Cornelius 75' User manual

IMI CORNELIUS CHILLER
Service Manual
Release Date: November 9, 2005
Publication Number: 620920816SER
Revision Date: NA
Revision: A
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
®

SERVICE MANUAL
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 varia-
tions 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 construction requirements are being
met, in addition to the information contained in this manual.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and copyrights:
Aurora, Cornelius, FlavorFusion, Hydro Boost, Optifill, Pinnacle, and Vanguard are regis-
tered trademarks of IMI Cornelius Inc.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2005, All Rights Reserved, IMI Cornelius, Inc.

TABLE OF CONTENTS
Cornelius Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cooling distance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
75’ Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
125’, 250’, and 500’ Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic Temperature Control with Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Changing Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Setting the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chiller Service Manual
© 2005, IMI Cornelius Inc. - 1 - Publication Number: 620920816SER
CORNELIUS CHILLER
AIR COOLED
621057526 Chiller 75’ 1/3 HP R134a 115 Volts
621057527, 621057528 Chiller 125’ 1/3 HP R134a 115 Volts
621057531, 621057532 Chiller 250’ 1/2 HP R134a 115 Volts
621057535, 621057536, 62057537 Chiller 500’ 1 HP R134a 208/230 Volts
WATER COOLED
621057529, 621057530 Chiller 125’ 1/3 HP R134a 115 Volts
621057533, 621057534 Chiller 250’ 1/2 HP R134a 115 Volts
621057538, 621057539, 621057540 Chiller 500’ 1 HP R134a 208/230 Volts

Chiller Service Manual
Publication Number: 620920816SER - 2 - © 2005, IMI Cornelius Inc.
EQUIPMENT SPECIFICATIONS
COOLING DISTANCE:
621057526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .UP TO 75’ of trunk line
621057527, 621057528, 621057529. 621057530 . . . . . . . . . . . . . . . . . . . . .UP TO 125’ of trunk line
621057531, 621057532, 621057533, 621057534 . . . . . . . . . . . . . . . . . . . . .UP TO 250’ of trunk line
621057535, 621057536, 621057537, 621057538, 621057539, 621057540 .UP TO 500’ of trunk line
Model 75’ 125’ 250’ 500’
Part Number 621057526
621057527,
621057528,
621057529,
621057530
621057531,
621057532,
621057533,
621057534
621057535,
621057536,
621057537,
621057538,
621057539,
621057540
Voltage 115 115 115 208/230
Start up 9.5A 12.8A 13.6A 7.5A
Running 7.2A 10.1A 10.9A 5.3A
Refrigerant R134a R134a R134a R134a
Charge 8.5 oz. 10.5 oz. 12 oz. 20 oz.
Pressure 100 (low) 100 (low) 100 (low) 100 (low)
360 (high) 360 (high) 360 (high) 360 (high)
Dimensions (inches)* H: 22 H: 32 H: 32 H: 37
W: 20 W: 18 W: 18 W:18
D: 24 D: 26 D: 26 D: 26
Weight 90 lbs. 110 lbs. 130 lbs. 155 lbs.
* Dimensions include pump and motor
Tank capacity 5 gal. 11.5 gal. 11.3 gal. 11.5 gal.
2-part Injection Foam
Insulation
1” 1” 1” 1”
75’ Unit: Submerged vertical pump with capacity of 60 GPH. No priming
required.
125’, 250’, and 500’ Units: Gear pump with capacity of 80 GPH gravity fed to insure longer pump
life.

