Cornelius Refrigerator CH1500 CH7500 User Manual

IMI CORNELIUS INC  
Telephone (800) 551–4423 Fax (800) 394–5140  
CHILLER  
Models: CH1500–CH7500  
Operator’s Manual  
with Installation,  
Service, and Parts  
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  
PRINTED IN U.S.A  
© IMI CORNELIUS INC; 2006  
 
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
5
FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION) . . . . . . . . .  
FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION)  
FIGURE 5. SAMPLE DATA PLATE FOR CH5002-A . . . . . . . . . . . . . . . . . . . . . . . .  
FIGURE 6. REFRIGERATION PIPING SCHEMATIC WITH HOT GAS BYPASS  
5
14  
17  
FIGURE 7. REFRIGERATION PIPING SCHEMATIC WITHOUT HOT GAS  
BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
17  
18  
19  
20  
FIGURE 8. CHILLER PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
FIGURE 9. PUMP AND TANK COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
FIGURE 10. ELECTRICAL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . .  
ii  
91961OPR  
 
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 applica-  
tions.  
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 circulat-  
ing system.  
CH Chillers are designed to operate in a clean laboratory or industrial environment where ambient temperatures  
range from 40F to 110F. 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  
Cooling Capacity* Watts/BTU  
Compressor  
CH1500  
CH2000  
CH3000  
CH5000  
CH7500  
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 (0–39C.)  
Condenser  
Temperature Controller  
Pump**  
Many Available  
10 Gallons  
40 Gallons  
Reservoir  
230/60/1(17)  
230/60/3(13)  
460/60/3(8)  
230/60/3(13)  
460/60/3(8)  
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)  
Voltage (Full Load Amps)***  
28 x 28 41  
3/4–inch  
36 x 36 x 65  
1–inch  
Dimensions W x D x H (inches)  
Inlet/Outlet Fitting Size  
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 80F 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 40F (5C) to 100F (38C). 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 speci-  
fications 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.  
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INSTALLATION  
LOCATION  
Install the Chiller indoors in a well ventilated area where ambient temperatures will never fall below 40F or rise  
above 110F. To obtain optimum cooling capacity, the ambient temperature should be 80F or below.  
Standard CH Chiller have air-cooled condensers. On air-cooled units it is important that the air intake and dis-  
charge 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 FILL 1–INCH FPT  
S.S. (CH5000, 7500)  
TANK DRAIN  
AIR OUTLET  
(AIR INLET ON  
OPPOSITE END)  
WATER OUTLET  
TANK LEVEL GAUGE  
CH 5000 AND 7500  
ON REAR FOR  
3/4–INCH OR 1–INCH  
FPT S.S.  
WATER INLET  
3/4–INCH OR 1–INCH  
FPT S.S.  
CH1500, 2000 AND 3000  
FIGURE 1. INSTALLATION DETAILS  
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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 auto-  
matically reset. Both Trip and Norm condition indicators are provided on the relay to aid in adjustment and sys-  
tem 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-to-  
phase voltage, where the unit is applied.  
Rotate the adjustment control fully clockwise, or until the red (Trip) indicator illuminated. Slowly rotate the ad-  
justment 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 sys-  
tem 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 tempera-  
tures 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 temper-  
ature ranges from 50F (10C) to 80F (27C) 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.  
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3
 
Chiller with Reservoir  
The reservoir can be filled by removing the water fill cap located on the upper rear of the Chiller (See Fluid Rec-  
ommendations 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 rein-  
stalled 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 auto-  
matically 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.  
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RESERVOIR  
LOW TEMP. CONTROL  
FROM PROCESS  
TO PROCESS  
CHILLER INLET  
EVAPORATOR  
PUMP  
BYPASS VALVE  
CHILLER OUTLET  
FIGURE 2. CHILLER PLUMBING SCHEMATIC WITH PUMP AND TANK (STANDARD)  
FROM PROCESS  
CHILLER INLET  
TO PROCESS  
BYPASS VALVE  
CHILLER OUTLET  
LOW TEMP. CONTROL  
EVAPORATOR  
FIGURE 3. CHILLER PLUMBING SCHEMATIC NO TANK (OPTION)  
FROM PROCESS  
CHILLER INLET  
TO PROCESS  
LOW TEMP. CONTROL  
CHILLER OUTLET  
EVAPORATOR  
FIGURE 4. CHILLER PLUMBING SCHEMATIC NO PUMP, NO TANK (OPTION)  
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6
91961OPR  
 
