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IMI CORNELIUS INC
Telephone (800) 551–4423 Fax (800) 394–5140
CHILLER
Models: CH1500–CH7500
Operator’s Manual
with Installation,
Service, and Parts
Part No. 91961OPR
September 12, 2006
Revised: N/A
Revision: A
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; 2006
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TABLE OF CONTENTS Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES FIGURE 1. INSTALLATION DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION) . . . . . . . . . 5 FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION) 5 FIGURE 5. SAMPLE DAT
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GENERAL INFORMATION INTRODUCTION Remcor “CH” Series Refrigerated Recirculating Water Chillers are designed to provide a continuous flow of clean cooling water at a constant temperature and to handle a variety of closed loop and tank cooling applica- tions. The CH consists of a refrigeration system with associated operating controls housed in a sturdy sheet metal cabinet. A standard pump and reservoir package provides a complete self-contained water cooling and circulat- ing system. CH Chillers a
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INSTALLATION LOCATION Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 40F or rise above 110F. To obtain optimum cooling capacity, the ambient temperature should be 80F or below. Standard CH Chiller have air-cooled condensers. On air-cooled units it is important that the air intake and dis- charge are not obstructed. Avoid hot air discharge from other equipment or enclosed areas where heat build-up could cause a significant rise in ambien
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ELECTRICAL 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 upper rear of the Chiller, includes a four-terminal strip for power supply connections The DATA PLATE, located beside th
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Chiller with Reservoir The reservoir can be filled by removing the water fill cap located on the upper rear of the Chiller (See Fluid Rec- ommendations page). After ensuring that the drain valve is closed, fill the reservoir via the full port with clean water until the water level sight glass on the front of the unit indicates “FULL” the fill cap should then be rein- stalled before operation begins. Auto Refill Option If the Chiller is provided with the Auto Refill Option, install 1/4–inch or 1/
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RESERVOIR LOW TEMP. CONTROL FROM PROCESS CHILLER INLET EVAPORATOR TO PROCESS PUMP BYPASS VALVE CHILLER OUTLET FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD) FROM PROCESS CHILLER INLET TO PROCESS BYPASS VALVE LOW TEMP. CONTROL CHILLER OUTLET EVAPORATOR FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION) FROM PROCESS CHILLER INLET TO PROCESS LOW TEMP. CONTROL CHILLER OUTLET EVAPORATOR FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION) 91961OPR 5
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START UP WATER FLOW START-UP Chiller with Pump It is important to check the pump rotation on the three phase units. Remove the lower side panel to expose the pump. Turn the pump power switch to the “ON” position for a few seconds. Observe the motor shaft to ensure that it is turning in the direction indicated by the arrow located on the pump housing. If the rotation is incorrect, reverse two of the three incoming power supply leads at the terminal strip. After changing the leads, check the pump
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Dual Point Adjustment 1. To set the “SET POINT” for Level 1. Press and release the “SET” button, Re1 should be displayed. 2. Press the “SET” button, the current SET POINT TEMPERATURE should be displayed. Press the UP or DOWN button to change the SET POINT. 3. To set the “SET POINT” for Level 2. Press and release the “SET” button, Re2 should be displayed. 4. Press the “SET” button, the current SET POINT TEMPERATURE should be displayed. Press the UP or DOWN button to change the SET POINT. 5. Press
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3. CONTROL POWER LIGHT- A white light that indicates that Chiller control power is present. 4. COOLING LIGHT- A green light that indicates refrigeration system operation. This light cycles on and off in response to the thermostat. 5. HIGH PRESSURE ALARM LIGHT- A red light that indicates high refrigeration pressure. 6. LOW PRESSURE ALARM LIGHT- A red light that indicates low refrigeration pressure. 7. LOW TEMPERATURE ALARM LIGHT- A red light that indicates and abnormally low system fluid temper-
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MAINTENANCE CAUTION: Disconnect electrical power before performing any of the following maintenance procedures. The Chiller will require very little normal maintenance. 1. On AIR-COOLED Chillers, the condenser fins should be cleaned by blowing compressed air through the condenser from the fan side as required to eliminate any dirt or debris that may accumulate over time. This can severely reduce the performance of the Chiller. Cleanable air filters are available as an option. Contact the facto
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FLUID RECOMMENDATION Chillers are designed to operate with water to provide maximum performance for tempera- tures of 40F–100F. Distilled Water Acceptable De–Ionized Water Acceptable (1–5 MEG/OHMS) De–Ionized Water Acceptable with Stainless Steel & PVC only (5+MEG/OHMS) *No Copper or Brass Propylene Glycol Acceptable – 30% Glycol/70% Water (Lab & Industrial Grade) *For Applications with Temperatures below 40F Lab & Industrial Grade Ethylene Glycol Acceptable – 30% Glycol/70% Water *For Applic
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TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit. Trouble Probable Cause Remedy CHILLER DOES NOT A. Control power switch “off”. A. Turn the control power switch to OPERATE. CONTROL the “on” position. POWER LIGHT “OFF” B. No power. B. Check the fuse and circuit breaker. C. Defective power supply C. Check wiring and
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Trouble Probable Cause Remedy D. Refrigerant loss. D. Check the sight glass. If bubbles are seen flowing through it, the Chiller needs to be leak checked and recharged with refrigerant. E. Water bypass valve failed. E. Consult technical service department. F. Defective pump. F. Replace pump. HIGH PRESSURE ALARM A. Restricted condenser airflow. A. Clean the fins of the condenser LIGHT “ON”. and ensure that the air flow is not restricted. B. Defective condenser fan B. Check to ensure that the fan
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SERVICE When servicing a 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 requirements and refrigerant information. The Serial Number is also needed when replacement parts are being ordered or for any warranty claims. REMCOR PRODUCTS COMPANY GLENDAL
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SAFETY CONTROLS Each Chiller is provided with three standard safety controls. These controls are arranged in series in the control circuit to automatically shut down the unit in the event that a condition exists which could be harmful to the re- frigeration system components. This section includes a brief description of each control, its location and some troubleshooting hints that may be helpful. HIGH PRESSURE CONTROL (HPC) This control prevents system operation in the event that the high side
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LIQUID LINE SIGHT GLASS SOL. VALVE FILTER/DRIER TXV LIQUID RECEIVER EVAPORATOR HOT GAS TXV EQUALIZER BYPASS LINE VALVE CONDENSER TXV SENSING BULB COMPRESSOR LOW PRESSURE HIGH PRESSURE SWITCH SWITCH FIGURE 6. REFRIGERATION PIPING SCHEMATIC WITH HOT GAS BYPASS SIGHT GLASS FILTER/DRIER TXV LIQUID RECEIVER TXV EQUALIZER LINE EVAPORATOR CONDENSER TXV SENSING BULB COMPRESSOR HIGH PRESSURE LOW PRESSURE SWITCH SWITCH FIGURE 7. REFRIGERATION PIPING SCHEMATIC WITHOUT HOT GAS BYPASS 17 91961OPR
