Cornelius CH1500, CH7500 User Manual

Telephone [phone] Fax [phone]

Models: CH1500–CH7500

Operator’s Manual
with Installation,
Service, and Parts

IMI CORNELIUS INC

CHILLER

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

IMI CORNELIUS INC; 2006©

PRINTED IN U.S.A

TABLE OF CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATION NOTES 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PHASE PROTECTION / 3–PHASE OPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PHASE PROTECTION / 3–PHASE OPTION ADJUSTMENT 3. . . . . . . . . . . . . . .

PLUMBING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-COOLED CONDENSERS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHILLER WITH RESERVOIR 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO REFILL OPTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHILLER WITHOUT RESERVOIR 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START UP 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER FLOW START-UP 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHILLER WITH PUMP 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHILLER WITHOUT PUMP 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT ADJUSTMENT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD THERMOSTAT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DUAL POINT ADJUSTMENT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING START-UP 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

FLUID RECOMMENDATIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHILLER DOES NOT OPERATE. CONTROL POWER LIGHT “OFF” 12. . . . . . . . .

PUMP DOES NOT OPERATE. PUMP POWER LIGHT “OFF” 12. . . . . . . . . . . . . . .

PUMP DOES NOT OPERATE. PUMP POWER LIGHT “ON”. 12. . . . . . . . . . . . . . . .

CHILLER DOES NOT COOL. COOLING LIGHT “OFF”. 12. . . . . . . . . . . . . . . . . . . . .

CHILLER DOES NOT OPERATE. COOLING LIGHT “ON”. 12. . . . . . . . . . . . . . . . . .

A. LOW PRESSURE ALARM LIGHT CYCLES ON/OFF. 13. . . . . . . . . . . . . . . . . . . .

HIGH PRESSURE ALARM LIGHT “ON”. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOW TEMPERATURE ALARM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY CONTROLS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH PRESSURE CONTROL (HPC) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOW TEMPERATURE CONTROL (LTC) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOW PRESSURE CONTROL (LPC) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

91961OPR

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 DATA PLATE FOR CH5002-A 14. . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. REFRIGERATION PIPING SCHEMATIC WITH HOT GAS BYPASS 17

FIGURE 7. REFRIGERATION PIPING SCHEMATIC WITHOUT HOT GAS

BYPASS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. CHILLER PARTS BREAKDOWN 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. PUMP AND TANK COMPONENTS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. ELECTRICAL BOX COMPONENTS 20. . . . . . . . . . . . . . . . . . . . . . . . . .

91961OPR

ii

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 applica­tions.

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 circulat­ing system.

CH Chillers are designed to operate in a clean laboratory or industrial environment where ambient temperatures
range from 40F to 110F. Once properly installed, the CH Chiller will run virtually maintenance free and provide
a constant supply of cooling liquid to the application.

NOTE: Please read through this manual before starting the chiller.

SPECIFICATIONS

Model CH1500 CH2000 CH3000 CH5000 CH7500

Cooling Capacity* Watts/BTU

Compressor

Condenser

Temperature Controller

Pump**

Reservoir

Voltage (Full Load Amps)***

Dimensions W x D x H (inches)

Inlet/Outlet Fitting Size

5,570/19,000 8,500/29,000 12,000/41,000 18,000/61,500 25,800/85,000

1.5 H.P. 2 H.P. 3 H.P. 5 H.P. 7.5 H.P.

Air Cooled (Water Cooled Optional)

Digital Display 30–100 F (0–39C.)

Many Available

10 Gallons 40 Gallons

230/60/1(17)
230/60/3(13)

460/60/3(8)

230/60/3(13)

460/60/3(8)

28 x 28 41 36 x 36 x 65

3/4–inch 1–inch

230/60/3(16)
460/60/3(10)

230/60/3(26.5)

460/60/3(14)

230/60/3(35)
460/60/3(22)

SPECIFICATION NOTES

1. The figures for power and cooling capacity are listed for air-cooled units with a circulation temperature of
68 F, and ambient temperature of 80F and standard pump.

2. Cooling capacity will be affected as follows: Derate 17% for 50 Hz operation. Derate 1% for each F drop
in recirculating temperature. Derate .5% for each F increase in ambient temperature. Optional pumps will
decrease net cooling capacity.

3. The operating water temperature range for water is 40F (5 C) to 100F (38C). If use of other fluids or
temperatures are required, the Technical Service Department must be contacted so the appropriate ranges
can be set.

4. Water-cooled units require about 20% less input power.

5. All CH Chillers are thoroughly tested before leaving the factory to ensure that each unit meets these speci­fications prior to shipment.

WARNING: Never operate the Chiller with the panels removed. Always use the power
switch to turn off the Chiller when it is not being used. Always ensure that all air inlets and
outlets are free from obstruction.

1

91961OPR

INSTALLATION

LOCATION

Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 40F or rise
above 110F. To 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 that the air intake and dis­charge are not obstructed. Avoid hot air discharge from other equipment or enclosed areas where heat build-up
could cause a significant rise in ambient temperatures. A minimum of two feet of space on all four sides of the
Chiller will be sufficient to prevent obstruction. Water-cooled units should be located near a water source and
drain.

