Cornelius CH1001-A Installation Manual

CHILLER

MODELS: CH1001-A

Operator’s & Installation Manual

Release Date: August 9, 2002

Publication Number: 620914301

Revision Date: May 6, 2010

Revision: E

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.

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Design Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Data Plate Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chiller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Location of Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chiller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Power Switch/Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Bypass Light (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

High-Pressure Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Low-Temperature Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Process Water Flow, Units with Pumpt and Tank (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Temperature Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chiller MAintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Circulation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Filters/Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CH1001-A Chiller Operator’s & Installation Manual

GENERAL INFORMATION

INTRODUCTION

The Cornelius ”CH” Series Recirculating Water Chiller is designed to provide an accurate, reliable, and user­friendly system for cooling a continuous flow of pure liquid and keep that liquid at a constant temperature in
various closed loop or tank cooling applications.

The ”CH” Series Chiller consists of an air–cooled refrigeration system housed in a sturdy sheet metal frame and
cabinet. A standard pump and insulated water reservoir package provides a complete water cooling and
circulating system.

The ”CH” Series 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 insta llation, operation, an d maintenance, the ”CH”
Series 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. Request
a written inspection report from the Claims Inspector to substantiate any necessary claims. In the event that an
immediate replacement is necessary, please contact Cornelius Chiller Sales at 1–800–551–4423.

DESIGN DATA

Table 1. Design Data

CH1001-A

Cooling Capacity:
BTU/hr (W) at 80° F (27° C) and 70° F

(21° C)
Compressor Horse Power 1 (.746 kW)
Electrical Data:

Voltage/Phase/Hertz/Amperage
Refrigerant Type: R134a
Reservoir Capacity (Gal) 6.0 (22.7 liters)
Dimensions: Depth (inches)

Width (inches)

Height (inches)
Process Connections 3/4-inch FPT (S/S)
Optimum Process Liquid Flow GPM

(Liters/Min)
Condenser Air Flow (CFM) 712

12,000 (3,515)

230/1/60, 11 Amps

26-1/2 (67cm)

22 (56cm

38-1/4 (97cm)

2.4 (9.0)

DATA PLATE INFORMATION

Figure 1. Sample Data Plate

© 2002-2010, IMI Cornelius Inc. - 1 - Publication Number: 620914301

CH1001-A Chiller Operator’s & Installation Manual

When servicing a Cornelius 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 information
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.

NOTE: 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 CIRCUIT
SHOULD BE FUSED AND NO OTHER ELECTRICAL APPLIANCE SHOULD BE CONNECTED TO THE

CIRCUIT. ALL ELECThe chiller must be located in a well ventilated, indoor area where ambient temperatures will

remain above 40° F (5° C) and never increase ab ov e 10 0° F (3 8° 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 obstructions.

It is also important to direct any hot air discharge from other equipment away from the air intake side of the chiller .
Condenser air entering the “CH” unit 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 un it.

Figure 2. Installation

ELECTRICAL CONNECTIONS

All wiring must conform to the National Electric Code and an y 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 prop erly rated
power cord and plugged into an outlet with the appropriate disconnect and amperage rating. The electrica l junction
box, located on the back panel of the chiller, includes a four terminal strip for power supply connection, as shown in
Figure 2 and

Publication Number: 620914301 - 2 - © 2002-2010, IMI Cornelius Inc.