Cornelius CH 1503-A, CH, CH 1502-A, CH 1500-A User 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)
Operator’s Manual
Models: CH 951-A
CH 1500-A
CH 1502-A
CH 1503-A
Part No. 92266
December 5, 1995
Revised: July, 1999
Revision C
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1995--99Ó
PRINTED IN U.S.A
TABLE OF CONTENTS
GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNPACKING AND INSPECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESIGN DATA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER INSTALLATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF CHILLER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCESS CONNECTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER OPERATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCESS LIQUID FLOW 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PHASE PROTECTION / 3--PHASE MONITOR OPTION 3. . . . . . . . . . . . . . . . . . .
PHASE PROTECTION / 3--PHASE OPTION ADJUSTMENT 3. . . . . . . . . . . . . . .
COOLING OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE INDICATOR/CONTROLLER (THERMOSTAT) 4. . . . . . . . . . . .
START--UP 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT CONTROL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER MAINTENANCE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN MOTOR 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP MOTOR 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCULATION SYSTEM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILTERS/STRAINERS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
CHILLER DOES NOT OPERATE, CONTROL POWER LIGHT “OFF” 7. . . . . . . . .
PUMP DOES NOT OPERATE, BUT COOLING LIGHT IS ”ON”. 7. . . . . . . . . . . . . .
CHILLER DOES NOT COOL, AND COOLING LIGHT IS ”OFF”. 7. . . . . . . . . . . . .
PUMP RUNS, COMPRESSOR ”SHORT CYCLES”. 7. . . . . . . . . . . . . . . . . . . . . . . .
UNIT RUNS CONTINUOUSLY, BUT IS NOT COOLING PROCESS LIQUID
ENOUGH. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER DOES NOT OPERATE, BUT COOLING LIGHT IS “ON” AND SAFETY
LIGHT IS “ON”. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. “CH” SERIES CHILLERS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. CONTROL PANEL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. CH SERIES TEMPERATURE CONTROLLER 5. . . . . . . . . . . . . . . . . . .
FIGURE 4. CABINET SECTION EXPLODED VIEW 9. . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. ELECTRICAL BOX ASSEMBLY EXPLODED VIEW 11. . . . . . . . . . . . . .
FIGURE 6. PUMP AND TANK ASSEMBLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES
TABLE 1. DESIGN DATA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION
INTRODUCTION
The REMCOR ”CH” Series Recirculating Liqu id Chiller is designed to provide an accurate, reliable, and user-friendly system for cooling a continuous flow of pure liquid and keep that liquid a t a constant temperature in various closed loop or tank coolin g applications.
The ”CH” Series Chiller consists of an air--cooled refrigeration system housed in a sturdy shee t metal frame and
cabinet. A standard pump and insulated liqu id reservoir package provides a complete liquid cooling and circulating system.
The ”CH” Series Chiller is designed to operate in a clean laboratory or industrial environment where ambient
temperatures ran ge 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 be fore leaving the factory and the carrier has accepted and signed for it.
Any d amage 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 a n immediate replacement is necessary,please contact REMCOR Chiller Sales at 1--800--551--4423.
DESIGN DATA
T able 1. Design Data
CH951 CH1500 CH1502 CH1503
Cooling Capacity:
BTU/hr (W) at 80_ F(27_ C) and
70_ F (21_ C) Liq uid Temperature.
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
Refrigerant Type: R134a R22 R22 R22
Reservoir Capacity 6.0 ga llons (22.7
Physical Dimensions, Width ¢ Depth
¢ Height:
Fittings:
Process Conn ections 3/4” FPT (S/S) 3/4I FPT (S/S) 3/4I FPT (S/S) 3/4I FPT (S/S)
12,000 (3,515) 18,000 (5,272) 18,000 (5,272) 1 8,000 (5,272)
230/1/60
11.0 Amps
liters)
22I¢ 26.5XI¢
38.25I
(56cm ¢ 67cm
¢ 97cm)
230/1/60
13.0 Amps
6.0 gallons (22.7
liters)
22I¢ 26.5XI¢
38.25I
(56cm ¢ 67cm
¢ 97cm)
230/3/60
16.4 Amps
6.0 gallons (22 .7
liters)
22I¢ 26.5XI¢
38.25I
(56cm ¢ 67cm
¢ 97cm)
460/3/60
10.0 Amps
6.0 gallons (22.7
liters)
22I¢ 26.5XI¢
38.25I
(56cm ¢ 67cm
¢ 97cm)
CHILLER INSTALLATION
Location of Chiller
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 a rea 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).
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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 chille r 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.
Electrical Connections
All wiring must conform to the National Electric Code and any applicable local codes.
The “CH” unit must b e PERMANENTLY wired by means of electrical conduit to a properly fused disconnect of
proper amperage OR wired to a prop erly rated power cord and plugged into an outlet with the appropriate disconnect a nd amperage rating. The electrical junction box includes a four terminal strip for power supply connections. The DATA PLATE located beside the junction box indicates the phase, voltage and amperage of the
chiller.
