Remcor 416117 Service Manual
IMI CORNELIUS INC One Cornelius Place Anoka, MN 55303-6234
Telephone (800) 238-3600 Facsimile (612) 422-3246
Service Manual
REMOTE CONDENSING UNIT
(PART NUMBERS 416117 AND 496117)
Part No. 1128
June 11, 1991
Revised: March 1, 1995
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1991
PRINTED IN U.S.A
UNPACKING AND INSPECTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING REMOTE CONDENSING UNIT 2. . . . . . . . . . . . . . . . . . . . . .
SERVICE AND MAINTENANCE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CONDENSER COIL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
troubleshooting refrigeration compressor 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
compressor cools but is very noisy especially when stopping and starting 7. . . . .
COMPRESSOR COOLS, BUT IS MODERATELY NOISY; LOUD ENOUGH TO BE NOĆ
TICED, BUT NO SHARP BANGS OR CLATTERING 7. . . . . . . . . . . . . .
COMPRESSOR OPERATES BUT REFRIGERATION SYSTEM DOES NOT COOL . . .
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COMPRESSOR STARTS AND OPERATES FOR A FEW SECONDS, THEN STOPS . .
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COMPRESSOR WILL NOT START 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR STARTS BUT WILL NOT OPERATE FOR MORE THAN A FEW SECĆ
ONDS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor starts but will not operate for more than a few seconds (cont'd) 9.
troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING REMOTE CONDENSING UNIT 10. . . . . . . . . . . . . . .
COMPRESSOR DOES NOT OPERATE. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT COOL SUFFICIENTĆ
LY 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN MOTOR NOT OPERATING. 11. . . . . . . . . . . . . . . . . . . . . .
WARRANTY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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The Remote Condensing Unit P/N 416117 (230V, 60HZ) and P/N 496117 (230V, 50 HZ) consists basically of a
refrigeration compressor, a receiver tank, a fan cooled condenser coil, a head pressure control, and a
strainer/dryer mounted on an enclosed platform. The Remote Condensing Coil Unit (see FIGURE 1) is designed
to be used with any Evaporator Assembly with a rated temperature range of -10F to -32F. The Evaporator
Assembly is connected by refrigeration lines to and is refrigerated by the Remote Condensing Unit.
FIGURE 1. REMOTE CONDENSING UNIT
Table 1. Design Data
REMOTE CONDENSING UNIT
Part No.
230V, 60 HZ Unit 416117
230V, 50 HZ Unit 496117
Overall Dimensions:
Height 22-1/4 inches
Width 28-1/2 inches
Depth 25-3/4 inches
Shipping Weight (approx) 240 Pounds
Compressor Horsepower 2 H.P.
Ambient Operating Temperature –20 F to 120 F
Electrical Requirements:
Operating Voltage See Unit Nameplate
Current Draw See Unit Nameplate
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UNPACKING AND INSPECTION
NOTE: The Remote Condensing 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 time of delivery (or
not later than 15 days from date of delivery) and immediately reported to the delivering carrier. Request
a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with
the delivering carrier, not with IMI Cornelius Inc.
1. Unpack Remote Condensing Unit. Remove all shipping tape and packing materials.
2. Inspect and make sure Remote Condensing Unit is in good condition as instructed in preceding NOTE.
SELECTING LOCATION
Locate the Remote Condensing Unit so the following requirements are satisfied:
1. The Remote Condensing Unit must be installed in a location which will allow shortest possible refrigeration
lines route from Condensing Unit to the Evaporator Assembly.
2. Close to a properly grounded 208/230 VAC 60HZ or 220/240 VAC 50HZ single-phase electrical circuit with
a 30-amp minimum-rated disconnect switch (not provided) fused at 25-amps (‘‘slow-blow’’) or power circuit
connected through an equivalent HACR circuit breaker must be available to the Unit. Use No. 8 AWG copper wire, or larger, depending upon line length, in suitable conduit or BX sheath. POWER CIRCUIT MUST
BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND
LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED.
