CHILLER MODEL: CH1500, 2000 AND 3000 Operator’s & Installation Manual Release Date: February 12, 2010 Publication Number: 621055837OPR Revision Date: March 25, 2014 Revision: E 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.
TABLE OF CONTENTS Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). • Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit. Recognition Recognize Safety Alerts ! This is the safety alert symbol.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following: ! 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.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual GENERAL INFORMATION INTRODUCTION Cornelius 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 Series consists of a refrigeration system with associated operating controls housed in a sturdy sheet metal cabinet.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual LOCATION Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 50o F or rise above 110o F. To obtain optimum cooling capacity, the ambient temperature should be 80o F or below. Standard CH Chillers have air-cooled condensers. On air-cooled units it is important that the air intake and discharge are not obstructed.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual PLUMBING Follow standard plumbing practices and local codes in making water connections. The chiller inlet and outlet connections are 3/4 inch. Flexible hoses 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 (field installation, not provided with chiller).
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual FROM PROCESS CHILLER INLET TO PROCESS L O W T E M P. C O N T R O L C H IL L E R O U T L E T EVAPORATOR Figure 4. Chiller Plumbing Schematic, no Pump, no Tank (Option) Publication Number: 621055837OPR -6- © 2010-2014, Cornelius Inc.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual START UP WATER FLOW START 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. Turn 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 located on the pump housing.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual THERMOSTAT (DUAL SET POINT) Dual Point Adjustment 1. To set the “SET POINT” for Level 1, press and release the “SET” button, Re1 should be displayed. 2. Press the “SET” button again, the current SET POINT TEMPERATURE should be displayed. Press the UP or DOWN button to change the SET POINT. 3. To set the “SET POINT” for Level 2, press and release the “SET” button. Re2 should be displayed. 4.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual CONTROL PANEL 1. TEMPERATURE INDICATOR/CONTROLLER (Thermostat) - Combines a precise temperature control and accurate set ability with a convenient LED temperature readout that indicates system liquid temperature. 2. CONTROL POWER SWITCH - A simple (Push Button) switch with light indicator that switches power to the control circuit (White). This switch must be “pressed in” for the Chiller to operate. 3.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual MAINTENANCE ! 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.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual SAFETY CONTROLS Each chiller is provided with three standard safety controls. There 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 refrigeration system components. High Pressure Control (HPC) This control prevents system operation in the event that the high side pressure exceeds 250 PSIG.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. ! 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. Trouble Chiller does not operate, Control Power Light OFF.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual High pressure alarm light “ON”. (Low pressure alarm light cycles ON/OFF). A. Restricted condenser airflow. A. Clean the fins of the condenser and ensure that the air flow is not restricted. B. Defective condenser fan and/or motor. B. Check to ensure that the fan blade is not blocked. Replace the fan motor, if necessary. C. Defective expansion valve. C. Replace the expansion valve. D. Low or no condenser water flow. D.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual SERVICE When servicing this 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 Model and Serial Number of your chiller. That information is found on the data plate. The Model and Serial Number are also needed when ordering replacement parts. MADE I N U.S.A.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual CHILLER ASSEMBLY 27 8 23 12 18 6 13 7 28 14 25 15 11 20 17 16 3 21 9 19 22 10 5 1 4 26 10 Figure 10. Chiller Exploded View Item No. 1 Part No. 22949 Item No. Name 1/2” FPT Coupling 14 Part No. Name 31298 Motor Fan 230Volt 31698 Motor Fan 460Volt CH3000 2 27866 Thermowell, Low Temp.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual Item No. Part No. 61083 Evapr Asy CH1500 60985 Evap Asy Foamed CH2000 61085 Evap Asy CH3000 61089 Condenser 60983 Cond CH2000 61090 Cond CH3000 Air Cool 25 60685 Receiver 26 70893 Caster 27 620049517 Panel Right Side 22 23 Item No. Name Publication Number: 621055837OPR 28 NS NS Part No.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual PUMP & TANK ASSEMBLY 3 5 2 1 4 Figure 11. Pump & Tank Exploded View Table 4. Pump & Tank Components Item No. Part No. Name 1 15404R Thermowell, Temperature Control 2 32589 Temperature Probe 3 51096 Tank Assembly 4 620408104 Pump 620710601 Pump CH2000, CH3000 40646 Valve By-Pass 5 * Call the Service Dept. for proper pump identification. © 2010-2014, Cornelius Inc.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual ELECTRICAL BOX ASSEMBLY 4 5 1 2 6 7 3 Figure 12. Electrical Box Assemby, Exploded View Table 6. Electrical Box Assembly Item No. 1 Part No. Name 31001 Low Temperature Thermostat 2 32804 Control Transformer 3 32992 Contactor, Compressor 4 60501 High Pressure Control 5 60502 Low Pressure Control 6 7 620314008 Contactor, Pump 620314002 Overload Relay, 1.0 to 1.4A 620314003 Overload Relay, 1.3 to 1.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual WIRING DIAGRAM Figure 10. © 2010-2014, Cornelius Inc.
CH1500, CH2000 & CH3000 Chiller Operator’s & Installation Manual Publication Number: 621055837OPR - 20 - © 2010-2014, Cornelius Inc.
Cornelius Inc. www.cornelius.
