Cornelius CH Series User manual

CH250 AND CH251 CHILLERS
Operator’s & Installation Manual
Release Date: April 19, 2004
Publication Number: 620914801
Revision Date: May 15, 2015
Revision: G
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. It is assumed that appro-
priate safety precautions are taken and that all local safety and construction requirements are being met, in addition to
the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject
to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident, (6)
alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained persons
to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating,
cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100% compatible with
the Product) which use voids the entire warranty, (13) Product parts in contact with water or the product dispensed
which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con-
tact:
www.cornelius-usa.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
This document contains the original instructions for the unit described.
CORNELIUS INC
101 Regency Drive
Glendale Heights, IL
Tel: + 1 800-238-3600
Printed in U.S.A.

TABLE OF CONTENTS
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Data Plate Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chiller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location of Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Process Water Flow, Units and Pump and Tank (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Thermostat Eliwell IC902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chiller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 1 - Publication Number: 620914801
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
DIFFERENT TYPES OF ALERTS
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment
damage.
CAUTION:
!
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment
damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or
infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND
PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN
SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
!

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 2 - © 2002-2015, Cornelius Inc.
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.
CAUTION:
!
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
CAUTION:
!
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 3 - Publication Number: 620914801
GENERAL INFORMATION
INTRODUCTION
The Cornelius “CH” Series Recirculating Water Chiller is designed to provide an accurate, reliable and user-friendly
system for cooling a continuous flow of water and keep it at a constant temperature in various 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 water reservoir package provides a complete liquid cooling and circulating
system.
The “CH” Series Chiller is designed to operate in a clean laboratory or industrial environment where ambient
temperatures range from 40 to100° F (5 to 38° C). With proper installation, operation and maintenance, the “CH”
Series Chiller will provide years of trouble free service.
UNPACKING AND INSPECTION
This unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any
damage or irregularities should be noted at the time of delivery and immediately reported to the carrier. Request a
written inspection report from the Claims Inspector to substantiate any necessary claims. In the event that an
immediate replacement is necessary, please contact Cornelius Chiller Sales at 1-800-551-4423.
DESIGN DATA
The voltage and the frequency are indicated on the serial number plate, located behind the drip tray and on the right
hand side near the controls.
Table 1:
CH250 CH251
Cooling Capacity:
BTU/hr (W) at 80° F (27° C) and 70° F
(21° C) Liquid Temperature 3,000 (879) 3,000 (879)
Compressor Horsepower .25 (.2 kW) .25 (.2 kW)
Electrical Data:
Voltage/Phase/Hertz/Amperage
115/1/60
7.5 Amps
230/1/60
3.8 Amps
Refrigerant Type R134a R134a
Physical Dimensions, Width X Depth X
Height
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34 cm)
17.125” X 14.125” X 13.375”
(43.5 cm X 35.9 cm X 34 cm)
Fittings:
Process Connections 1/2” FPT (S/S) 1/2” FPT (S/S)
Optimum Process Liquid Flow GPM
(Liters/Min) 0.6 (2.72) 0.6 (2.72)
Condenser Air Flow (CFM) 225 225

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 4 - © 2002-2015, Cornelius Inc.
DATA PLATE INFORMATION
Figure 1. Sample Data Plate
When servicing a Cornelius 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 requirement and refrigerant information.
The serial Number is also needed when replacement parts are being ordered or for warranty claims.
NOTE: Be sure to include the serial number on any documentation or billing information.

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 5 - Publication Number: 620914801
CHILLER INSTALLATION
LOCATION OF CHILLER
CAUTION:
!
The chiller must be located near a properly grounded electrical outlet. the circuit should be fused and no other
electrical appliance should be connected to the circuit. All electrical wiring must conform to national and local
electrical codes.
The chiller must be located in a well ventilated, indoor area where ambient temperatures will remain above 40° F (5°
C) and will never increase above 100° F (38° C). To obtain optimum cooling capacity, the ambient temperature should
be at or below 80° F (27° C).
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 obstructions.
It is also important to direct any hot air discharge from other equipment away from the air intake side of the chiller.
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 pressure safety control to shut down the unit.
ELECTRICAL CONNECTIONS
CAUTION:
!
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 back panel of the chiller, includes a four terminal strip for power supply connection. Refer to Figure
2 for the CH250 model and Figure 3 for the CH251 model. The data plate, located next to the junction box, includes
the actual voltage, phase and amperage of the chiller.
Figure 2. Wiring Diagram (115V)

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 6 - © 2002-2015, Cornelius Inc.
Figure 3. Wiring Diagram (230V)
START UP
!
WARNING:
Never operate the chiller with it’s panels removed. Always use the power switch to turn off the chiller when it is not
being used. Always ensure that all air inlet and outlets are free from obstruction. Be sure that the reservoir is filled with
fluid prior to powering up the unit (see Fluid Recommendations page).
Process Water Flow, Units and Pump and Tank (Standard)
Follow standard plumbing practices and local codes in making water connections. The chiller inlet and outlet
connections are 1/2”. 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 system 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 temperatures should be insulated to prevent
condensation and/or significant liquid heat loss.
After ensuring that the system is free from the obstruction, that all valves are open and the reservoir when available is
full, push the CONTROL POWER switch to the “ON” position. The pump should now be operating.
STANDARD THERMOSTAT ELIWELL IC902
The following procedure should be followed to adjust the Eliwell IC902 thermostat temperature setting:
1. To set the SET POINT, press and release the SET button. SET displays.
2. Press the SET button again, the current SET POINT is displayed. Press the UP or DOWN button to
change the SET POINT to the desired temperature.
3. Press the fnc button twice to exit the program. The current liquid temperature is displayed.
The thermostat has a range that is pre-set at the factory. The range is 40° F (5° C) to 100° F (38° C). If operation
outside of this range is required, please contact the Cornelius Technical Service Department.

