CHILLER MODELS: CH5000 Operator’s & Installation Manual Release Date: July 01, 1997 Publication Number: 91961 Revision Date: April 25, 2014 Revision: J 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CH5000 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.
CH5000 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. Failure to disconnect the power could result in serious injury, death or equipment damage.
CH5000 Chiller Operator’s & Installation Manual 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.
CH5000 Chiller Operator’s & Installation Manual INSTALLATION LOCATION Install the chiller indoors in a well ventilated area where ambient temperatures will never fall below 50o F or rise above 100o 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.
CH5000 Chiller Operator’s & Installation Manual 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.
CH5000 Chiller Operator’s & Installation Manual Figure 3. Chiller Plumbing Schematic No Tank (Option) Figure 4. Chiller Plumbing Schematic No Pump, No Tank (Option) Publication Number: 91961 -6- © 2006-2014, Cornelius Inc.
CH5000 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. If the rotation is incorrect, reverse two of the three incoming power supply leads at the terminal strip.
CH5000 Chiller Operator’s & Installation Manual Dual Point Adjustment (Optional) 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.
CH5000 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. 1.
CH5000 Chiller Operator’s & Installation Manual 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 refrigeration system components. This section includes a brief description of each control, its location and some troubleshooting hints that may be helpful.
CH5000 Chiller Operator’s & Installation Manual Figure 7. Refrigeration Piping Schematic without Hot Gas Bypass © 2006-2014, Cornelius Inc.
CH5000 Chiller Operator’s & Installation Manual 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 information is found on the Data Plate along with the model number, voltage requirements and refrigerant information.
CH5000 Chiller Operator’s & Installation Manual TROUBLESHOOTING Table 3. Trouble Chiller does not operate. Control power light “off” Pump does not operate. pump power light “off” Pump does not operate. Pump power light “On”. Probable Cause Remedy A. Control power switch “Off”. A. Turn the control power switch to the “On” position. B. No power. B. Check the fuse or circuit breaker. C. Check wiring and correct loose or poor connections. D. Replace the switch. E. Replace the transformer. C.
CH5000 Chiller Operator’s & Installation Manual PARTS LIST CHILLER ASSEMBLY Figure 9. Table 4. Chiller Assembly Table 4. Chiller Assembly SL No Part No.
CH5000 Chiller Operator’s & Installation Manual PUMP AND TANK COMPONENTS Figure 10. Pump and Tank Components Table 5. Pump and Tank SL No Part No. Description 1 15404R Thermowell, Temperature Control 2 32589 Temperature Probe 3 52136 4 620710601 5 40646 Tank Assembly Pump Centrifugal 230 Volt Pump Centrifugal 460 Volt By-Pass Valve * Call the Service Department for proper pump identification. Publication Number: 91961 - 15 - © 2006-2014, Cornelius Inc.
CH5000 Chiller Operator’s & Installation Manual ELECTRICAL BOX COMPONENTS Figure 11. Electrical Box Components Table 6. Electrical Box Table 6. Electrical Box SL No Part No. Description 1 31001 Low Temperature Thermostat 2 32804 Control Transformer 3 32805 Contactor, Compressor 4 60501 High pressure Control © 2006-2014, Cornelius Inc. - 16 - SL No Part No. Description 5 60502 6 620314008 Relay Contactor 7 620314005 Overload Relay, 2.20 to 3.
CH5000 Chiller Operator’s & Installation Manual WIRING DIAGRAM Figure 12. Wiring Diagram Publication Number: 91961 - 17 - © 2006-2014, Cornelius Inc.
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