CHILLERS

M

ODELS

: CH550

AND

CH551

Operator’s & Installation Manual

Release Date: August 9, 2002

Publication Number: 91272

Revision Date: May 10, 2010

Revision: D

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

CH SERIES CHILLER

OPERATOR’S & INSTALLATION MANUAL

The products, technical information and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact: www.cornelius.com

1-800-551-4423

This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.

Printed in U.S.A.

Copyright © 2002-2010, All Rights Reserved, IMI Cornelius Inc.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Start-Up/Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(Temperature Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Standard Thermostat Eliwell IC902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removing Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacing Swtich . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Replacing Fan Blade and/or Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Replacing Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fluid Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CH550 and CH551 Chiller Operator’s & Installation Manual

INTRODUCTION

The Cornelius “CH” Series Water Chillers (Models CH550-A and CH551-A) are specifically designed to cool clean water before it is circulated to the cooling application. The Unit includes a complete refrigeration system and associated controls housed in a sturdy sheet metal enclosure with perforated panels for air circulation.

Options include a reservoir and a choice of pumps and temperature controls to provide a self-contained liquid cooling circulation system tailored to a particular closed loop or tank application.

On closed loop systems, the Unit is provided with a pump and reservoir for recirculation of water from the chiller to the process. On tank cooling systems, the Unit is provided without the reservoir and the pump is optional for recirculation of water from the chiller to the tank. Control temperature is sensed on the outlet of the chiller for closed loop systems and it is sensed on the inlet of the chiller for tank cooling systems.

The pump options consist of a small magnetic drive pump as standard with a variety of magnetic drive and positive displacement pumps available for particular flow and pressure requirements. An optional bypass valve is available for the pump circulation system. (This valve is standard on Units utilizing the positive displacement pumps). This can be used to adjust pump flow and pressure to match process requirements. This valve also allows internal recirculation within the chiller in the event the chiller outlet is obstructed.

Condensing Unit Horse Power

Electrical (Volts/Phase/Hz)

F. L. A. (Amps)

Reservoir Capacity (Gal.)

Refrigerant 134-A (Lbs)

Stainless Steel Connections

Operating Water Temperature Range

Net Weight (Lbs)

Dimensions : Depth (Inches)

Width (Inches)

Height (Inches)

SPECIFICATIONS

CH550-A

1/2

115/1/60

12.5

2

1.375

1/2 in. FPT

40°-100° F

160

16-3/4

15-1/8

28-1/2

CH551-A

1/2

230/1/60

6.2

2

1.375

1/2 in. FPT

40°-100° F

160

16-3/4

15-1/8

28-1/2

© 2002-2010, IMI Cornelius Inc.

- 1 Publication Number: 91272

CH550 and CH551 Chiller Operator’s & Installation Manual

INSTALLATION INSTRUCTIONS

L

OCATION

Locate the chiller indoors in a well ventilated area with ambient temperatures in the range of 65° to 100° F. Allow a minimum of six inches of clearance around the chiller for proper air circulation. Avoid hot air discharge from other equipment or enclosed areas where heat could build up and cause a rise in ambient temperature.

P

LUMBING

Follow standard plumbing practices and local codes in making water connections. Piping that is exposed to high ambient temperatures may need to be insulated to prevent condensation and/or significant liquid heat gain. Hook up the outlet of the chiller but delay making the final connection to the inlet of the chiller until the system is filled with water (see START–UP/OPERATION).

E

LECTRICAL

All wiring must conform to the National Electric Code and any applicable local codes. The chiller must be:

1.

Permanently wired by means of conduit from the junction box in the rear of the chiller cabinet to a properly fused disconnect of proper amperage or:

2.

Wired to a properly rated power cord and plugged into an outlet with appropriate disconnect and amperage rating.

START-UP/OPERATION

Before the Unit can be operated, it is important that the circulating system be filled with water. On systems with a reservoir, ensure that the drain plug is in place and the plug is secure. Fill the reservoir through the fill port with water. The water level sight glass on the front panel will indicate “Full” when enough water has been added. Once full, make the final connection to the inlet and outlet of the chiller. On system without a reservoir, the pump should be primed before operation. Attach a water source to the inlet of the chiller and fill the Unit with clean water. The system is filled when the water can be seen flowing at the chiller outlet. Once full, make the final connection to the inlet of the chiller.