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 7 - Publication Number: 620914801
Figure 4. Control Panel
fnc
set
out1
oF

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 8 - © 2002-2015, Cornelius Inc.
CHILLER 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.
CONDENSER
On air-cooled chillers, the CONDENSER FINS should be cleaned by blowing compressed air through the condenser
from the fan side. Dirt and debris accumulate on the condenser fins over time and this build up can severely reduce
the performance of the chiller. Cleaning of the CONDENSER COIL FINS should be done approximately every three
months, depending upon cleanliness of your application.
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 a possible flow
restriction caused by contaminants.

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 9 - Publication Number: 620914801
FLUID RECOMMENDATIONS
Cornelius chillers are designed to operate with water to provide maximum performance for temperatures of 40° F
(4.4° C) to 100° F (37.8° C).
For questions regarding special or other fluids contact Cornelius at 800-551-4423.
To purchase Lab or Industrial Glycol contact:
Cornelius, 1-800-551-4423 - Part No. 111521000, 5 Gal.
Table 2:
Distilled Water Acceptable
De-Ionized Water
(1-5 Meg ohms) Acceptable
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 40° F)
Lab & Industrial Grade Ethylene Glycol Acceptable - 30% Glycol/70% Water
(For Applications with Temperatures below 40° F)
Mineral/Hydraulic Oils
(Commercial/Automotive Antifreeze)
NOT Acceptable
(Silicate Rust Inhibitors in Automotive/Commercial anti-
freeze damages pump seals and housing which lead to fail-
ure.)
Acidic/Basic Solutions
(Above 8 or below 6 PH) Not Acceptable
Mineral/Hydraulic Oils
(Viscosity > 50 Centistrokes) Not Acceptable

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 10 - © 2004-2015, Cornelius Inc.
TROUBLESHOOTING
!
WARNING:
Disconnect electrical power to the chiller to prevent personal injury before attempting any internal maintenance. Only
qualified personnel should service the internal components or electrical wiring.
If repairs to the chiller must be made, disconnect electrical power to the unit, then shut off the water source.
Table 3:
Trouble Problem Cause Remedy
Chiller does not operate, Power Light
“OFF”
A. No Power to unit
B. Defective Control Power Switch
C. Defective Control Transformer
D. Wrong Voltage supplied to Unit
A. Check main disconnect fuses, wir-
ing and power lead to unit.
B. Replace Switch
C. Replace Transformer
D. Supplied Voltage MUST be within +/
- 10% of nameplate rating
Pump does not Operate but Power
Light is “ON”
A. Line to or from chiller is restricted.
B. Internal or external filter is blocked
with debris.
C. Pump contactor is defective
D. Damaged pump motor or impeller.
A. Inspect lines and remove any
obstructions.
B. Remove and clean strainer, then
replace.
C. Replace contactor
D. Replace pump motor or impeller.
Unit runs continuously, but is not cool-
ing process water enough.
A. Condenser is restricted.
B. Unit low on refrigerant.
C. Inefficient compressor.
D. Unit is undersized for application.
A. Clean condenser.
B. Call Service.
C. Call Service.
D. Call Cornelius Chiller Sales Rep.
NOTE: When servicing a Cornelius chiller, it is important to note all information provided on the
DATA PLATE located on the upper rear of the unit. If technical assistance is needed, the Cor-
nelius Service Technician will need this information along with any description of the prob-
lem(s) you are encountering. The serial no. and other information will also be required when
ordering replacement parts and any other Warranty Claims.

CH Series Chiller Operator’s & Installation Manual
© 2002-2015, Cornelius Inc. - 11 - Publication Number: 620914801
Figure 5. Cabinet Section Exploded View
Table 4. 115V Chiller
Item
No.
Part No. Description
132386 Temperature Controller
231934 Power Switch
361014 Evaporator
4620023502 Wrapper Panel
551882 Priming Reservoir Assy
624388 Panel, Left Side
7620062996 Comp 1/4hp 120/60 Tcmseh
134A
831955 Pump
924390R Base Assy
10 31962 Fan Motor
11 31488 Fan Blade
12 620023503 Panel, Right Side
13 60576 Condenser
14 33082 Relay
15 32378 Transformer
16 32588 Temperature Probe
17 620023504 Panel, Front
18 24389 Shroud, Condenser
Table 4. 115V Chiller
Item
No.
Part No. Description

CH Series Chiller Operator’s & Installation Manual
Publication Number: 620914801 - 12 - © 2002-2015, Cornelius Inc.
Table 5. 230V Chiller
Item No. Part No. Description
132386 Temperature Controller
231935 Power Switch
361014 Evaporator
4620023502 Wrapper Panel
551882 Priming Reservoir Assy
624388 Panel, Left Side
718361 Compressor
830730 Pump
924390R Base Assy
10 31487 Fan Motor
11 31488 Fan Blade
12 620023503 Panel, Right Side
13 60576 Condenser
14 33082 Relay
15 32378 Transformer
16 32588 Temperature Probe
17 620023504 Panel, Front
18 24389 Shroud, Condenser

Cornelius Inc.
www.cornelius.com