Chiller Service Manual
© 2005, IMI Cornelius Inc. - 3 - Publication Number: 620920816SER
INSTALLATION AND OPERATION
1. Remove packaging from the unit in the vicinity of the area where it will be installed.
2. Carefully lift the unit into the desired position.
NOTE: DO NOT PUSH UNIT - damage will be caused to the legs if the unit is pushed into position.
75’ UNIT
1. Connect one of the glycol tubes to the pump outlet. Insulate any exposed tubing.
2. Connect the second glycol line to the pump outlet. Insulate any exposed tubing.
3. Carefully push the glycol bath lid to one side, allowing sufficient space to fill the bath with liquid.
4. Inspect the bath for debris.
5. Fill the glycol bath with propylene glycol solution (mixed 2 ½ parts water to 1 part glycol). Fill the
bath to the fill level on the glycol level indicator.
6. Connect unit to the electrical outlets capable of handling the required voltage loads. This should be
carried out by suitably trained personnel and comply with all state and national electrical codes.
7. Glycol level will fall as glycol is pumped through the glycol lines. Continue to fill the bath to the fill
level on the glycol level indicator.
8. Replace top cover.
9. Inspect for any leaks.
125’, 250’, AND 500’ UNITS
1. Remove the refrigeration deck from the unit.
2. Inspect the glycol tank for any debris.
3. Connect one of the glycol lines from the beer python to the pump outlet. Insulate any exposed
tubing.
NOTE: In units with more than one pump, connect a glycol line to each pump outlet.
4. Connect the second glycol line from each circuit to the glycol bath inlet.
5. Fill the glycol bath with propylene glycol solution (mixed 2 ½ parts water to 1 part glycol). Fill bath
to the level of the fill line on the glycol level indicator.
6. Replace the refrigeration deck.
7. Connect the unit to the electrical outlets capable of handling the required voltage loads. This should
be carried out by suitably trained personnel and must comply with all state and national codes.
8. Glycol level will fall as glycol is pumped through the glycol lines. Continue to fill the bath to the fill
level on the glycol level indicator.
9. Inspect for any leaks.
10. Temperature of the glycol outlet will drop slowly to 30oF.
NOTE: To adjust the glycol temperature please see Adjusting the Electronic Thermostat.

Chiller Service Manual
Publication Number: 620920816SER - 4 - © 2005, IMI Cornelius Inc.
ELECTRONIC TEMPERATURE CONTROL WITH DISPLAY
NOTE: When the unit leaves the factory the electronic thermostat is pre-set to the following
parameters:
Temperature Scale: F (Farenheit)
Setpoint: 30oF
Differential: 3oF
Operating Mode: C1 (Cooling)
NOTE: To ensure the correct operation of your unit these parameters must be adhered to.
NOTE: The Keypad Lockout switch must be in the “UNLOCK” position (factory setting) before
adjusting the control. If the keypad is locked, pressing buttons has no effect on the control. The
Keypad Lockout switch is located on the back inside of the front cover. If necessary, remove the
cover by loosening the four captive cover screws.
Changing Temperature Units
1. Press Set button once to display temperature unit.
2. Press the Up or Down button to toggle between °F and °C.
3. Continue pressing and releasing Set button until tank temperature is displayed in normal operating
mode (“S1” not flashing).
Setting the Setpoint
Before setting the setpoint, be sure the control is set to the temperature units you want to use, Celsius or
Fahrenheit.
To view and adjust the setpoint, use the following method:
1. Press the Set button twice to display Setpoint (“S1” flashing).
2. Press the Up or Down button to adjust Setpoint.
3. Continue pressing and releasing Set button until tank temperature is displayed in normal operating
mode (“S1” not flashing).
NOTE: If no entries are made for thirty (30) seconds, the control reverts back to the tank
temperature display.
MAINTENANCE
1. Inspect the unit monthly to ensure that the glycol level is maintained to the fill level.
2. If the level is low replace with a propylene glycol solution, (mixed 2 ½ parts water to 1 part
glycol).
3. If there is evidence of ice build up in the unit, allow the ice to melt and replace all the water/glycol
solution with a fresh solution.
4. The glycol/water solution should be changed every 2 years. In regions of high humidity
considerations should be given to replacing the solution on an annual basis.
5. Check and clean the condenser fins every 6 months.
6. Check that there is adequate air flow through the unit ensuring enough space all around and that
there are no obstructions in front of the air flow vents.
7. Check the condition and effectiveness of the trunk line insulation.
8. At regular intervals, to be determined by the owner, the unit should be checked for electrical safety.

