Cornelius CH 1500-A Operator's Manual

Text of Cornelius CH 1500-A User Guide:

• CHILLER (“CH” SERIES) Operator’s Manual Models: CH 951-A CH 1500-A CH 1502-A CH 1503-A PRINTED IN U.S.A IMI CORNELIUS INC; 1995--99Ó IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139--2268 Telephone (800) 551--4423 Facsimile (800) 519--4423 Part No. 92266 December 5, 1995 Revised: July, 1999 Revision C THIS DOCUMENT CONTAINS IMPORTANT INFOR

• i 92266 TABLE OF CONTENTS Page GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNPACKING AND INSPECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Cornelius CH 1500-A, 1 92266 GENERAL INFORMATION INTRODUCTION The REMCOR ”CH” Series Recirculating Liquid Chiller is designed to provide an accurate, reliable, and user-- friendly system for cooling a continuous flow of pure liquid and keep that liquid at a constant temperature in vari- ous 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 liquid reservoir package provides a complete liquid cooling and circu- l

• Cornelius CH 1500-A, 2 92266 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 ob- structions. It is also important to direct any hot air discharge from other equipment away from the air intake side of the chill- er. 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

• Cornelius CH 1500-A, 3 92266 Chiller Operation 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. BE SURE THAT THE RESERVOIR IS FILLED WITH FLUID PRIOR TO POWERING UP THE UNIT. Process Liquid Flow After ensuring that the system piping is free from obstruction, that all valves are open, and the reservoir is full, push the CONTROL POWER switch to the ”ON” position. The pump should now be operating. On three phas

• Cornelius CH 1500-A, 4 92266 COOLING OPERATION CONTROL PANEL WHITE INDICATOR/PUSH BUTTON GREEN INDICATOR RED INDICATOR SAFETY CONTROL POWER REMCOR CHXXX SERIES CHILLER COOLING FIGURE 2. CONTROL PANEL Temperature Indicator/Controller (Thermostat) Combines a precise temperature control and easy programmability with a convenient LED temperature readout that indicates system liquid temperature (2_ F Differential). To adjust thermostat, see next section. 1. CONTROL POWER SWITCH/LIGHT A simple ON/OFF push--button that switches power to the 24 volt control circuit. When the switch is pressed, the white light on the push--button illuminates to indicate that Chiller Control Power is present. Light is no

• Cornelius CH 1500-A, 5 92266 START--UP IT IS IMPORTANT THAT THE LIQUID LEVEL SIGHT GLASS READS ”FULL”. IN THE EVENT THAT THE RESERVOIR IS EMPTY, THE UNIT WILL REMAIN OFF UNTIL AN ADEQUATE LEVEL OF LIQUID IS AT- TAINED. MAKE SURE CHILLER POWER IS ”OFF” PRIOR TO FILLING RESERVOIR. Push CONTROL POWER button IN. All alarm indicators should be extinguished and the Chiller system will cycle in order to maintain the established set-point. The Chiller is now ready for normal operation. Thermostat Control 7 0 up set down

• Cornelius CH 1500-A, 6 92266 Pump Motor The PUMP MOTOR should be lubricated with thirty drops of SAE 20 oil once a year. Circulation System The CIRCULATION SYSTEM should be drained and flushed periodically to avoid build up and possible flow re- striction caused by contaminants. Filters/Strainers The FILTER located inside of the unit at the inlet of the pump should be cleaned periodically depending on ap- plications. If a reduction in flow or cavitation of the pump occurs, remove the in--line FILTER, back-flush it with water, rinse, a

• Cornelius CH 1500-A, 7 9 2 2 6 6 TROUBLESHOOTING WARNING: Disconnect electrical power to the Chiller to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. TROUBLE PROBABLE CAUSE REMEDY CHILLER DOES NOT OPERATE, CONTROL POWER LIGHT “OFF” A. No Power To Unit. A. Check Main disconnect fuses, wiring, and power lead to unit. B. Defective Control Power Switch. B. Replace Switch C. Defective Control Transformer. C. R

