Cornelius Refrigerator CH 250 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)  
Models: CH 250  
CH 251  
Operator’s Manual  
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  
PRINTED IN U.S.A  
IMI CORNELIUS INC; 1999–2002  
 
GENERAL INFORMATION  
INTRODUCTION  
The REMCOR CHSeries 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 CHSeries Chiller consists of an aircooled 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 circu-  
lating system.  
The CHSeries 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  
CHSeries 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. Re-  
quest 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 18005514423.  
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  
17.125X 14.125X 13.375”  
(43.5 cm X 35.9 cm X 34cm)  
17.125X 14.125X 13.375”  
(43.5 cm X 35.9 cm X 34cm  
Fittings:  
Process Connections  
Optimum Process Liquid Flow GPM  
(Liters/Min)  
1/2FPT (S/S)  
1/2I FPT (S/S)  
0.6 (2.72)  
0.6 (2.72)  
Condenser Air Flow (CFM)  
225  
225  
DATA PLATE INFORMATION  
REMCOR PRODUCTS COMPANY  
GLENDALE HEIGHTS, IL. 601392268  
PART NO.  
MODEL NO.  
PH  
SERIAL NO.  
VOLTS  
HZ  
AMPS  
R134A  
BAR CODE  
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 informa-  
tion 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 CIR-  
CUIT 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 ob-  
structions.  
It is also important to direct any hot air discharge from other equipment away from the air intake side of the chill-  
er. Condenser air entering the CHunit 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 its 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 avail-  
able is full, push the CONTROL POWER switch to the ONposition. 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  
WATER  
LINE  
LEVEL  
EXTERNAL  
RESERVOIR  
CHILLER  
W/O TANK  
CORRECT  
CHILLER  
INLET  
LINE  
CHILLER  
INLET  
LINE  
CHILLER  
INLET  
LINE  
WATER  
LEVEL  
WATER  
LEVEL  
EXTERNAL  
RESERVOIR  
EXTERNAL  
RESERVOIR  
WATER  
LEVEL  
CHILLER  
W/O TANK  
CHILLER  
W/O TANK  
CHILLER  
W/O TANK  
EXTERNAL  
RESERVOIR  
WATER LEVEL IS  
AIR CAN BE TRAPPED IN  
WATER FEEDING FROM  
BELOW CHILLER INLET  
CHILLER INLET  
TOP OF TANK  
INCORRECT  
INCORRECT  
INCORRECT  
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 SETbutton located to the right of the digital display. The current set-point will be displayed.  
2. Push the UPor DOWNbutton 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 SETbutton.  
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 aircooled Chillers, the CONDENSER FINS should be cleaned by blowing compressed air through the con-  
denser from the fan side. Dirt and debris accumulate on the condenser fins over time, and this build up can se-  
verely 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 aircooled 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 YSTRAINER, 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_F100_F.  
Distilled Water  
Acceptable  
Acceptable  
DeIonized Water  
(15 MEG/OHMS)  
DeIonized 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  
Acceptable 30% Glycol/70% Water  
*For Applications with Temperatures below 40_F  
Acceptable  
Lab & Industrial Grade Ethylene Glycol  
Mineral/Hydraulic Oils  
(Viscosity<50 Centistrokes)  
Ethylene Glycol  
NOT Acceptable  
(Commercial/Automotive Antifreeze)  
*Silicate Rust Inhibitors in Automotive/Commer-  
cial Antifreeze will damage pump seals and  
housing which lead to failure.  
Acidic/Basic Solutions  
(Above 8/Below 6 PH)  
Not Acceptable  
Mineral/Hydraulic Oils  
Not Acceptable  
(Viscosity>50 Centistrokes)  
For questions regarding special or other fluids contact IMI Cornelius Remcor at  
8005514423.  
To Purchase Lab or Industrial Glycol contact:  
Hubbard Hall  
IMI Cornelius  
(800) 6483412 Dow Therm SR1 available in 5 gallon  
(800) 5514423 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  
A. No Power To Unit.  
REMEDY  
CHILLER DOES NOT  
OPERATE, CONTROL  
POWER LIGHT OFF”  
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.  
PUMP DOES NOT OPERATE, A. Line to or from Chiller is  
A. Inspect lines and remove any  
obstructions.  
BUT POWER LIGHT IS ON.  
restricted.  
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. Clean condenser.  
UNIT RUNS CONTINUOUSLY, A. Condenser is restricted.  
BUT IS NOT COOLING  
PROCESS WATER ENOUGH.  
B. Unit low on refrigerant.  
C. Inefficient compressor.  
B. Call Service.  
C. Call Service.  
D. Unit is undersized for  
application.  
D. Call REMCOR Chiller Sales Rep.  
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.  
6
620914801  
 
COMPRESSOR  
1
C
3
M
OVERLOAD  
115/1/60  
5
8
1
9
M
6
115V  
24V  
PUMP  
FAN  
7
M
4
S
R
M
COMPRESSOR  
START  
CAPACITOR  
START RELAY  
ELECTRICAL WIRING DIAGRAM  
LIGHT, POWER ON  
FIGURE 3. WIRING DIAGRAM (115V)  
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COMPRESSOR  
1
2
3
C
M
OVERLOAD  
230/1/60  
1
5
8
9
M
6
PUMP  
FAN  
230V  
24V  
7
M
4
S
R
M
COMPRESSOR  
START  
CAPACITOR  
START RELAY  
LIGHT, POWER ON  
ELECTRICAL WIRING DIAGRAM  
 
4
17  
2
16  
1
6
3
14  
15  
7
5
8
10  
18  
11  
12  
13  
9
FIGURE 5. CABINET SECTION EXPLODED VIEW  
Item  
Item  
No.  
Part No.  
Name  
No.  
10  
11  
Part No.  
Name  
1
2
3
4
5
6
7
8
9
32386  
TemperatureController  
Power Switch  
Evaporator  
31962  
Fan Motor  
Fan Blade  
31934  
31488  
61014  
12  
13  
14  
15  
16  
17  
18  
620023503  
60576  
Panel, Right Side  
Condenser  
620023502  
51882  
Wrapper Panel  
Priming Reservoir Assy  
Panel, Left Side  
Compressor  
33082  
Relay  
24388  
32378  
Transformer  
60992  
32588  
Temperature Probe  
Panel, Front  
31955  
Pump  
620023504  
24389  
24390R  
Base Assy  
Shroud, Condenser  
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WARRANTY  
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un-  
der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod-  
uct, 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  
620914801  
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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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