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. If the rotation is incorrect,  
reverse two of the three incoming power supply leads at the terminal strip. After changing the leads, check the  
pump rotation.  
NOTE: Running the pump in reverse for more than a few seconds will result in permanent  
pump damage.  
After ensuring that the system piping is free from obstruction and that all valves are open, turn the pump power  
switch to the “ON” position. The pump power indicator should illuminate, indicating that the pump is operating.  
All Chillers with pumps are provided with a pressure regulating valve on the pump discharge. This valve is pre-  
set at the factory to ensure that system pressure does not exceed the capabilities of the pump motor and/or pip-  
ing. If this valve requires adjustment, please contact the factory for proper setting procedure and pressures.  
A flow meter and throttling valve can be added in the chiller inlet line in order to monitor and/or adjust the flow  
rate through the Chiller.  
Once the flow has been established, the thermostat can be adjusted to the desired set-point.  
Chiller without Pump  
A flow meter and throttling valve can be added in the Chiller inlet line in order to monitor and/or adjust the flow  
rate through the Chiller.  
Once the flow has been established, the thermostat can be adjusted to the desired set-point. See thermostat  
adjustment.  
THERMOSTAT ADJUSTMENT  
Standard Thermostat  
The following procedure should be followed to adjust the standard thermostat:  
1. To set the “SET POINT”, press and release the “SET” button, the current “SET POINT” will be displayed.  
2. While the current “SET POINT” is displayed, press the “UP” or “DOWN” button to change the “SET POINT”  
to desired temperature.  
3. Release all buttons. The display will show the system water temperature after a few seconds. The “SET  
POINT” can be viewed at any time by pushing the “SET” button.  
The thermostat has a range that has been preset at the factory. The range is 40F (5C) to 100F (38C). If  
operation outside of this range is required, please contact the Technical Service Department.  
UP  
DOWN  
SET  
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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, 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. Press the “SET” button, the current SET POINT TEMPERATURE should be displayed. Press the UP or  
DOWN button to change the SET POINT.  
5. Press the fnc button to exit the program.  
The thermostat has a range that has been preset at the factory. The range is 40F (5C) to 100F (38C). If  
operation outside of this range is required, please contact the Technical Service Department.  
Cooling Start-Up  
Once flow is established and the thermostat is set to the desired set-point, turn the control power switch to  
“ON”. Ensure that the air is flowing in the left side (facing the control panel) and out the right side. If not, reverse  
two of the three incoming power supply leads at the terminal strip. Once again, check for correct air flow. All  
alarm indicators should be extinguished and the Chiller refrigeration system will cycle in order to maintain the  
established set-point.  
Re-check the reservoir level to ensure that it is ”FULL” (if so equipped) and add water if necessary.  
The Chiller is now ready for normal operation.  
5
2 &  
3
4
6
8 &  
9
7
CONTROL  
POWER  
COOLING  
HIGH  
LOW  
LOW  
PUMP  
PRESSURE  
PRESSURE  
TEMP.  
POWER  
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 (ON/OFF) switch that switches power to the control circuit. This  
switch must be “ON” for the Chiller to operate.  
8
91961OPR  
 
