CHILLER MODEL: CFF-500 Operator s & Installation Manual Release Date: November 3, 1996 Publication Number: 90667 Revision Date: May 10, 2010 Revision: E Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
CH SERIES CHILLER OPERATOR S & INSTALLATION 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 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 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 1-800-551-4423 This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius. Printed in U.S.A. Copyright 1996-2010, All Rights Reserved, IMI Cornelius Inc.
Description...................................................................... 1 Installation...................................................................... 2 Front Panel Removal............................................................ 2 Locations..................................................................... 2 Water Connections............................................................. 2 Electrical Connections........................................................... 3 Start-Up...................................................................... 3 Operation..................................................................... 3 Maintenance..................................................................... 4 Pump........................................................................ 4 Heater....................................................................... 4 Cooling System................................................................ 4 Thermostat.................................................................... 4 CFF Performance Data............................................................ 7 All Data is Based on Water Heating Capacity (3412 BTUH-858 K-CAL/HR)...................................................... 7 Fluid Recommendations........................................................... 8 Troubleshooting.................................................................. 9 Warranty....................................................................... 10
DESCRIPTION The Cornelius Model CFF-500 Water Circulator is a self-contained unit consisting of a pump, heater, cooling system, and 2-stage thermostat housed in a rugged cabinet with a baked-on finish. It operates with any water system up to a maximum of 30 gallons (113 liters). The CFF-500 is not designed for continuous cooling at water temperatures above 85 F (29 C); although short term operation at higher temperatures with no external heat load is acceptable for pulling down the system temperature. Physical CFF-500 Shipping Weight 135 Lbs. Internal Liquid Volume 1.5 Gal. Inlet/Outlet Connectors 5/8 in. ID. Hose Construction Materials (In contact with liquid) Pump Polypropylene, 316 SS Buna-N Tank 316 SS Tubing PVC Electrical Operating Voltage 115/1/60 Full Load Current 14A Inrush Current 48A Technical Temperature Range 30-130 F Temperature Differential (max.) 3/4 F (0.4 C) Compressor 1/2 HP Heater 1 kw Refrigerant (134a) 2 Lbs. 1996-2010, IMI Cornelius Inc. - 1 - Publication Number: 90667
FRONT PANEL REMOVAL INSTALLATION In order to make connections to the chiller, it is necessary to remove the front panel by removing the fasteners on the front of the unit and then sliding the panel forward. When replacing the panel, slide it straight back until it is engaged under the rear retaining flange, and replace the front fasteners. LOCATIONS The chiller must be located so that the pump inlet is below the normal operating level of the bath to which it is connected. Failure to do so causes improper operation and damage to the pump. The following clearances must be maintained around the unit for proper operation: Top Right Side Left Side Open 24 in. 12 in. WATER CONNECTIONS 2 shows the proper and improper methods of making water connections. Water tubing should be 5/8 I. D., and hose clamps should be used to insure a leak-free connection. The inlet hose should run through the hole in the rear panel and connect to the pump suction connection. This line must run from a drain at the lowest point in the bath, and should not contain any inverted traps which could cause air binding to loss of prime. In open systems where foreign material may be present the bath drain should be raised slightly and fitted with a screen to prevent the entrance of such material into the inlet hose. The outlet hose connects to the top of the chiller tank and may enter the bath at any convenient point. Care should be taken to prevent short circuiting of water between inlet and outlet connections which are too close together in the bath. This may cause wide temperature variations. If an air trap must be present in the outlet line, then it should be provided with a vent valve to allow the complete removal of air. In closed systems (where the system is not open to the atmosphere) 3, the installation should include a surge pot located at the highest point in the outlet line, to facilitate proper purging of air and to allow for expansion and contraction of the water in the system with changes in temperature. This pot should normally have approximately 1/10th the total volume of the system, and small air space must remain at the top for proper operation. Figure 1. Water Connections Publication Number: 90667-2 - 1996-2010, IMI Cornelius Inc.