Chiller Service Manual
© 2005, IMI Cornelius Inc. - 5 - Publication Number: 620920816SER
TROUBLESHOOTING
Trouble Cause Solution
1. Excessive foam A. Warm walk-in cooler A. Adjust cooler temperature to
34oto 36oF (use quality
thermometer)
B. Check applied pressure to
barrel
B. Adjust setting on regulator for
proper pressure
C. Check equipment C. Check the physical
equipment from keg to faucet
D. Warm product lines D. Refer to 5
2. Compressor
does not start
(no hum), but the
fan motor runs.
A. Compressor relay or
capacitor malfunction
A. Replace compressor relay,
relay or capacitor.
B. Inadequate voltage B. Measure voltage across
common and run terminal on
compressor. Voltage must
not drop below 90% of rated
voltage.
C. Compressor failure C. Replace compressor.
3. Compressor
starts and
continues to run
until freeze up
and will not cut
off.
A. Thermostat control failure A. Replace thermostat
B. Freon leak B. Repair leak and recharge
4. Compressor
does not run but
hums.
A. Inadequate voltage A. Measure voltage across
common and run terminal on
compressor. Voltage must
not drop below 90% of rated
voltage
B. Starting relay malfunction B. Replace starting relay
Be sure to use correct relay.
Failure to use correct relay
will cause compressor
failure.
C. Compressor malfunction C. Replace compressor

Chiller Service Manual
Publication Number: 620920816SER - 6 - © 2005, IMI Cornelius Inc.
5. Warm beer A. Defective Pump (check motor
also)
A. Check return line in reservoir
for liquid flow. Replace pump
B. Defective motor (check pump
also)
B. Replace motor
C. Refrigeration unit not running C. Refer to 2
D. Conduit lines located in
overheated area
D. Remove from any hot water
pipes or kitchen area with
stove or glass washer.
E. Conduit lines flooded in PVC
chase.
E. Remove lines from PVC,
thoroughly dry PVC and
repair or replace conduit as
needed.
F. Uninsulated or poorly
insulated lines
F. All lines should be fully
insulated from cooler into
dispenser. Includes glycol
lines from power pack into
cooler.
G. Thermostat G. Adjust temperature to colder
setting.
H. Condenser fan motor not
working
H. Replace condenser fan
motor.
I. Freon leak I. Repair leak and recharge.
J. Dirty condenser J. Clean the condenser
K. Condensation inside conduit
insulation (may be caused
from cleaning lines)
K. Check trunk housing in areas
for drooping or low spots,
split insulation approximately
5” and separate. Allow any
water to drain, then air dry,
the seal closed.
L. Warm walk in cooler L. Check temperature of walk-in
cooler-liquid temperature, set
cooler at 36oto 38o.

Chiller Service Manual
© 2005, IMI Cornelius Inc. - 7 - Publication Number: 620920816SER
TYPICAL SPARE PARTS
WARRANTY
All glycol coolers carry a full warranty against defects in materials and workmanship for a period of one
year from the date of sale. The compressor has a five year warranty.
Defective parts, subject to inspection by Cornelius, will be replaced or repaired during the warranty
period on a no charge basis.
Labor warranty is provided for 90 days after the date of sale. All loss of sales must be borne by the
purchaser.
Component Part Number 75’ 125’ 250’
1 pump
250’
2 pumps
500’
2 pumps
500’
3 pumps
500’
4 pumps
Vertical Pump 620202626 x
Gear Pump 620202662 x x x x
Gear Pump 620202810 x x x
Motor 115V 60030058 x x x
Motor 230V 71860673 x x x
Clamp 187483000 x x x x x x
Temp Controller 620202617 x
Digital Controller 620202675 x x x x x x
Wick 620202633 x x x x x x x
Wick Tray 620202634 x x x x x x x
Compressor 2129 x
Compressor 620202815 x
Compressor 620202816 x x
Compressor 620202817 x x x
125’ Refrigeration Deck 620202818 x
250’ Refrigeration Deck 620202819 x x
Leg 70439 x x x x x x x
Nipple for Gear Pump 6170 x x x x x x

IMI Cornelius Inc.
www.cornelius.com