TANK FILL, 1–INCH FPT

CH1500, 2000, 3000

ELECTRICAL JUNCTION BOX

CONTROL PANEL

(SEE DETAIL)

TANK LEVEL GAUGE

CH 5000 AND 7500

ON REAR FOR

CH1500, 2000 AND 3000

AIR OUTLET

(AIR INLET ON

OPPOSITE END)

TANK FILL 1–INCH FPT

S.S. (CH5000, 7500)

TANK DRAIN

WATER OUTLET

3/4–INCH OR 1–INCH

FPT S.S.

WATER INLET

3/4–INCH OR 1–INCH

FPT S.S.

91961OPR

FIGURE 1. INSTALLATION DETAILS

2

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 the junction box, indicates the actual phase, voltage and
amperage for each Chiller.

After the electrical connections are made, power must be supplied to the Chiller for a period of 12 hours (with
control switched off) to allow the compressor crankcase heater to warm the compressor lubricant.

CAUTION: On three phase applications, it is important that the rotation of the pump, when
supplied, is correct. Running the pump in reverse for more than a few seconds will result in

permanent pump damage. When the pump is running, shaft rotation must match the
direction indicated on the pump housing. If the rotation is incorrect, reverse two of the three
incoming power supply leads. The Phase Protection/3–Phase Monitor Option will prevent the
pump from operating backwards. See the option description.

Phase Protection / 3–Phase Option

The 3–Phase Monitor detects phase loss, low voltage, and phase reversal by continuously monitoring the
3–Phase power lines for abnormal conditions. When correct voltage and phase rotation are applied, the internal
relay will energize. A fault condition will de–energize the relay. When the fault is corrected, the monitor will auto­matically reset. Both Trip and Norm condition indicators are provided on the relay to aid in adjustment and sys­tem trouble–shooting.

This control is located in the enclosure labeled “Monitor” on top of the electrical box.

Phase Protection / 3–Phase Option Adjustment

The following procedure will allow the 3–Phase Monitor to achieve a trip point just below the nominal phase-to­phase voltage, where the unit is applied.

Rotate the adjustment control fully clockwise, or until the red (Trip) indicator illuminated. Slowly rotate the ad­justment control in a counter-clockwise direction, just until the green (Norm) indicator illuminates. At this point,
the 3–Phase Monitor is the most sensitive to irregular power line conditions. If nuisance tripping occurs, turn the
control slightly further counter–clockwise.

PLUMBING

Follow standard plumbing practices and local codes in making water connections. The Chiller inlet and outlet
connections are 3/4–inch or 1–inch FPT. Flexible hose and fittings are recommended for plumbing the system.
A No. 20 mesh strainer should be installed on the Chiller inlet to prevent foreign particles from entering the sys­tem and should be cleaned monthly. Lines should be routed with as few bends as possible. Prevent lines from
running near radiators, hot water pipes, etc. Any lengths of tubing that are exposed to high ambient tempera­tures should be insulated to prevent condensation and/or significant liquid heat loss.

Water-Cooled Condensers

Water-cooled units must be connected to a source of tap water of chilled water and a drain. The connections for
the water supply (3/4–inch FPT or 1–inch FPT) are located on the rear of the unit. These units are supplied with
a WATER REGULATING VALVE that allows only the required amount of water to pass through the condenser
for a given heat load. The water flow through the condenser can vary from 0 when the cooling system is in the
“OFF” cycle to approximately 5.0–gpm at maximum rated loads for 1–1/2 ton units and approximately 20–gpm
at maximum rated loads for 7–1/2 ton units. This valve is factory set to operate where the water supply temper­ature ranges from 50F (10C) to 80F (27C) with a supply pressure of 30 to 60–PSIG. For temperatures or
pressure outside these ranges, contact our Technical Service Department for assistance in “field” adjustment of
the valve. Once the system as been properly plumbed, it is important that the circulation system be filled with
water.

3

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 Rec­ommendations 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 rein­stalled before operation begins.

Auto Refill Option

If the Chiller is provided with the Auto Refill Option, install 1/4–inch or 1/2–inch tubing from the auto refill fitting
located on the lower rear of the Chiller to a fresh water supply line. The Chiller reservoir will fill with water auto­matically and the proper reservoir level will always be maintained.

Chiller without Reservoir

The Chiller and system piping should be filled with clean water ensuring that all air is purged from the system.

91961OPR

4

RESERVOIR

LOW TEMP. CONTROL

FROM PROCESS

EVAPORATOR

PUMP BYPASS VALVE

CHILLER INLET

TO PROCESS

CHILLER OUTLET

FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD)

FROM PROCESS

EVAPORATOR

EVAPORATOR

CHILLER INLET

LOW TEMP. CONTROL

BYPASS VALVE

CHILLER OUTLET

FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION)

CHILLER INLET

LOW TEMP. CONTROL CHILLER OUTLET

TO PROCESS

FROM PROCESS

TO PROCESS

FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION)

5

91961OPR