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Cornelius CH550 Installation manual
CHILLERS
MODELS: 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up/Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Temperature Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Thermostat Eliwell IC902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Swtich . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Fan Blade and/or Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
SPECIFICATIONS
CH550-A
CH551-A
1/2
115/1/60
12.5
2
1.375
1/2 in. FPT
40°-100° F
160
16-3/4
1/2
230/1/60
6.2
2
1.375
1/2 in. FPT
40°-100° F
160
16-3/4
Width (Inches)
15-1/8
15-1/8
Height (Inches)
28-1/2
28-1/2
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)
© 2002-2010, IMI Cornelius Inc.
-1-
Publication Number: 91272
CH550 and CH551 Chiller Operator’s & Installation Manual
INSTALLATION INSTRUCTIONS
LOCATION
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.
PLUMBING
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).
ELECTRICAL
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.
THERMOSTAT
(Temperature Controller)
Figure 1. Control Panel
Publication Number: 91272
-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
Acceptable
De-Ionized Water
(1-5 Meg ohms)
Acceptable
De-Ionized 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)
Lab & Industrial Grade Ethylene Glycol
Acceptable - 30% Glycol/70% Water
(For Applications with Temperatures below 40° F)
NOT Acceptable
Mineral/Hydraulic Oils
(Commercial/Automotive Antifreeze)
(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)
Not Acceptable
Mineral/Hydraulic Oils
(Viscosity > 50 Centistrokes)
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
Remedy
A. No Power to unit.
A. Check main disconnect fuses,
wiring and power lead to unit.
B. Loose or poor wire connection.
B. Check wiring. Correct for loose
or poor wire connection.
C. Inoperable On/Off switch.
C. Replace switch
D. Overlaod device open.
D. Allow compressor to cool, the
install a new overload device;
replace compressor if necessary.
E. Inoperable relay.
E. Replace relay.
F.
F.
Low input voltage.
Supplied voltage must be within
±10% of nameplate rating.
A. Line to or from chiller is
restricted.
A. Inspect lines and remove any
obstructions.
B. Low water level.
B. Ensure that tank is full.
C. Inoperable pump.
C. Check for obstruction or binding
impeller, replace pump and/or
motor if necessary.
A. Condenser is restricted.
A. Clean condenser.
B. Fan motor not operating freely.
B. Replace fan blade and/or motor,
if necessary.
C. Water not circulating.
C. See “No Circulation of Chilled
Water”.
D. Low refrigerant level.
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
Figure 8. Cabinet Section Exploded View
Table 1. Cabinet Section
Table 1. Cabinet Section
Item
No.
1
2
3
4
5
6
7
8
9
10
11
Part No.
31934
31935
32386
620603708
620603711
620603709
Switch, Illuminated (CH550), 115V
Switch, Illuminated (CH551), 230V
Thermostat, Eliwell No. EWPC902
Blade, Fan
Motor, Fan (CH550), 115V
Motor, Fan (CH551), 230V
*
Condenser
Not Used
Compressor, (CH550), 115V
Compressor, (CH551), 230V
Relay
Capacitor
TXV
Sight Glass
620603701
620603702
*
*
61058
60514
Item
No.
Name
© 2002-2010, IMI Cornelius Inc.
Name
12
13
14
15
16
60502
61002
*
*
Control, Low Pressure
Filter Drier
Reciever
Not Used
Pump, Circulating
17
32378
32606
32607
Transformer, Thermostat
Contactor, Relay 115V
Contactor, Relay 230V
18
-7-
Part No.
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
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