Cornelius CH1500-CH7500 User manual

CHILLER
MODELS: CH5000 & CH7500
Operator’s & Installation Manual
Release Date: July, 1997
Publication Number: 91961OPR
Revision Date: March 24, 2011
Revision: F
Visit the IMI 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 appropriate safety precautions are taken and that all local safety and con-
struction 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.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.
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
Specification Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chiller with Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chiller without Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Flow Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chiller with Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chiller without Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Standard Therostat Eliwell IC902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dual Point Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluid Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Pressure Control (HPC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Temperature Control (LTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Pressure Control (LPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chiller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump and Tank Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 1 - Publication Number: 91961OPR
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.
!

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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.

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 3 - Publication Number: 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 applications.
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 circulating system.
CH Chillers are designed to operate in a clean laboratory or industrial environment where ambient temperatures
range from 40o F (4.4o C) to 110oF (43.3oC). 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.
SPECIFICATION NOTES
1. The figures for power and cooling capacity are listed for air-cooled units with a circulation temperature of
68oF, and ambient temperature of 80o F and standard pump.
2. Cooling capacity will be affected as follows: Derate 17% for 50 Hz operation. Derate 1% for each degree
Fahrenheit drop in recirculating temperature. Derate .5% for each degree Fahrenheit increase in ambient
temperature. Optional pumps will decrease net cooling capacity.
3. The operating water temperature range for water is 40o F (4.4o C) to 100oF (37.8oC). 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 spec-
ifications 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 of obstructions.
Table 1. Specifications
Model CH5000 CH7500
Cooling Capacity* Watts/BTU 17,584/60,000 26,376/90,000
Compressor 5 H.P. 7.5 H.P.
Condenser Air Cooled
Temperature Controller Digital Display 40-100oF (4.4-37.8o C.)
Pump** 2CS (12 GPM @ 50 PSI)
Reservoir 40 Gallons
Voltage (Full Load Amps) CH5002A 230/60/3 (28) CH7502A 230/60/3 (36)
CH5003A 460/60/3 (14) CH7503A 460/60/3 (18)
Dimensions W x D x H (inches) 36” x 36” x 65” (91.4cm x 91.4cm x 165cm)
Inlet/Outlet Fitting Size 1 inch

CH5000 & CH7500 Chiller Operator’s & Installation Manual
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INSTALLATION
LOCATION
Install the chiller indoors in a well ventilated area where ambient temperatures will never fall below 40oF 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. Avoid hot air discharge from other equipment or enclosed areas where heat buildup 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.
Figure 1. Installation Details
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
Control Panel
(See Detail)
Electrical Junction Box
Tank Fill 1 In. FPT
Tank Level Gauge
Air Outlet
(Air Inlet on Opposite Side)
Water Inlet
Water Outlet
Tank Drain

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 5 - Publication Number: 91961OPR
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 results 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.
PLUMBING
Follow standard plumbing practices and local codes in making water connections. The chiller inlet and outlet
connections are 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 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.
Chiller with Reservoir
The reservoir can be filled by removing the water fill cap located on the upper rear of the chiller (See Fluid
Recommendations section). 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 reinstalled
before operation begins.
Chiller without Reservoir
The chiller and system piping should be filled with clean water ensuring that all air is purged from the system.
Figure 2. Chiller Plumbing Schematic with Pump and Tank (Standard)
Reservoir
Low Temp. Control
Evaporator Chiller Inlet
From Process
To Process
Pump Bypass Valve Chiller Outlet

CH5000 & CH7500 Chiller Operator’s & Installation Manual
Publication Number: 91961OPR - 6 - © 2006-2011, IMI Cornelius Inc.
Figure 3. Chiller Plumbing Schematic No Tank (Option)
Figure 4. Chiller Plumbing Schematic No Pump, No Tank (Option)
Low Temp. Control
Evaporator
Chiller Inlet
From Process
To Process
Pump
Bypass Valve Chiller Outlet
Low Temp. Control
Evaporator
Chiller Inlet
Chiller Outlet
From Process
To Process

