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IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139–2268
Telephone (800) 551–4423 Facsimile (800) 519–4423
Operator’s Manual
CHILLER (“CH” SERIES)
Models: CH 250
CH 251
Part No. 620914801
February 16, 1999
Revised: August 12, 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
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TABLE OF CONTENTS
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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START UP 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCESS WATER FLOW, UNITS WITH PUMP AND TANK (STANDARD) 2. .
PROCESS WATER FLOW, UNITS WITHOUT RESERVOIR (OPTIONAL) 3. . .
THERMOSTAT ADJUSTMENT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD THERMOSTAT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER MAINTENANCE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN MOTOR 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP MOTOR 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCULATION SYSTEM 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILTERS/STRAINERS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLUID RECOMMENDATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHILLER DOES NOT OPERATE, CONTROL POWER LIGHT “OFF” 6. . . . . . . . .
PUMP DOES NOT OPERATE, BUT POWER LIGHT IS “ON”.6. . . . . . . . . . . . . . .
UNIT RUNS CONTINUOUSLY, BUT IS NOT COOLING PROCESS
WATER ENOUGH. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. SAMPLE DATA PLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. EXTERNAL RESERVOIR WATER LEVEL 3. . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. WIRING DIAGRAM (115V) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. WIRING DIAGRAM (230V) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. CABINET SECTION EXPLODED VIEW 8. . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
TABLE 1. DESIGN DATA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 water and keep it 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 liquid 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
CH250 CH251
Cooling Capacity:
BTU/hr (W) at 80_ F(27_ C) and
70_ F (21_ C) Liquid Temperature.
3,000 (879) 3,000 (879)
Compressor Horsepower .25 (.2 kW) .25 (.2 kW)
Electrical Data:
Voltage/Phase/Hertz/Amperage
115/1/60
7.5 Amps
230/1/60
3.8 Amps
Refrigerant Type: R134a R134a
Physical Dimensions, Width X Depth
X Height
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34cm)
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34cm
Fittings:
Process Connections 1/2” FPT (S/S)
Optimum Process Liquid Flow GPM
0.6 (2.72) 0.6 (2.72)
1/2I FPT (S/S)
(Liters/Min)
Condenser Air Flow (CFM) 225 225
DATA PLATE INFORMATION
REMCOR PRODUCTS COMPANY
GLENDALE HEIGHTS, IL. 60139–2268
MODEL NO. SERIAL NO.PART NO.
VOLTS AMPS
MADE IN U.S.A.
BAR CODE
R134AHZ PH
FIGURE 1. SAMPLE DATA PLATE
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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
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.
Electrical Connections
(see Figure 3)
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.
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.
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 (see Fluid
Recommendations page).
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
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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.
Process Water Flow, Units Without Reservoir (Optional)
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 water 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 2).
CHILLER
INLET
LINE
WATER
LEVEL
CHILLER
INLET
LINE
CHILLER
W/O TANK
WATER LEVEL IS
BELOW CHILLER INLET
INCORRECT
CHILLER
W/O TANK
WATER
LEVEL
EXTERNAL
RESERVOIR
EXTERNAL
RESERVOIR
CORRECT
CHILLER
INLET
LINE
CHILLER
W/O TANK
AIR CAN BE TRAPPED IN
CHILLER INLET
INCORRECT
WATER
LEVEL
EXTERNAL
RESERVOIR
CHILLER
INLET
LINE
CHILLER
W/O TANK
WATER FEEDING FROM
TOP OF TANK
INCORRECT
WATER
LEVEL
EXTERNAL
RESERVOIR
FIGURE 2. EXTERNAL RESERVOIR WATER LEVEL
THERMOSTAT ADJUSTMENT
Standard Thermostat
The following procedure should be followed to adjust the standard thermostat:
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1. Push the “SET” button located to the right of the digital display. The current set-point will be displayed.
2. Push the “UP” or “DOWN” button until the desired set-point is displayed.
3. After approximately 3 seconds, the display will show the system water temperature. The set-point can be
viewed at any time by pressing the “SET” button.