3. An extreme warm climate installation may require extra caution in Remote Condensing Unit location. Avoid
hot sunny locations and seek shaded area if possible. If Remote Condensing Unit is to be installed on the
rooftop, the use of a structure to shade the Unit from direct sun exposure and/or a platform extending Unit
an additional 18–inches above the is highly recommended and will improve performance. Ample space
(24 inches on all sides and 48 inches above Unit) must be provided for proper air circulation through the
Unit and also access for service and maintenance. DO NOT BLOCK AIR CIRCULATION THROUGH THE
UNIT.
4. If the Remote Condensing Unit is installed on the rooftop, the Unit must be installed in a level position and
must be anchored with adequate fastening devices.
INSTALLING REMOTE CONDENSING UNIT
(see Figures 2, 3, and 4)
1. Install Remote Condensing Unit meeting requirements of SELECTING LOCATION. The Unit must be
installed in a level position and must be anchored with adequate fastening devices.
NOTE: The following Refrigeration Lines Kits are recommended to connect the Remote Condensing
Unit to the Evaporator Assembly.
Part No. Description
300598025 Refrigeration Lines Kit, 25-ft. long 90
300598050 Refrigeration Lines Kit, 50-ft. long 90
2. Route refrigeration lines from Remote Condensing Unit to the Evaporator Assembly.
3. Connect ends of refrigeration lines to Remote Condensing Unit refrigeration connectors.
4. Remove four screws securing Remote Condensing Unit top cover, then remove cover for access to electrical control box.
5. Remove one screw securing electrical control box cover, then remove cover.
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WARNING: The Remote Condensing Unit must be electrically grounded to avoided
possible fatal electrical shock or serious injury to the operator. A green ground wire is
provided inside electrical control box to connect power circuit ground wire which
electrically grounds the Unit.
6. Connect 208/230 VAC 60HZ or 220/240 VAC 50 H
ments of SELECTING LOCATION) to L1 and L2 terminals on contactor inside the Unit electrical control box
as shown in FIGURE 4. MAKE SURE POWER CIRCUIT GREEN GROUND WIRE IS INSTALLED UNDER
GREEN GROUND SCREW INSIDE ELECTRICAL CONTROL BOX TO PROPERLY GROUND THE UNIT.
POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.
7. A 24 VAC power circuit, which must conform to national and local electrical codes, must be routed and
connected between the Evaporator Assembly Temperature Control and the Remote Condensing Unit. Purpose of the 24VAC power control circuit is to allow the Evaporator Assembly Temperature Control to control ‘‘ON’’ and ‘‘OFF’’ operation of the Remote Condensing Unit. Route and connect 24VAC power control
circuit between the Evaporator Assembly and the Remote Condensing Unit as follows:
A. Route 24 VAC power control circuit electrical wires through hole in end panel to inside of the Remote
Condensing Unit.
B. Connect 24 VAC power control circuit electrical wires to labeled 24 V grey and red wires hanging out
of the electrical control box.
C. Install electrical control box cover and secure with screw.
D. Route 24VAC power control circuit from Remote Condensing Unit to the Evaporator Assembly loca-
tion.
E. Refer to manual provided with the Evaporator Assembly for instructions to connect 24VAC power cir-
cuit to Evaporator Assembly Temperature Control.
Single-Phase electrical power circuit (meeting require-
Z
SERVICE AND MAINTENANCE
WARNING: Disconnect electrical power to Remote Condensing Unit to prevent personal
injury before attempting any internal maintenance. Only qualified personnel should service
internal components or electrical wiring.
PERIODIC INSPECTION
Make sure Remote Condensing Unit Condenser Coil is free from debris. Restricting air through the condenser
coil will decrease the refrigeration systems cooling efficiency.
LUBRICATION
The Remote Condensing Unit condenser fan motor must be lubricated once every six months with S.A.E. 20W
oil. DO NOT OVER OIL.
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ELECTRICAL
CONTROL BOX
TOP COVER
TOP COVER
RETAINING SCREW(4)
COMPRESSOR
CONDENSER
COIL
CONDENSER
FAN MOTOR
REFRIGERATION
LINES CONNECTORS
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RECEIVER
TANK
FIGURE 2. PARTS IDENTIFICATION
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