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 7 - Publication Number: 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.
!
WARNING:
Running the pump in reverse for more than a few seconds results 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 preset at
the factory to ensure that system pressure does not exceed the capabilities of the pump motor and/or piping. 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.
STANDARD THEROSTAT 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 preset at the factory. The range is 40oF (4.4oC) to 100oF (37.8oC). If operation
outside of this range is required, please contact the Technical Service Department.
Figure 5. IC902 Eliwell Thermostat

CH5000 & CH7500 Chiller Operator’s & Installation Manual
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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 40oF (4.4oC) to 100oF (37.8oC). 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.
Figure 6. Control Panel
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.
3. COOLING LIGHT– A green light that indicates refrigeration system operation. This light cycles on and off
in response to the thermostat.
4. HIGH PRESSURE ALARM LIGHT– A red light that indicates high refrigeration pressure.
5. LOW PRESSURE ALARM LIGHT– A red light that indicates low refrigeration pressure.
6. LOW TEMPERATURE ALARM LIGHT– A red light that indicates and abnormally low system fluid temperature.
7. 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.

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 9 - Publication Number: 91961OPR
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. 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 drops
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 restriction
of flow by contaminates.
5. The strainer at the Chiller inlet should be removed and cleaned monthly (field installed).

CH5000 & CH7500 Chiller Operator’s & Installation Manual
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FLUID RECOMMENDATION
Chillers are designed to operate with water to provide maximum performance for temperatures of 40oF (4.4oC) to
100oF (37.8oC).
For questions regarding special or other fluids contact IMI Cornelius at 800-238-3600.
To Purchase Lab or Industrial Glycol contact:
IMI Cornelius - [phone] - Part # 111521000, 5 gallons
Bevcor [phone] - Part # 1008534, Chem Glycol Food Grade , 5 gallons
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 40oF (4.4oC)
Lab & Industrial Grade Ethylene Glycol Acceptable - 30% Glycol/70% Water
*For Applications with Temperatures below 40oF (4.4oC)
Mineral/Hydraulic Oils
(Viscosity<50 Centistokes) Acceptable
Ethylene Glycol
(Commercial/Automotive Antifreeze)
NOT Acceptable
*Silicate Rust Inhibitors in Automotive/Commercial Antifreeze dam-
ages pump seals and housing which leads to failure.
Acidic/Basic Solutions
(Above 8/Below 6 PH) Not Acceptable
Mineral/Hydraulic Oils
(Viscosity>50 Centistrokes) Not Acceptable

CH5000 & CH7500 Chiller Operator’s & Installation Manual
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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 refrigeration
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 250 PSIG (17.2 bar). If this
occurs, 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 110oF (43.3oC).
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 35oF (1.67oC). If
this occurs, check the following:
1. That the thermostat set point is set at 40oF (4.4oC) 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 38oF (3.3oC). 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 section).
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 40oF (4.4oC) or greater.
2. That the flow through the system is greater than 2 gallons (7.6 liters) 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 (4.4 bar). If the control opens again, check the control setting with
refrigeration gauges. If setting is correct, contact Technical Service Department.

CH5000 & CH7500 Chiller Operator’s & Installation Manual
Publication Number: 91961OPR - 12 - © 2006-2011, IMI Cornelius Inc.
Figure 7. Refrigeration Piping Schematic without Hot Gas Bypass
TXV Equalizer Line
TXV
Evaporator
TXV Sensing Bulb
Compressor
Low Pressure Switch High Pressure Switch
Condenser
Liquid Reveiver
Filter/Drier
Sight Glass

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 13 - Publication Number: 91961OPR
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.
The Serial Number is also needed when replacement parts are being ordered or for any warranty claims.
Figure 8. Sample Data Plate for CH5002-A
Be sure to include the serial number on any documentation or billing information.