Process Connections
Follow standard plumbing practices and local codes in making liquid connections. The Chiller inlet and outlet
connections are 3/4”--inch FPT couplings. It is recommended that 3 /4--inch I.D. or larger flexible hose and tube
fittings be used as process connections. 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 sign ificant liquid heat gain.
Once the system has been properly plumbed, it is important that the circulation system be filled with liquid. Th e
reservoir can be filled by removing the fill port cap located on top of the Chiller. After ensuring that the drain is
closed, fill the reservoir via the fill po rt with pure liquid until the liquid level sight glass on the front of the unit indicates ”FULL”. Th e fill port cap should then be replaced prior to operation.
DATAPLATE/SERIAL NO.
35.138
37.638
CONTROL PANEL
TEMPERATURE CONTROLLER
FILL PORT
PRESSURE GAUGE
”FULL”
RESERVOIR LEVEL INDICATOR
DRAIN
38.224
14.000
JUNCTION BOX
TERMINAL STRIP
INTERLOCK STRIP
(IF APPLICABLE)
OUTLET
INLET
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21.963
FRONT
REAR
FIGURE 1. “CH” SERIES CHILLERS
2
Chiller Operation
WARNING: NEVER OPERATE THE CHILLER WITH THE 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 WITH FLUID PRIOR TO POWERING UP THE UNIT.
Process Liquid Flow
After ensuring that the system piping is free from ob struction, that all valves are open, and the reservoir is full,
push the CONTROL POWER switch to the ”ON” p osition. The pump should now be operating.
On three phase units such as the CH1502 and CH1503, it is important to check the pump rotation. Remove the
left sid e panel, push the POWER button in, and observe the motor shaft. Make sure that the shaft is rotating in
the direction of the a rrow indicated on the pump housing. If the rotation is incorrect, reverse two of the three incoming power supply leads at the terminal strip.
NOTE: Running the pump in reverse for too long will result in permanent pump damage. The Phase
Protection/3--Phase Monitor Option will prevent the pump from operating backwards. See the full description of the option for complete explanation.
All Chillers with pumps are supplied with a pressure reg ulating valve on the pump discharge. This valve is preset a t the factory to ensure that system pressure does not exceed the capabilities of the pump motor and/or piping. If this valve requires ad justment, please contact the REMCOR Service Group for the proper setting
procedure and p ressures.
Once the flow has been established the thermostat can be p rogrammed to the desired set--point.
Phase Protection / 3--Phase Monitor Option
The 3--Phase Monitor detects phase loss, low voltage, and phase reversal b y continuously monitoring the
3--Phase power lines for abnormal conditions. When correct voltage and phase rotation are applied, the internal
relay will en ergize. A fault condition will de--energize the relay. When the fault is corrected, the monitor will automatically reset. Both T rip and Norm condition indicators are provided on the relay to aid in adjustment and sys-
tem trouble--shooting.
This control is located in the enclosure labeled “Monitor” on top of the electrical box.
Phase Protection / 3--Phase Option Adjustment
The following procedure will a llow the 3--Phase Monitor to achieve a trip point just below the nominal phase-tophase voltage, where the unit is applied.
Rotate the adjustment control fully clockwise, or until the red (Trip) indicator illuminated. Slowly rotate the
adjustment control in a counter-clockwise direction, just until the green (Norm) indicator illuminates. At this point,
the 3--Phase Monitor is the most sensitive to irregular power line condition s. If nuisance tripping occurs, turn the
control slightly further counter--clockwise.
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COOLING OPERATION
REMCOR CHXXX SERIES CHILLER
CONTROL
POWER
FIGURE 2. CONTROL PANEL
Temperature Indicator/Controller (Thermostat)
COOLING
WHITE INDICATOR/PUSH BUTTON
SAFETY
CONTROL PANEL
RED INDICATOR
GREEN INDICATOR
Combines a precise temperature control and easy programmability with a convenient LED temperature
readout that indicates system liquid temperature (2_ F Differential). To adjust thermostat, see next section.
1. CONTROL POWER SWITCH/LIGHT
A simple ON/OFF push--bu tton that switches power to the 24 volt control circuit. When the switch is
pressed, the white light on the push--button illuminates to indicate that Chiller Control Power is present.
Light is no longer illuminated when button is returned to ”OFF” position.
2. COOLING LIGHT
A gre en light that illuminates to indicate that the refrigeration system is operating. This light may cycle on
and off in response to the thermostat or in response to HOT GAS BYPASS if the u nit is equipped with the
hot--gas bypass option .
3. SAFETY LIGHT
A red light that illuminates to indicate that a problem is present with the chiller. The safety light will illumi-
nate under the following conditions:
A. High Refrigerant Pressure
B. Low Refrigerant Pressure
C. Low Reservoir Level (Alarm also sounds)
D. Low Evaporator Temperature
It is important to note that each of these conditions will shut down the ”CH” unit. For additional protection to
your equipment, some models are equipped with a LOW FLOW INTERLOCK which terminates p ower to
your equipment in the event that liquid flow from the ”CH” unit drops below 1.25 GPM.
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