The thermostat has a range that has been pre-set at the factory. The range is 40° F (5° C) to 100° F (38° C). If
operation outside of this range is required, please contact the Remcor Technical Service Department.
UP
5
F
DOWN SET
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.
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)
De–Ionized Water
(5+MEG/OHMS)
Propylene Glycol
(Lab & Industrial Grade)
Lab & Industrial Grade Ethylene Glycol Acceptable – 30% Glycol/70% Water
Mineral/Hydraulic Oils
(Viscosity<50 Centistrokes)
Ethylene Glycol
(Commercial/Automotive Antifreeze)
Acidic/Basic Solutions
(Above 8/Below 6 PH)
Mineral/Hydraulic Oils
(Viscosity>50 Centistrokes)
Acceptable
Acceptable with Stainless Steel & PVC only
*No Copper or Brass
Acceptable – 30% Glycol/70% Water
*For Applications with Temperatures below 40_F
*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 (800) 648–3412 – Dow Therm SR1 available in 5 gallon
IMI Cornelius (800) 551–4423 – Part# 111521000 5 gallons
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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 PROBABLE CAUSE REMEDY
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.
A. No Power To Unit. A. Check Main disconnect fuses,
wiring, and power lead to unit.
B. Defective Control Power
Switch.
C. Defective Control Transformer. C. Replace Transformer
D. Wrong Voltage Supplied to
Unit.
A. Line to or from Chiller is
restricted.
B. Internal or external filter is
blocked with debris.
C. Pump Contactor is
defective.
D. Damaged pump motor or
impeller.
A. Condenser is restricted. A. Clean condenser.
B. Unit low on refrigerant. B. Call Service.
B. Replace Switch
D. Supplied Voltage Must be within
± 10% of nameplate rating.
A. Inspect lines and remove any
obstructions.
B. Remove and clean strainer, then
replace.
C. Replace Contactor.
D. Replace pump motor or impeller.
C. Inefficient compressor. C. Call Service.
D. Unit is undersized for
application.
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.
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D. Call REMCOR Chiller Sales Rep.
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115/1/60
COMPRESSOR
1
3
PUMP FAN
M
OVERLOAD
15
9
8
24V115V
7
M
6
C
4
M
COMPRESSOR
LIGHT, POWER ON
M
START RELAY
ELECTRICAL WIRING DIAGRAM
S
R
START
CAPACITOR
FIGURE 3. WIRING DIAGRAM (115V)
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COMPRESSOR
1
230/1/60
2
FIGURE 4. WIRING DIAGRAM (230V)
8
M
COMPRESSOR
3
PUMP FAN
4
M
OVERLOAD
5
8
24V230V
1
9
M
6
7
M
C
S
R
LIGHT, POWER ON
ELECTRICAL WIRING DIAGRAM
START RELAY
START
CAPACITOR
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4
16
1
12
18
14
17
10
6
3
7
5
8
11
2
15
13
FIGURE 5. CABINET SECTION EXPLODED VIEW
Item
No. Part No. Name
1 32386 Temperature Controller
2 31934 Power Switch
3 61014 Evaporator
4 620023502 Wrapper Panel
5 51882 Priming Reservoir Ass’y
6 24388 Panel, Left Side
7 60992 Compressor
8 31955 Pump
9 24390R Base Ass’y
9
Item
No. Part No. Name
10 31962 Fan Motor
11 31488 Fan Blade
12 620023503 Panel, Right Side
13 60576 Condenser
14 33082 Relay
15 32378 Transformer
16 32588 Temperature Probe
17 620023504 Panel, Front
18 24389 Shroud, Condenser
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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
D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930
AUSTRIA
D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307
BELGIUM
D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829
BRAZIL
ENGLAND
D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644
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
FRANCE
D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
GERMANY
D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491
GREECE
KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
HONG
D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, IT ALY D (39) 39 608 0817 D FAX (39) 39 608 0814
ITALY
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
NEW
SINGAPORE
SPAIN
USA
D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
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
D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (763) 421-6120 D FAX (763) 422-3255
LD004
4/21/98
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IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600
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