Turn the power switch to the “On” position. The switch illuminates indicating power to the Unit and the pump operates, the thermostat can be adjusted to the proper setpoint.

T

HERMOSTAT

(Temperature Controller)

Publication Number: 91272

Figure 1. Control Panel

- 2 © 2002-2010, IMI Cornelius Inc.

CH550 and CH551 Chiller Operator’s & Installation Manual

Standard Thermostat Eliwell IC902

The following procedure should be followed to adjust the Eliwell IC902 thremostat termperature setting:

1.

To set the SET POINT, press and release the SET button. SET displays.

2.

Press the SET button again, the current SET POINT is displayed. Press the UP or DOWN button to change the SET POINT to the desired temperature.

3.

Pres the fnc button twice to exit the program. The current liquid temperature is displayed.

The thermostat has a range that is 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 Cornelius Technical Service Department.

When the flow rate to the process is critical, a flow meter and valve should be installed in the line in order to obtain the proper flow rate. On Units with optional bypass valve, the aforementioned valve can be omitted and the flow can be adjusted with this valve. Turning the valve clockwise increases the flow to the process whereas turning the valve counterclockwise decrease the flow to the process.

Once these start–up procedures are complete, the chiller is ready for standard operation.

NOTE:

1.

Never operate the chiller with enclosure panels removed.

2.

Always use the illuminated switch to turn off the chiller when it is not being used.

3.

Always ensure that all air inlets and outlets are free of obstructions.

MAINTENANCE

WARNING: Disconnect electrical power to the chiller to prevent personal injury before attempting the following maintenance procedures.

The chiller requires very little normal maintenance. The condenser fins should be cleaned by blowing compressed air through the condenser. from the fan side as required to prevent blockage of air flow by dirt and debris that may accumulate over time. The positive displacement pump motor should be lubricated with thirty drops of SAE 20 oil once each year. The circulation system should be drained and flushed periodically to avoid build up and possible restriction of flow contaminants. Following these simple procedures will ensure many trouble free hours of chiller operation.

SERVICE

Service of the chiller is limited to replacing the switch, the thermostat, the fan motor, and the pump. Charging and other refrigeration problems must be performed by a qualified refrigeration technician.

Removing Wrapper

1.

Disconnect electrical power from the unit.

2.

Remove the seven screws from each side of the wrapper and the two screws that secure the wrapper to the front and back panels. Retain all hardware and lift the wrapper off the unit.

Replacing Swtich

1.

Remove the wrapper, as described in Removing Wrapper.

2.

Remove the spade lugs from the existing switch and note connection points.

3.

Remove the switch from the front panel.

4.

Install the new switch in the front panel and connect the leads to the new switch.

5.

Install the wrapper.

© 2002-2010, IMI Cornelius Inc.

- 3 Publication Number: 91272

CH550 and CH551 Chiller Operator’s & Installation Manual

Replacing Thermostat

1.

Remove the wrapper, as described in Removing Wrapper.

2.

Loosen the screw terminals securing the wires at the rear of the thermostat. Note connection points and remove the wires.

3.

Remove the screw securing the mounting bracket to the back of the thermostat.

4.

Remove the thermostat from the front panel.

5.

Install the new thermostat in the front panel and secure it with the mounting bracket.

6.

Reconnect the wires at back of the thermostat.

7.

Install the wrapper.

Replacing Fan Blade and/or Motor

1.

Remove the wrapper, as specified in Removing Wrapper.

2.

Remove the screws securing the fan guard to the fan shroud.

3.

Remove the conduit connection at the back of the motor and disconnect the wire leads.

4.

Remove the bolts securing the fan mounting bracket to the base and remove the fan/motor assembly.

5.

Separate the fan blade from the motor and install the new blade or motor.

6.

Re-install the fan mounting bracket and fan guard. Re-connect the wire leads and conduit connection.

7.

Install the wrapper.

Replacing Pump

1.

Remove the wrapper, as specified in Removing Wrapper.

2.

Remove the clamps and hoses from the suction and discharge of the pump.

3.

Remove the screws securing the pump to the base.

4.

Disconnect the wire leads from the pump motor and remove the pump.

5.

Remove all fittings from the pump and install them on the new pump.

6.

Install the pump and re-connect wire leads and hoses.

7.

Install the wrapper.

Publication Number: 91272 - 4 © 2002-2010, IMI Cornelius Inc.

