantPressure
C.Low ReservoirLevel(Alarmalsosounds)
D.LowEvaporatorTemperature
It isimportant to notethateach of theseconditionswill shutdownthe ”CH”unit. Foradditionalprotection to
yourequipment, somemodelsare equipped with a LOWFLOWINTERLOCKwhichterminatespowerto
yourequipmentinthe event thatliquidflowfromthe ”CH”unitdropsbelow1.25 GPM.

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START--UP
ITISIMPORTANT THAT THELIQUIDLEVELSIGHTGLASS READS”FULL”. INTHE EVENT THAT THE
RESERVOIRIS EMPTY,THEUNITWILL REMAINOFF UNTILAN ADEQUATELEVELOF LIQUIDISAT-
TAINED.MAKE SURECHILLERPOWERIS”OFF”PRIORTOFILLINGRESERVOIR.
PushCONTROLPOWERbutton IN.All alarmindicators should be extinguished and the Chillersystemwill
cyclein ordertomaintainthe established set-point. The Chillerisnowreadyfornormaloperation.
ThermostatControl
70
up
set
downout
_F
FIGURE3.CH SERIES TEMPERATURECONTROLLER
The following procedureshould be followed to adjust the thermostat foranyliquidcooling application:
1.Pushthe ”SET”button located tothe rightof the digitaldisplay.Thiswill displaythe currentset-pointpro-
grammed inthe thermostat.
2.The set-pointcan onlybe adjusted while being displayed.To adjust the set-point, pushthe ”UP”or
”DOWN”button until the desired setpointisdisplayed on the thermostat.
3.Oncethe desired set-pointisdisplayed,waitseveralsecondsand the thermostatwill displaythe process
liquidtemperature.The set-pointcan be viewed atanytime bypressing the ”SET”button.
The parametersettingsof the thermostathave been presetat the factory.The range of the thermostatis
40_ F(5_ C)to 100_ F(38_ C). If operation outside of thisrange isdesired,pleasecontact the REMCOR
TECHNICALSERVICEDEPARTMENTat1--800--551--4423.
CHILLERMAINTENANCE
WARNING:Disconnectelectricalpowerbeforeperforming anymaintenance on theChiller.
Condenser
On aircooled chillers, the CONDENSERFINSshouldbecleaned byblowing compressed airthrough the con-
denserfromthe fan side.Dirtand debrisaccumulateonthe condenserfinsovertime,and thisbuild up can se-
verelyreducethe performance of the Chiller.Cleaning of the CONDENSERFINSshould be done
approximatelyeverythree months,depending upon the cleanliness ofyourapplication.
FanMotor
On aircooled chillersthe condenserFANMOTORshouldbelubricated every6monthswith a fewdropsofSAE
10 oil.

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PumpMotor
The PUMPMOTORshouldbelubricated withthirtydropsofSAE 20 oil once a year.
Circulation System
The CIRCULATIONSYSTEMshould be drained and flushed periodicallyto avoid build up and possibleflowre-
striction caused by contaminants.
Filters/Strainers
The FILTERlocated inside of the unitat the inletof the pumpshouldbecleaned periodicallydepending on ap-
plications. If areduction infloworcavitation of the pump occurs,removethe in--line FILTER,back-flushitwith
water,rinse,and replace.

7
9
2
2
6
6
TROUBLESHOOTING
WARNING:DisconnectelectricalpowertotheChillerto preventpersonal injurybefore
attempting anyinternalmaintenance. Onlyqualified personnelshouldservice internal
componentsorelectrical wiring.
TROUBLE PROBABLECAUSE REMEDY
CHILLER DOES NOT
OPERATE,CONTROL
POWERLIGHT“OFF”
A.NoPowerToUnit. A.Check Main disconnect fuses,
wiring,and powerlead to unit.
B.DefectiveControlPower
Switch.B.ReplaceSwitch
C.DefectiveControlTransformer.C.ReplaceTransformer
D.Wrong Voltage Supplied to
Unit. D.Supplied Voltage Mustbe within ±10%ofnameplaterating.
E.3--PhaseMonitortripped.E.Check forcorrectvoltage levelon
each phase ofincoming 3--phase
power.Check forcorrectphase
rotation.
PUMPDOES NOTOPERATE,
BUTCOOLINGLIGHTIS
”ON”.
A.Line to orfromChilleris
restricted.A. Inspectlinesand remove any obstructions.
B. Internalorexternalfilteris
blocked with debris.B.Removefilter,back-flush,and replace.
C.PumpContactoris
defective.C.Replace.
D.Damaged pumpmotoror
impeller.D.Replace pumpmotororimpeller.
CHILLER DOES NOTCOOL,
AND COOLINGLIGHTIS
”OFF”.
A.Thermostatisdefective.A.ReplaceThermostat
PUMPRUNS,COMPRESSOR
”SHORTCYCLES”.A.No process load on chiller.A. Increase process load.
B.Refrigerantislow.B.Check refrigerantcharge.
UNITRUNSCONTINUOUSLY,
BUTISNOTCOOLING
PROCESS LIQUIDENOUGH.
A.Condenserisrestricted.A.Clean condenser.
B.Unitlowon refrigerant. B.Call Service.
C. Inefficientcompressor.C.Call Service.
D.Unitisundersized for
application.D.Call REMCOR ChillerSalesRep.

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TROUBLEREMEDYPROBABLECAUSE
CHILLER DOES NOT
OPERATE,BUTCOOLING
LIGHTIS“ON”AND SAFETY
LIGHTIS“ON”.
A.Unitisoperating underhigh
pressureconditions.A.Check fordirty condenserfinsor obstruction ofchillerairintake.
Press high pressuremanualreset
switch.
B.Unitisoperating underlow
pressureconditions.B.Check sightglass,ifbubblesare seen,leak check unitand
recharge withrefrigerant.
or
If no bubblesareseen,replace
defectiveTXV.
C.Unitisoperating underlow
levelconditions.C.Add liquidtoreservoirviafill port. or
If level isaboveswitch,replace
floatswitch.
D.Unitisoperating underlow
temperatureconditions.D.Loworno process liquidflow. Ensurethat thereisadequateflow
through systemplumbing.
or
Process liquidistoo cold,below
35_ F. Increasethermostat
setting.
or
Defectivethermostat, replace.
When servicingaREMCOR Chiller,itisimportant to note all information provided on the DATA PLATElocated
inthe upper rearof the unit. If technicalassistanceisneeded, the REMCORServiceTechnician will need this
information along with anydescription of the problem(s)you are encountering.The serialnumberand other
information will alsoberequired when ordering replacementpartsand anyotherWarrantyClaims.