CH550 & CH551 Chillers Operator`s & Installation
Contents
1. QUALIFIED SERVICE PERSONNEL A WARNING Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY DEATH OR EQUIPMENT DAMAGE 2002 2014 Cornelius Inc 1 Publication Number 91272 CH550 and CH551 Chiller Operator s amp Installation Manual Gino D SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury To ensure continued protection observe the following A WARNING Disconnect power to the unit before servicing following all lock out tag out procedures established by the user Verify all of the power is off to the unit before any work is performed Failure to disconnect the power could result in serious injury death or equipment damage A CAUTION Always be sure to keep area around the unit clean and free of clutter Failure to keep this area clean may result in injury or equipment damage SHIPPING AND STORAGE A CAUTION Before shipping storing or relocating the unit the unit must be sanitized and all sanitizing solution must be drained from the system A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components Publication Number 91272 2 2002 2014 Cornelius Inc Cines CH550 and CH551 Chiller Op2. Remove the bolts securing the fan mounting bracket to the base and remove the fan motor assembly Separate the fan blade from the motor and install the new blade or motor Re install the fan mounting bracket and fan guard Re connect the wire leads and conduit connection Install the wrapper NQOoPOoON Replacing Pump 1 Remove the wrapper as specified in Removing Wrapper Remove the clamps and hoses from the suction and discharge of the pump Remove the screws securing the pump to the base Disconnect the wire leads from the pump motor and remove the pump Remove all fittings from the pump and install them on the new pump Install the pump and re connect wire leads and hoses Install the wrapper SNOOP 0 m 2002 2014 Cornelius Inc 7 Publication Number 91272 CH550 and CH551 Chiller Operator s amp Installation Manual C ines 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 lonized Water 1 5 Meg ohms Acceptable De lonized Water 5 Meg ohms Acceptable with Stainless Steel amp PVC only No Copper or Brass Propylene Glycol Lab amp Industrial Grade Acceptable 30 Glycol 70 Water For Applications with Temperatures below 40 F Lab amp Industrial Grade Ethylene Glycol Acceptable 30 Glycol 70 Water For Applications with Temperat
3. Fluid Recommendations page O 2002 2014 Cornelius Inc 5 Publication Number 91272 CH550 and CH551 Chiller Operator s amp Installation Manual Ginclius gt MAINTENANCE A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment 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 Publication Number 91272 6 2002 2014 Cornelius Inc C Gua D CH550 and CH551 Chiller Operator s amp Installation Manual SERVICE A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment Service of the chill
4. 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 Publication Number 91272 4 2002 2014 Cornelius Inc Cines D CH550 and CH551 Chiller Operator s 4 Installation Manual 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 set point THERMOSTAT Temperature Controller Figure 1 Control Pane
5. Cini gt CH550 AND CH551 CHILLERS Operator s amp Installation Manual REMC Ie Release Date August 9 2002 Publication Number 91272 Revision Date May 22 2014 Revision F Visit the Cornelius web site at www cornelius com for all your Literature needs 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 con struction requirements are being met in addition to the information contained in this manual This Product is warranted only as provided in Cornelius Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty Cornelius will not be responsible for any repair replacement or other service required by or loss or damage resulting from any of the following occurrences including but nat limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper voltage 3 ina
6. S e pes SUE 1 Safety MPSS elta Ciao esate stabile ek 1 Qualified Service Personnel u te ee ae 1 Sarety Preca tionS SE suas dans asias Che Ue S ped AM o a Ed ni criar 2 Shipping And Strada fe rs a Ut cua ds dl aa es cl a ta AO US o MP M E A 2 Infrod clloni k aa S EROR ar NA AIDA 3 sz eli a sane pd Eb S SRE id da Pts EA AE 3 Installation Instructions er A ANA UL ec o e i ees 4 Eo o A etre due fand a a E A a A IMB IER 4 Plumbing ong 41 1 EA A A AAA A EV EA UR S 4 A ER SN 4 Start Up Operatlon ssi ot thet E HR ais a AER sk Petes 5 Tertia deus Bu e SA a e o E S e a a a Me 5 Temperature Controller 4e a k i RR AUR pa a SY GER e AE 5 Standard Thermostat Eliwell IC902 ooooocoooccooccr nenn 5 uiri mee Tc Nil 6 cla ra METRI EP 7 Removing Wrapper iubes des RU RE a s Rd PR AM EEG EAR A RAE 7 Replacing SWilchr ieskanas pea a a aa ea E oremus Met set 7 Replacing Thermostal s ss pias pete ute apse aS REST SPIRI VIE ges 7 Replacing Fan Blade and or Motor ooocccoccccoo nn 7 Beplacing Pumps 11524 545 a nob iare S ere a Sa i O a S S Sela 7 Fluid Recommendations ec aor are RR aaa er 8 Troublesnoolllg n s c eb ai 9 TABLE OF CONTENTS Parts Eist a Sa LI eeu ee de le reu oar ax E e Eon at lo 11 C inet gt Cines gt CH550 and CH551 Chiller Operator s 4 Installation Manual SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Safety Overview e Read and follow ALL SAFETY INSTRUCTIONS in this manual and any wa
7. ansf Thermostat ransformer Thermosta 620603701 Compressor CH550 115V 7 32606 Contactor Relay 115V 620603702 Compressor CH551 230V 18 8 Relay 32607 Contactor Relay 230V O 2002 2014 Cornelius Inc Publication Number 91272 CH550 and CH551 Chiller Operator s amp Installation Manual Cine Publication Number 91272 12 2002 2014 Cornelius Inc Cornelius Inc www cornelius com