3. CONTROL POWER LIGHT- A white light that indicates that Chiller control power is present.  
4. COOLING LIGHT- A green light that indicates refrigeration system operation. This light cycles on and off in  
response to the thermostat.  
5. HIGH PRESSURE ALARM LIGHT- A red light that indicates high refrigeration pressure.  
6. LOW PRESSURE ALARM LIGHT- A red light that indicates low refrigeration pressure.  
7. LOW TEMPERATURE ALARM LIGHT- A red light that indicates and abnormally low system fluid temper-  
ature.  
8. PUMP POWER SWITCH (OPTIONAL)- A simple (ON/OFF) switch that switches power to the Chiller  
pump. This switch must be “ON” for the Chiller to operate.  
9. PUMP POWER LIGHT (OPTIONAL)- A white light that indicates that the Chiller pump power is present.  
10. LOW FLOW/HIGH TEMPERATURE INTERLOCK (OPTIONAL)- Contacts are energized when abnormally  
low fluid flow or an abnormally high fluid water temperature is sensed by Chiller controls.  
11. LOW LEVEL AUDIBLE ALARM (OPTIONAL)- An audible alarm that indicates an unsafe reservoir level.  
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MAINTENANCE  
CAUTION: Disconnect electrical power before performing any of the following maintenance  
procedures.  
The Chiller will require very little normal maintenance.  
1. On AIR-COOLED Chillers, the condenser fins should be cleaned by blowing compressed air through the  
condenser from the fan side as required to eliminate any dirt or debris that may accumulate over time. This  
can severely reduce the performance of the Chiller. Cleanable air filters are available as an option. Contact  
the factory for information.  
2. On AIR-COOLED Chillers the condenser fan motor should be lubricated every 6–months with a few drop  
of SAE10 oil.  
3. The pump motor should be lubricated with thirty drops of SAE20 oil once a year.  
4. The circulation system should be drained and flushed periodically to avoid build-up and possible restric-  
tion of flow by contaminates.  
5. The strainer at the Chiller inlet should be removed and cleaned monthly.  
10  
91961OPR  
 
