Cornelius CH1500-CH7500 manual

CHILLER Models: CH1500–CH7500 Operator ’ s Manual with Installation, Service, and Parts PRINTED IN U.S.A IMI CORNELIUS INC; 2006 © IMI CORNELIUS INC T elephone (800) 551–4423 Fax (800) 394–5140 Part No. 91961OPR September 12, 2006 Revised: N/A Revision: A THIS DOCUMENT CONT AINS IMPORT ANT INFORMA TION This Manual must be read and understo[...]

i 91961OPR T ABLE OF CONTENTS Page GENERAL INFORMA TION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATION NOTES 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

ii 91961OPR T ABLE OF CONTENTS (cont’d) Page LIST OF FIGURES FIGURE 1. INST ALLA TION DET AILS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 2. CHILLER PLUMBING SCHEMA TIC WITH PUMP AND T ANK (ST ANDARD) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1 91961OPR GENERAL INFORMA TION INTRODUCTION Remcor “CH” Series Refrigerated Recirculating W ater 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[...]

2 91961OPR INST ALLA TION LOCA TION Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 40  F or rise above 1 10  F . T o obtain optimum cooling capacity , the ambient temperature should be 80  F or below . Standard CH Chiller have air-cooled condensers. On air-cooled units it is important[...]

3 91961OPR ELECTRICAL All wiring must conform to the National Electric Code and any applicable local codes. The Chiller must be PERMANENTL Y 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. Th[...]

4 91961OPR 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”[...]

5 91961OPR RESER VOIR LOW TEMP . CONTROL FROM PROCESS CHILLER INLET EV APORA T OR PUMP BYP ASS V AL VE CHILLER OUTLET T O PROCESS FIGURE 2. CHILLER PLUMBING SCHEMA TIC WITH PUMP AND T ANK (ST ANDARD) CHILLER INLET FROM PROCESS EV APORA T OR LOW TEMP . CONTROL CHILLER OUTLET T O PROCESS FIGURE 3. CHILLER PLUMBING SCHEMA TIC NO T ANK (OPTION) CHILLER[...]

6 91961OPR THIS P AGE LEFT BLANK INTENTIONALL Y[...]

7 91961OPR ST ART UP W A T ER FLOW ST A RT -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. T urn 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 loc[...]

8 91961OPR Dual Point Adjustment 1. T o 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 TEMPERA TURE should be displayed. Press the UP or DOWN button to change the SET POINT . 3. T o set the “SET POINT” for Level 2. Press and release the ?[...]

9 91961OPR 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 of f in response to the thermostat. 5. HIGH PRESSURE ALARM LIGHT - A red light that indicates high refrigeration pressure. 6. LOW PRESSURE AL[...]

10 91961OPR 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 de[...]

11 91961OPR FLUID RECOMMENDA TION Chillers are designed to operate with water to provide maximum performance for tempera- tures of 40  F–100  F. Distilled W ater Acceptable De–Ionized W ater (1–5 MEG/OHMS) Acceptable De–Ionized W ater (5+MEG/OHMS) Acceptable with Stainless Steel & PVC only *No Copper or Brass Propylene Glycol (Lab[...]

12 91961OPR W ARNING: If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit. TROUBLESHOOTING IMPORTANT : Only qualified personnel should service internal components or electrical wiring. T rouble Probable Cause Remedy CHILLER DOES NOT OPERA TE. CONTROL POWER LIGHT “OFF” A. Control power [...]

13 91961OPR T rouble Remedy Probable Cause 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. W ater bypass valve failed. E. Consult technical service department. F . Defective pump. F . Replace pump. HIGH PRESSURE ALARM LIGHT “ON”. A. Re[...]

14 91961OPR SER VICE 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 requireme[...]

15 91961OPR THIS P AGE LEFT BLANK INTENTIONALL Y[...]

16 91961OPR 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, it[...]

17 91961OPR TXV EQUALIZER LINE TXV SENSING BULB TXV EV APORA T OR LIQUID LINE SOL. V AL VE HOT GAS BYP ASS VA LV E COMPRESSOR LOW PRESSURE SWITCH HIGH PRESSURE SWITCH SIGHT GLASS FIL TER/DRIER LIQUID RECEIVER CONDENSER FIGURE 6. REFRIGERA TION PIPING SCHEMA TIC WITH HOT GAS BYP ASS TXV EQUALIZER LINE TXV SENSING BULB TXV EV APORA T OR COMPRESSOR LO[...]

18 91961OPR P ARTS LIST 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 4 10 FIGURE 8. CHILLER P ARTS BREAKDOWN Index No. Description 1 1/2” FPT Coupling 2 Thermowell, Low T emp. Thermostat (Not Shown) 3 Corner Cover 4 Side Panel 5 Rear Panel 6 Upper Front Panel 7 Lower Front Panel 8 Lid 9 Control Panel 10 FPT Coupling 1 1 T em[...]

19 91961OPR 1 2 3 4 5 FIGURE 9. PUMP AND T ANK COMPONENTS Index No. Description 1 Thermowell, T emperature Control 2 T emperature Probe 3 T ank Assembly Index No. Description 4 Pump 5 Pump Relief V alve ** Call the Service Department for proper pump identification.[...]

20 91961OPR 1 2 3 4 5 6 7 FIGURE 10. ELECTRICAL BOX COMPONENTS Index No. Description 1 Lo w T emperature Thermostat 2 Control T ransformer 3 Contactor , Compressor 4 High pressure Control 5 Low Pressure Control Index No. Description 6 Contactor , Pump 7 Overload Relay , 1.0 to 1.6A Overload Relay , 1.4 to 2.0A Overload Relay , 2.0 to 3.0A Overload [...]

21 91961OPR W ARRANTY 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 W ilshire prod- uct, in your country , please write, fax or telephone the IMI Cornelius office nearest you. Please provide[...]

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