8. dequate wiring 4 abuse 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation operating cleaning or maintenance instructions 12 use of non authorized parts i e parts that are not 100 compatible with the Product which use voids the entire warranty 13 Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition Contact Information To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con tact www cornelius com 800 238 3600 Trademarks and Copyrights This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius This document contains the original instructions for the unit described CORNELIUS INC 101 Regency Drive Glendale Heights IL Tel 1 800 238 3600 Printed in U S A C Gne D Safety IHSIFUCHONSS ovio aci eiae No ee d Rie De Eu eu 1 Read and Follow ALL Safety Instructions LL eh 1 Safety OVBIVIBU eos etl s et tus eus oec e Vat a p Mato doa ud el deri iie eu e 1 PROCOGMINONM A enr S iia t Font urat he e RO E ect ee Fina a ee ees dod 1 Different Types OU AIGNS sonder unti ect teens e tune ESO CR Rud UE Eco AI VES L
9. e chiller in the event the chiller outlet is obstructed SPECIFICATIONS CH550 A CH551 A Condensing Unit Horse Power 1 2 1 2 Electrical Volts Phase Hz 115 1 60 230 1 60 F L A Amps 12 5 6 2 Reservoir Capacity Gal 2 2 Refrigerant 134 A Lbs 1 375 1 375 Stainless Steel Connections 1 2 in FPT 1 2 in FPT Operating Water Temperature Range 40 100 F 40 100 F Net Weight Lbs 160 160 Dimensions Depth Inches 16 3 4 16 3 4 Width Inches 15 1 8 15 1 8 Height Inches 28 1 2 28 1 2 2002 2014 Cornelius Inc Publication Number 91272 CH550 and CH551 Chiller Operator s amp Installation Manual iq 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
10. er 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 Switch 1 Remove the wrapper as described in Removing Wrapper Remove the spade lugs from the existing switch and note connection points Remove the switch from the front panel Install the new switch in the front panel and connect the leads to the new switch Install the wrapper anon 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 Remove the screw securing the mounting bracket to the back of the thermostat Remove the thermostat from the front panel Install the new thermostat in the front panel and secure it with the mounting bracket Reconnect the wires at back of the thermostat Install the wrapper NOP wo Replacing Fan Blade and or Motor 1 Remove the wrapper as specified in Removing Wrapper Remove the screws securing the fan guard to the fan shroud Remove the conduit connection at the back of the motor and disconnect the wire leads
11. erator s 4 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 th
12. ge must be within 610 of nameplate rating A Line to or from chiller is restricted Inspect lines and remove any obstruc tions B Low water level Ensure that tank is full No circulation of chilled water C Inoperable pump Check for obstruction or binding impeller replace pump and or motor if necessary A Condenser is restricted Clean condenser B Fan motor not operating freely Replace fan blade and or motor if 1 necessary Inadequate cooling C Water not circulating See No Circulation of Chilled Water D Low refrigerant level Charge system with refrigerant E Inoperative temperature control Replace thermostat 2002 2014 Cornelius Inc Publication Number 91272 O OO LB B CH550 and CH551 Chiller Operator s amp Installation Manual PARTS LIST 9 Figure 8 Cabinet Section Exploded View Table 1 Cabinet Section Table 1 Cabinet Section Item Part No Name iens Part No Name No 9 Capacitor 4 31934 Switch Illuminated CH550 115V 10 61058 I 31935 Switch Illuminated CH551 230V 11 60514 Sight Glass 2 32386 Thermostat Eliwell No EWPC902 12 60502 Control Low P ntrol Low Pressure 3 620603708 Blade Fan 13 638004393 Filter Drier 620603711 Motor Fan CH550 115V 4 14 Receiver 620603709 Motor Fan CH551 230V 15 Not Used 5 Condenser 16 Pump Circulating Nols 17 182378 Tr
13. l Standard Thermostat Eliwell IC902 The following procedure should be followed to adjust the Eliwell IC 902 thermostat temperature 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 A WARNING Never operate the chiller with enclosure panels removed Always use the illuminated switch to turn off the chiller when it is not being used Always ensure that all air inlets and outlets are free of obstructions Be sure that the reservoir is filled with fluid prior to powering up the unit see
14. rning caution labels on the unit decals labels or laminated cards e Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety regulations before operating this unit Recognition Recognize Safely Alerts A This is the safety alert symbol When you see it in this manual or on the unit be alert to the potential of personal injury or damage to the unit DIFFERENT TYPES OF ALERTS A DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or equipment damage A WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment damage A CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS e Carefully read and follow all safety messages in this manual and safety signs on the unit Keep safety signs in good condition and replace missing or damaged items Learn how to operate the unit and how to use the controls properly Do not let anyone operate the unit without proper training This appliance is not intended for use by very young children or infirm persons without supervision Young children should be supervised to ensure that they do not play with the appliance e Keep your unit in proper working condition and do not allow unauthorized modifications to the unit
15. ures below 40 F Mineral Hydraulic Oils Commercial Automotive Antifreeze NOT Acceptable Silicate Rust Inhibitors in Automotive Commercial anti freeze damages pump seals and housing which lead to fail ure 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 Cornelius at 800 551 4423 To purchase Lab or Industrial Glycol contact Cornelius 1 800 551 4423 Part No 111521000 5 Gal Publication Number 91272 8 2002 2014 Cornelius Inc C Gne D A WARNING CH550 and CH551 Chiller Operator s amp Installation Manual TROUBLESHOOTING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment Trouble Problem Cause Remedy A No Power to unit Check main disconnect fuses wiring and power lead to unit B Loose or poor wire connection Check wiring Correct for loose or poor wire connection C Inoperable On Off switch Replace switch Chiller does not operate D Overload device open Allow compressor to cool the install a new overload device replace com pressor if necessary E Inoperable relay Replace relay F Low input voltage Supplied volta
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