ELECTRICAL CONNECTIONS All wiring must conform to NEC and local Codes. The unit must be permanently wired by means of conduit. The conduit should be run through the hole provided in the rear of the cabinet & be connected by means of a fitting to the 1/2 knockout in the electric box. The field supply wires must be spliced to the pigtails provided in the electric box. Keep all wiring way from the relay, to avoid interfering with its proper operation. Do not operate the unit until the start-up procedure has been followed. START-UP When the installation steps have been completed, the system is ready to fill (see Page 8). With the power switch Off, begin adding water to the system until the inlet hose and pump housing are completely full. This occurs automatically if the unit has been properly installed. If this priming action does not occur, go back and review the installation to be sure that there are no restrictions or air traps in the inlet hose. Once the inlet hose is full, the pump may be started by turning the power switch on. As water is pumped through the system, air is expelled from the outlet hose. (In closed systems, the vents valve must be opened to allow air to escape from the system). Figure 2. Typical Closed System Once the pump has been started, it is important to add liquid at a sufficient rate so the inlet hose remains full. Continue adding liquid until all of the air has been expelled and the liquid is at its normal operating level. After filling, check all connections for tightness. In many cases, a leaking connection on the inlet side of the pump allows air to enter the system. This can be observed as a stream of bubbles in the hose accompanied by a growling noise in the pump. If not eliminated, this air can interfere with proper system operation and can shorten the pump life. Once the system has been properly filled and purged of air, it maintains its prime automatically. The Start-Up procedure only needs to be repeated if the system has been drained. OPERATION The unit should be turned on and off by means of the power switch. The pilot light indicates the presence of power when the switch is on. Setting the thermostat dial to the desired temperature causes either the heater or cooling system to operate, depending on the water temperature. In applications requiring extreme accuracy, a thermometer should be used in the liquid bath to determine the temperature. In operation, the circulating pump runs continuously, drawing water from the system and pumping it through the tank and back out to the system. The 2-stage thermostat senses the water temperature in the tank and cycles the heater or cooling system in response to temperature changes below or above the setpoint respectively. Heating is accomplished by means of an immersion heater located at one end of the tank. The cooling system is completely sealed and consists of a compressor, condenser, receiver, thermal expansion valve and a heat exchanger which is an integral part of the tank. It utilizes refrigerant 134a to remove heat from the liquid in the tank. 1996-2010, IMI Cornelius Inc. - 3 - Publication Number: 90667
MAINTENANCE The CFF-500 requires very little normal maintenance. The condenser fins should be cleaned occasionally with a brush or compressed air to keep them from becoming blocked by dirt. If the unit is to be shut off for a prolonged period, it should be flushed with clean water and then drained completely. Every 6 months, the pump should be oiled with SAE20 non-detergent oil at the two motor oil ports. Except for the refrigeration system, the CFF-500 is easily serviced in the field, if required. The following section serves as a guide to making general repairs. PUMP The pump consists of only one moving part, the impeller, which is magnetically driven by an open type, thermally protected motor. This magnetic drive construction eliminates shaft seals and their associated leakage and wear problems. The most common source of pump failure is dry operation, which causes the impeller to bind. HEATER The immersion heater is installed in a threaded connection in the tank. Electrical connections are made through slipon terminals. When installing a new heater, teflon tape should be used on the threads to insure a leak proof seal. COOLING SYSTEM The cooling system is hermetically sealed, and repairs to the refrigeration components should only be made by the factory. Field replaceable parts include the compressor electrical equipment and the condenser fan. The compressor electrical equipment consists of a thermal protector, starting relay and a starting capacitor. These components are located in the compressor terminal box. Care should be taken to ensure that the wires are reconnected properly when replacing these components. THERMOSTAT The thermostat consists of a temperature actuated bellows assembly which operates two micro-switches. These switches operate at slightly different temperatures to control the heating or cooling of the water in the tank. The internal thermostat parts are not field replaceable or adjustable. In case of any failure, the thermostat should be replaced. When replacing the thermostat, note the routing of the capillary, and be sure to avoid any kinks or sharp bends. The bulb is located in a well in the tank and can be removed or replaced simply by sliding it in and out. When reinstalling a new thermostat, the bulb should be coated with a heat conducting compound such as silicone grease or thermal mastic, which is available at most refrigeration supply houses. Publication Number: 90667-4 - 1996-2010, IMI Cornelius Inc.