FLUID RECOMMENDATION  
Chillers are designed to operate with water to provide maximum performance for tempera-  
tures of 40F–100F.  
Distilled Water  
Acceptable  
Acceptable  
De–Ionized Water  
(1–5 MEG/OHMS)  
De–Ionized Water  
(5+MEG/OHMS)  
Acceptable with Stainless Steel & PVC only  
*No Copper or Brass  
Propylene Glycol  
(Lab & Industrial Grade)  
Acceptable – 30% Glycol/70% Water  
*For Applications with Temperatures below 40F  
Acceptable – 30% Glycol/70% Water  
*For Applications with Temperatures below 40F  
Acceptable  
Lab & Industrial Grade Ethylene Glycol  
Mineral/Hydraulic Oils  
(Viscosity<50 Centistrokes)  
Ethylene Glycol  
(Commercial/Automotive Antifreeze)  
NOT Acceptable  
*Silicate Rust Inhibitors in Automotive/Commer-  
cial Antifreeze will damage pump seals and  
housing which lead to failure.  
Acidic/Basic Solutions  
(Above 8/Below 6 PH)  
Not Acceptable  
Mineral/Hydraulic Oils  
Not Acceptable  
(Viscosity>50 Centistrokes)  
For questions regarding special or other fluids contact IMI Cornelius at 800–238–3600.  
To Purchase Lab or Industrial Glycol contact:  
IMI Cornelius  
Bevcore  
(800) 551–4423 – Part# 111521000 5 gallons  
(866) 275–6392 – Part#1008534 Chem Glycol Food Grade 5 gallon  
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TROUBLESHOOTING  
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.  
WARNING: If repairs are to be made to the refrigeration system, make sure electrical power  
is disconnected from the unit.  
Trouble  
Probable Cause  
Remedy  
CHILLER DOES NOT  
OPERATE. CONTROL  
POWER LIGHT “OFF”  
A. Control power switch “off”.  
A. Turn the control power switch to  
the “on” position.  
B. No power.  
B. Check the fuse and circuit  
breaker.  
C. Defective power supply  
connection.  
C. Check wiring and correct loose or  
poor connections.  
D. Defective control power  
switch.  
D. Replace the switch.  
E. Defective control transfromer.  
F. 3–Phase Monitor tripped  
E. Replace the transformer.  
F. Check for correct voltage level on  
each phase of incoming 3–Phase  
power. Check for correct phase  
rotation.  
PUMP DOES NOT OPERATE. A. Pump power switch “off”.  
PUMP POWER LIGHT “OFF”  
A. turn the pump power switch to the  
“on” position.  
B. Defective pump power switch. B. Replace the switch.  
C. Defective control transformer.  
C. Replace the transformer.  
A. Fill reservoir.  
PUMP DOES NOT OPERATE. A. No water in reservoir.  
PUMP POWER LIGHT “ON”.  
B. Restriction in the line to or  
from the Chiller.  
B. Remove restriction.  
C. Open or defective pump  
overload relay.  
C. Manually reset the relay or  
replace if necessary and check  
amp setting on overload.  
D. Defective pump contactor.  
D. Replace the pump contactor.  
E. Replace the pump or impeller.  
E. Defective pump motor or  
damaged impeller.  
CHILLER DOES NOT COOL.  
COOLING LIGHT “OFF”.  
A. Defective thermostat.  
A. Replace thermostat.  
CHILLER DOES NOT  
OPERATE. COOLING LIGHT  
“ON”.  
A. LOW PRESSURE ALARM  
LIGHT CYCLES ON/OFF.  
A. Process water too cold.  
B. Low process water flow.  
A. Increase the thermostat setting.  
B. Ensure that there is adequate flow  
through the process piping.  
C. Defective expansion valve.  
12  
C. Replace the expansion valve.  
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Trouble  
Probable Cause  
D. Refrigerant loss.  
Remedy  
D. Check the sight glass. If bubbles  
are seen flowing through it, the  
Chiller needs to be leak checked  
and recharged with refrigerant.  
E. Water bypass valve failed.  
E. Consult technical service  
department.  
F. Defective pump.  
F. Replace pump.  
HIGH PRESSURE ALARM  
LIGHT “ON”.  
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. Check to ensure that the fan  
blade is not blocked. Replace the  
fan motor if necessary.  
D. Low or no condenser water  
flow.  
D. Ensure that there is adequate flow  
throught piping to condenser.  
LOW TEMPERATURE ALARM A. Low or no process liquid flow.  
A. Ensure that there is adequate flow  
through the process piping.  
B. Defective thermostat.  
B. Replace the thermostat.  
C. Pro cess water too cold -  
C. Increase the thermostat setting.  
below 35F.  
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SERVICE  
When servicing a 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 informa-  
tion is found on the Data Plate along with the model number, voltage requirements and refrigerant information.  
The Serial Number is also needed when replacement parts are being ordered or for any warranty claims.  
REMCOR PRODUCTS COMPANY  
GLENDALE HEIGHTS, IL. 60139–2268  
PART NO.  
VOLTS  
MODEL NO.  
PH  
SERIAL NO.  
AMPS R134A  
HZ  
BAR CODE  
FIGURE 5. SAMPLE DATA PLATE FOR CH5002-A  
Be sure to include the serial number on any documentation or billing information.  
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SAFETY CONTROLS  
Each Chiller is provided with three standard safety controls. These 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 re-  
frigeration system components. This section includes a brief description of each control, its location and some  
troubleshooting hints that may be helpful.  
HIGH PRESSURE CONTROL (HPC)  
This control prevents system operation in the event that the high side pressure exceeds 350 PSIG. If this oc-  
curs, check the following:  
1. That the condenser is clean and that the air inlets and outlets are unobstructed.  
2. That the ambient temperature at the chiller location is below 110F.  
3. That the fan blade is rotating.  
Press the reset button located on the front of the control to restart the chiller. This control is located in the upper  
left hand corner of the electric box. If the control opens again, check the control setting with refrigeration  
gauges. If the setting is correct, contact technical service department.  
LOW TEMPERATURE CONTROL (LTC)  
This control prevents system operation in the event that the fluid inside the evaporator falls below 35F. If this  
occurs, check the following:  
1. That the thermostat set point is set at 40F or greater.  
2. That the flow through the system is greater than 2 gallons per minute.  
This control is mounted in the lower left hand corner of the electric box. It automatically resets itself once the  
water temperature is restored to 38F. The low temperature control may be adjusted for lower temperatures if a  
glycol solution is used. Contact Technical Service Department for temperatures below those stated here (See  
Fluid Recommendations page).  
LOW PRESSURE CONTROL (LPC)  
This control prevents system operation in the event that the low side pressure falls below 44 psi. If this occurs,  
check the following:  
1. That the thermostat set point is set at 40F or greater.  
2. That the flow through the system is greater than 2 gallons per minute.  
3. That no bubbles are present in the sight glass.  
4. That water bypass valve allows flow through the Chiller in a “dead head” situation.  
This control is located to the right of the high pressure control in the electric box. It automatically resets itself  
once the low side pressure rises to approximately 64 psi. If the control opens again, check the control setting  
with refrigeration gauges. If setting is correct, contact Technical Service Department.  
16  
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LIQUID LINE  
SOL. VALVE  
SIGHT GLASS  
FILTER/DRIER  
TXV  
LIQUID  
RECEIVER  
EVAPORATOR  
HOT GAS  
TXV EQUALIZER  
LINE  
BYPASS  
VALVE  
CONDENSER  
TXV SENSING  
BULB  
COMPRESSOR  
LOW PRESSURE  
SWITCH  
HIGH PRESSURE  
SWITCH  
FIGURE 6. REFRIGERATION PIPING SCHEMATIC WITH HOT GAS BYPASS  
SIGHT GLASS  
FILTER/DRIER  
TXV  
LIQUID  
RECEIVER  
TXV EQUALIZER  
LINE  
EVAPORATOR  
CONDENSER  
TXV SENSING  
BULB  
COMPRESSOR  
HIGH PRESSURE  
SWITCH  
LOW PRESSURE  
SWITCH  
FIGURE 7. REFRIGERATION PIPING SCHEMATIC WITHOUT HOT GAS BYPASS  
17  
91961OPR  
 