CH5000 & CH7500 Chiller Operator’s & Installation Manual
Publication Number: 91961OPR - 14 - © 2006-2011, IMI Cornelius Inc.
TROUBLESHOOTING
Table 3.
Trouble Probable Cause Remedy
Chiller does not operate. Control
power light “off”
A. Control power switch “Off”.
B. No power.
C. Defective power supply connection.
D. Defective control power switch.
E. Defective control transfromer.
A. Turn the control power switch to the
“On” position.
B. Check the fuse or circuit breaker.
C. Check wiring and correct loose or
poor connections.
D. Replace the switch.
E. Replace the transformer.
Pump does not operate. pump
power light “off”
A. Pump power switch “Off”.
B. Defective pump power switch.
C. Defective control transformer.
A. Turn the pump power switch to the
“On” position.
B. Replace the switch.
C. Replace the transformer.
Pump does not operate. Pump
power light “On”.
A. No water in reservoir.
B. Restriction in the line to or from the
chiller.
C. Open or defective pump overload relay.
D. Defiective pump contactor.
E. Defective pump motor or damaged
impller.
A. Fill reservoir.
B. Remove restriction.
C. Manually reset the relay or replace if
necessary and check amp setting
on overload.
D. Replace the pump contactor.
E. Replace the pump or impeller.
Chiller does not cool. Cooling light
“Off”. A. Defective thermostat. A. Replace thermostat.
Chiller does not operate. Cooling
light “On”.
Low pressure alarm light cycles
on/off.
A. Process water too cold.
B. Low process water flow.
C. Defective expansion valve.
D. Refrigerant loss.
E. Water bypass valve failed.
F. Defective pump.
A. Increase the thermostat setting.
B. Ensure that there is adequate flow
through the process piping.
C. Replace the expansion valve.
D. Check the sight glass. If bubbles are
seen flowing through it, the chiller
needs to be leak checked and
recharged with refrigerant.
E. Consult Technical Service Depart-
ment.
F. Replace pump.
High pressure alarm light “On”.
A. Restricted condenser airflow.
B. Defective condenser fan and/or motor.
C. Defective expansion valve.
D. Low or no condenser water flow.
A. Clean the fins of the condenser and
ensure that the air flow is not
restricted.
B. Check to ensure that the fan blade
is not blocked. Replace the fan
motor if necessary.
C. Check to ensure that the fan blade
is not blocked. Replace the fan
motor if necessary.
D. Ensure that there is adequate flow
throught piping to condenser.
Low temperature alarm
A. Low or no process liquid flow.
B. Defective thermostat.
C. Process water too cold – below 35oF.
A. Ensure that there is adequate flow
through the process piping.
B. Replace the thermostat.
C. Increase the thermostat setting.

CH5000 & CH7500 Chiller Operator’s & Installation Manual
© 2006-2011, IMI Cornelius Inc. - 15 - Publication Number: 91961OPR
PARTS LIST
CHILLER ASSEMBLY
Figure 9. Chiller Parts Breakdown
1
2
3
4
5
6
7
8
9
10
11
26
12
13
14
15
16 17
18
19
20
21
4
10
22
23
24
25
Table 4. Chiller Assembly
Index No. Description
1 1/2” FPT Coupling
2 Thermowell, Low Temp. Thermostat (Not Shown)
3 Corner Cover
4 Side Panel
5 Rear Panel
6 Upper Front Panel
7 Lower Front Panel
8Lid
9 Control Panel
10 FPT Coupling
11 Temperature Control
12 Electric Box Assembly
13 Fan Blade
14 Fan Motor
15 White Switch/Indicator
16 Red Indicator
17 Green Indicator
18 Compressor
19 Accumulator
20 Filter/Drier
21 TX Valve
22 Evaporator Assembly
23 Condenser
24 Compressor
25 Receiver
26 Caster
NS Condenser, Water Cooled
NS Regulating Valve, Water Cooled Condenser
* Call the Techncial Service Department for Proper Panel.
Table 4. Chiller Assembly
Index No. Description

CH5000 & CH7500 Chiller Operator’s & Installation Manual
Publication Number: 91961OPR - 16 - © 2006-2011, IMI Cornelius Inc.
PUMP AND TANK COMPONENTS
Figure 10. Pump and Tank Components
Table 5. Pump and Tank
Index No. Description
1 Thermowell, Temperature Control
2 Temperature Probe
3 Tank Assembly
4Pump
5 Pump Relief Valve
** Call the Service Department for proper pump identifaction.
1
2
3
4
5