Figure 3. Wiring Diagram 1996-2010, IMI Cornelius Inc. - 5 - Publication Number: 90667
Figure 4. Circulator Dimensions Publication Number: 90667-6 - 1996-2010, IMI Cornelius Inc.
CFF PERFORMANCE DATA ALL DATA IS BASED ON WATER HEATING CAPACITY (3412 BTUH-858 K-CAL/HR) Figure 5. Performance Data 1996-2010, IMI Cornelius Inc. - 7 - Publication Number: 90667
Ice Frost Operator s Manual 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). Distilled Water De-Ionized Water (1-5 Meg ohms) De-Ionized Water (5+ Meg ohms) Propylene Glycol (Lab & Industrial Grade) Lab & Industrial Grade Ethylene Glycol Mineral/Hydraulic Oils (Commercial/Automotive Antifreeze) Acidic/Basic Solutions (Above 8 or below 6 PH) Mineral/Hydraulic Oils (Viscosity > 50 Centistrokes) Acceptable Acceptable Acceptable with Stainless Steel & PVC only (No Copper or Brass) Acceptable - 30% Glycol/70% Water (For Applications with Temperatures below 40 F) Acceptable - 30% Glycol/70% Water (For Applications with Temperatures below 40 F) NOT Acceptable (Silicate Rust Inhibitors in Automotive/Commercial antifreeze damages pump seals and housing which lead to failure.) Not Acceptable Not Acceptable For questions regarding special or other fluids contact IMI Cornelius at 1-800-551-4423. To purchase Lab or Industrial Glycol contact: IMI Cornelius, 1-800-551-4423 - Part No. 111521000, 5 Gal. Publication Number: M620919596OPR - 8-2004-2007, IMI 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. Trouble Problem Cause Remedy Unit does not operate, Power Light OFF. Unit does not pump water. Unit does not heat. Unit runs continuously, but is not cooling. Compressor doesn t run, body cool. Compressor doesn t run, body hot. System Temerature Erratic A. Power switch off. A. Check main disconnect fuses, wiring and power lead to unit. A. Pump motor burned out or pump impeller frozen. B. Restriction or air trap in inlet line. C. Restriction in outlet line. A. Heater burned out. B. Bad Heat switch on thermostat. A. Condenser is restricted. B. Unit low on refrigerant. C. Bad expansion valve. D. Fan motor burned out. A. Bad cool switch on thermostat. B. Bad thermal protector. C. Bad control relay in electric box. D. Compressor burned out. A. Bad starting relay. B. Bad start capacitor C. Compressor burned out. A. Air in system. B. Bad thermostat. A. Replace pump. B. Clean inlet line. C. Remove restriction for outlet line. A. Replace heater. B. Replace heat switch on thermostat. A. Clean condenser. B. Call service C. Call service. D. Replace fan motor. A. Replace cool switch on thermostat. B. Replace thermal protector. C. Replace control relay in electric box. D. Replace compressor. A. Replace starting relay. B. Replace start capacitor. C. Replace compressor. A. Purge air from system. B. Replace thermostat. 1996-2010, IMI Cornelius Inc. - 9 - Publication Number: 90667
WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius or Wilshire product, 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. Publication Number: 90667-10 - 1996-2010, IMI Cornelius Inc.
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