PARTS LIST  
4
8
23  
12  
18  
24  
6
13  
7
14  
25  
11  
15  
20  
3
17  
16  
21  
9
19  
10  
22  
5
1
26  
10  
4
FIGURE 8. CHILLER PARTS BREAKDOWN  
Index  
No.  
Index  
No.  
Description  
Description  
1
1/2” FPT Coupling  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
NS  
NS  
Red Indicator  
Green Indicator  
Compressor  
Accumulator  
Filter/Drier  
2
Thermowell, Low Temp. Thermostat (Not Shown)  
Corner Cover  
3
4
Side Panel  
5
Rear Panel  
6
Upper Front Panel  
Lower Front Panel  
Lid  
TX Valve, R-22  
7
Evaporator Assembly  
Condenser  
8
9
Control Panel  
Compressor  
10  
11  
12  
13  
14  
15  
FPT Coupling  
Receiver  
Temperature Control  
Electric Box Assembly  
Fan Blade  
Caster  
Condenser, Water Cooled  
Regulating Valve, Water Cooled Condenser  
Fan Motor  
* Call the Techncial Service Department for  
Proper Panel.  
White Switch/Indicator  
91961OPR  
18  
 
3
5
2
1
4
FIGURE 9. PUMP AND TANK COMPONENTS  
Index  
No.  
Index  
No.  
Description  
Description  
1
Thermowell,Temperature Control  
Temperature Probe  
4
5
Pump  
2
3
Pump Relief Valve  
Tank Assembly  
** Call the Service Department for proper pump  
identification.  
19  
91961OPR  
 
4
5
1
2
6
7
3
FIGURE 10. ELECTRICAL BOX COMPONENTS  
Index  
No.  
Index  
No.  
Description  
Description  
1
Low Temperature Thermostat  
Control Transformer  
6
7
Contactor, Pump  
2
3
4
5
Overload Relay, 1.0 to 1.6A  
Overload Relay, 1.4 to 2.0A  
Overload Relay, 2.0 to 3.0A  
Overload Relay, 2.8 to 4.4A  
Overload Relay, 4.0 to 6.0A  
Contactor, Compressor  
High pressure Control  
Low Pressure Control  
91961OPR  
20  
 
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.  
91961OPR  
21  
 
 
IMI CORNELIUS INC.  
 

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