CH550 and CH551 Chiller Operator’s & Installation Manual

FLUID RECOMMENDATION

Cornelius chillers are designed to operate with water to provide maximum performance for temperatures of 40° F

(4.4° C) to 100° F (37.8° C).

Distilled Water

De-Ionized Water

(1-5 Meg

ohms)

De-Ionized Water

(5+ Meg

ohms)

Propylene Glycol

(Lab & Industrial Grade)

Lab & Industrial Grade Ethylene Glycol

Mineral/Hydraulic Oils

(Commercial/Automotive Antifreeze)

Acceptable

Acceptable

Acceptable with Stainless Steel & PVC only (No Copper or Brass)

Acceptable - 30% Glycol/70% Water

(For Applications with Temperatures below 40° F)

Acceptable - 30% Glycol/70% Water

(For Applications with Temperatures below 40° F)

NOT Acceptable

(Silicate Rust Inhibitors in Automotive/Commercial antifreeze damages pump seals and housing which lead to failure.)

Acidic/Basic Solutions

(Above 8 or below 6 PH)

Mineral/Hydraulic Oils

(Viscosity > 50 Centistrokes)

Not Acceptable

Not Acceptable

For questions regarding special or other fluids contact IMI Cornelius at 800-551-4423.

To purchase Lab or Industrial Glycol contact:

IMI Cornelius, 1-800-551-4423 - Part No. 111521000, 5 Gal.

© 2002-2010, IMI Cornelius Inc.

- 5 Publication Number: 91272

CH550 and CH551 Chiller Operator’s & Installation Manual

TROUBLESHOOTING

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.

If repairs to the chiller must be made, disconnect electrical power to the unit, then shut off the water source.

Trouble

Chiller does not operate.

No circulation of chilled water.

Inadequate cooling.

Problem Cause

A. No Power to unit.

B. Loose or poor wire connection.

C. Inoperable On/Off switch.

D. Overlaod device open.

E. Inoperable relay.

F.

Low input voltage.

A. Line to or from chiller is restricted.

B. Low water level.

C. Inoperable pump.

A. Condenser is restricted.

B. Fan motor not operating freely.

C. Water not circulating.

D. Low refrigerant level.

Remedy

A. Check main disconnect fuses, wiring and power lead to unit.

B. Check wiring. Correct for loose or poor wire connection.

C. Replace switch

D. Allow compressor to cool, the install a new overload device; replace compressor if necessary.

E. Replace relay.

F.

Supplied voltage must be within

±10% of nameplate rating.

A. Inspect lines and remove any obstructions.

B. Ensure that tank is full.

C. Check for obstruction or binding impeller, replace pump and/or motor if necessary.

A. Clean condenser.

B. Replace fan blade and/or motor, if necessary.

C. See “No Circulation of Chilled

Water”.

D. Charge system with refrigerant.

E. Inoperative temperature control.

E. Replace thermostat.

Publication Number: 91272 - 6 © 2002-2010, IMI Cornelius Inc.

CH550 and CH551 Chiller Operator’s & Installation Manual

PARTS LIST

Item

No.

Figure 8. Cabinet Section Exploded View

Table 1. Cabinet Section

Table 1. Cabinet Section

Part No.

Name

Item

No.

Part No.

Name

1

2

3

4

31934

31935

32386

Switch, Illuminated (CH550), 115V

Switch, Illuminated (CH551), 230V

Thermostat, Eliwell No. EWPC902

620603708 Blade, Fan

620603711 Motor, Fan (CH550), 115V

620603709 Motor, Fan (CH551), 230V

* Condenser 5

6

7

8

Not Used

620603701 Compressor, (CH550), 115V

620603702 Compressor, (CH551), 230V

* Relay

9 *

10 61058

11 60514

Capacitor

TXV

Sight Glass

12 60502

13 61002

14 *

15

16 *

17 32378

32606

18

32607

Control, Low Pressure

Filter Drier

Reciever

Not Used

Pump, Circulating

Transformer, Thermostat

Contactor, Relay 115V

Contactor, Relay 230V

© 2002-2010, IMI Cornelius Inc.

- 7 Publication Number: 91272

CH550 and CH551 Chiller Operator’s & Installation Manual

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 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.

Publication Number: 91272 - 8 © 2002-2010, IMI Cornelius Inc.

IMI Cornelius Inc.

www.cornelius.com