• Cornelius CH 1500-A, 8 92266 TROUBLE REMEDYPROBABLE CAUSE CHILLER DOES NOT OPERATE, BUT COOLING LIGHT IS “ON” AND SAFETY LIGHT IS “ON”. A. Unit is operating under high pressure conditions. A. Check for dirty condenser fins or obstruction of chiller air intake. Press high pressure manual reset switch. B. Unit is operating under low pressure conditions. B. Check sight glass, if bubbles are seen, leak check unit and recharge with refrigerant. or If no bubbles are seen, replace defective TXV. C. Unit is operating under low level conditions. C. Add liquid to reservoir via fill port. or If level is

• 922669 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 48 49 51 17 16 24 16 35 17 35 39 36 17 13 17 35 45 50 33 50 52 32 46 FIGURE 4. CABINET SECTION EXPLODED VIEW

• Cornelius CH 1500-A, 92266 10 CABINET SECTION Index No. Part No. Qty Name 1 15166 1 Frame 2 15207 2 Support Panel (CH 951) 15426 2 Support Panel (CH 1502) 3 61170 1 Pump and Tank Ass’y (CH 951; See Figure 6) 61167 1 Pump and Tank Ass’y (CH 1502; See Figure 6) 4 70190 2 Screw, Hex Hd, No. 8-32 By 1/2-In. Long 5 15159 1 Support, Condenser 6 15172 1 Fill Port Ass’y 7 15165 2 Panel, Side (CH 951) 15427 2 Panel, Side (CH 1502) 8 15164 2 Panel, Rear (CH 951) 15425 2 Panel, Rear (CH 1502) 9 33437 1 Electrical Box Ass”y (CH 951; See Figure 5) 33585 1 Electrical Box Ass”y (CH 1502; See Figure 5) 10 15167 1 Li

• Cornelius CH 1500-A, 9226611 12 3 4 5 6 7 14 15 16 17 18 18 18 19 20 21 22 23 24 FIGURE 5. ELECTRICAL BOX ASSEMBLY EXPLODED VIEW ELECTRICAL BOX ASSEMBLY Item No. Part No. Qty. Name 1 15269 1 Electrical Box 2 309060 1 Terminal Board 3 31001 1 Thermostat 4 32804 1 Transformer, 24V 50VA 5 32922 1 Contactor, Compressor 6 33082 1 Relay, 24V 7 33339 1 Alarm, 24V 8 33573 1 Wire Harness, Main Power (CH 951; Not Shown) 33607 1 Wire Harness, Main Power (CH 1502; Not Shown) 9 33574 1 Wire Harness, Condenser (CH 951; Not Shown) 33608 1 Wire Harness, Condenser (CH 1502; Not Shown) 10 33575 1 Wire Harness, Alarm (Not Shown) 11 33576 1 Wire Harness, Switch (Not Shown) Item No. Part No. Qty. Name 12 33577 1 Wire Ha

• Cornelius CH 1500-A, 92266 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 14 14 14 16 16 16 16 17 17 17 17 18 18 18 18 18 18 18 16 18 19 19 20 21 22 22 23 24 25 26 27 28 28 28 29 30 30 30 31 32 32 33 33 34 35 3535 35 35 35 36 37 38 39 40 41 42 43 44 45 46 46 47 48 FIGURE 6. PUMP AND TANK ASSEMBLY

• Cornelius CH 1500-A, 9226613 PUMP AND TANK ASSEMBLY Item No. Part No. Qty. Name 1 15162 1 Base 2 53206 1 Tank 3 53192 1 Cover 4 27866 1 Thermalwell 5 61169 1 Evaporator 6 32382 1 Motor, Pump, 1/3 HP 115/230V 7 53223 1 PVC Valve 8 50351 1 Tube, .500 I.D. By 28-In. Long 9 33159 2 Sensor, Low Level 10 70028 4 Hex Nut, 5/16-18 11 70274 4 Screw, Cap, Hex Hd, No. 5/16-18 By 3/4-In. Long 12 70065 4 Lockwasher 13 70070 4 Flatwasher 14 50991 4 Bulkhead, 1/2 I.D. 15 51842 1 Bulkhead, 3/4 I.D. 16 41266 6 Elbow, 1/2-NPT, Stainless Steel (CH 951) 40904 6 Elbow, 1/2-NPT, Brass (CH 1502) 17 41474 4 Bushing, Fitting, 3/4-NPT By 1/2-NPT, Stainless

• Cornelius CH 1500-A, 14 92266 WARRANTY 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 Wilshire prod- uct, 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. IMI Cornelius Offices AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166 AUSTRIA D AM LANGEN FE

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