Marksa CSSW 50 User manual

INDUSTRIAL REFRIGERATION UNITS
TECHNICAL NOTICE V1.0

Page 2 / 100 Technical Notice V1.0 / 01.09
Identification
Marksa SA
Industrial refrigeration units
39, avenue du Technicum
CH-2400 Le Locle
Tél.: [phone]
Fax: [phone]
Version Date Comments
1.0 01.2009 First Edition
Correspondence
All correspondence regarding our products must provide the serial
number.
The serial number is located on the identification tablet fixed on the re-
frigeration unit.
LEISTUNGSAUFNAHME
Copyright ©
The reproduction, even partially, of this document is forbidden. No part may be copied in any form, and it may not
be used, edited nor transmitted by any electronic means (photocopy, photography, magnetic supports or other re-
cording processes), without the written authorization of Marksa SA. All rights and particularly reproduction, transla-
tion, edition, distribution and also industrial property and recording are reserved.

Technical Notice V1.0 / 01.09 Page 3 / 100
Table of contents
1 Introduction .................................................................................................................... 9
1.1 Foreword............................................................................................................................................ 9
1.1 Typographical conventions.............................................................................................................. 10
1.1.1 Description ....................................................................................................................... 10
1.1.2 Command......................................................................................................................... 10
1.1.3 Procedure......................................................................................................................... 10
1.1.4 Procedure result ............................................................................................................... 10
1.1.5 Cross reference................................................................................................................ 11
1.1.6 List of items ...................................................................................................................... 11
1.1.7 Troubleshooting................................................................................................................ 11
1.1.8 Warning ............................................................................................................................ 12
1.1.9 Recommendation and Note.............................................................................................. 12
2 Generalities ..................................................................................................................15
2.1 Appropriate usage .......................................................................................................................... 15
2.2 Safety and usage warnings ............................................................................................................. 15
2.2.1 Importance of the safety instructions................................................................................ 15
2.2.2 Safety ............................................................................................................................... 15
2.2.3 Graphic symbols............................................................................................................... 16
2.3 Operation ......................................................................................................................................... 17
2.3.1 Basic schematic ............................................................................................................... 17
2.3.2 Principles of operation...................................................................................................... 18
2.3.3 Separated tank and refrigeration units ............................................................................. 19
2.4 Models and available options .......................................................................................................... 20
3 Model CSW 50/65/80 .................................................................................................... 21
3.1 Description....................................................................................................................................... 21
3.1.1 Overall view...................................................................................................................... 21
3.1.2 Technical specifications ...................................................................................................23
3.2 Handling .......................................................................................................................................... 25
3.3 Installation ....................................................................................................................................... 25
3.3.1 Hydraulic connections ......................................................................................................25
3.3.2 Electrical connections....................................................................................................... 25
3.3.3 Filling the reservoir ........................................................................................................... 25
3.4 Commissioning ................................................................................................................................ 26
4 Model CSW 100/150 ..................................................................................................... 27
4.1 Description....................................................................................................................................... 27
4.1.1 Overall view...................................................................................................................... 27
4.1.2 Technical specifications ...................................................................................................28
4.2 Handling .......................................................................................................................................... 30
4.3 Installation ....................................................................................................................................... 30
4.3.1 Hydraulic connections ......................................................................................................30
4.3.2 Electrical connections....................................................................................................... 30
4.3.3 Filling the reservoir ........................................................................................................... 30
4.4 Commissioning ................................................................................................................................ 31
4.5 Specific tuning ................................................................................................................................. 31
4.5.1 Draining the reservoir ....................................................................................................... 31

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Table of contents
5 Model CSW 200/300 .....................................................................................................33
5.1 Description....................................................................................................................................... 33
5.1.1 Overall view...................................................................................................................... 33
5.1.2 Technical specifications.................................................................................................... 34
5.2 Handling........................................................................................................................................... 36
5.3 Installation........................................................................................................................................ 36
5.3.1 Hydraulic connections ......................................................................................................36
5.3.2 Electrical connections....................................................................................................... 36
5.3.3 Filling the reservoir ........................................................................................................... 36
5.4 Commissioning ................................................................................................................................ 37
5.5 Specific tuning ................................................................................................................................. 37
5.5.1 Draining the reservoir ....................................................................................................... 37
6 Model CSW 400 ............................................................................................................39
6.1 Description....................................................................................................................................... 39
6.1.1 Overall view...................................................................................................................... 39
6.1.2 Technical specifications.................................................................................................... 40
6.2 Handling........................................................................................................................................... 42
6.3 Installation........................................................................................................................................ 42
6.3.1 Hydraulic connections ......................................................................................................42
6.3.2 Electrical connections....................................................................................................... 42
6.3.3 Filling the reservoir ........................................................................................................... 42
6.4 Commissioning ................................................................................................................................ 43
6.5 Specific tuning ................................................................................................................................. 43
6.5.1 Draining the reservoir ....................................................................................................... 43
7 Model CSW 600/800 .....................................................................................................45
7.1 Description....................................................................................................................................... 45
7.1.1 Overall view...................................................................................................................... 45
7.1.2 Technical specifications.................................................................................................... 47
7.2 Handling........................................................................................................................................... 49
7.3 Installation........................................................................................................................................ 49
7.3.1 Hydraulic connections ......................................................................................................49
7.3.2 Electrical connections....................................................................................................... 49
7.3.3 Filling the reservoir ........................................................................................................... 49
7.4 Commissioning ................................................................................................................................ 50
7.5 Specific tuning ................................................................................................................................. 50
7.5.1 Draining the reservoir ....................................................................................................... 50
7.6 Close the drainage tap once the reservoir is empty. ....................................................................... 50
8 Model CSW 900/1000/1300/1700 .................................................................................51
8.1 Description....................................................................................................................................... 51
8.1.1 Overall view...................................................................................................................... 51
8.1.2 Technical specifications.................................................................................................... 53
8.2 Handling........................................................................................................................................... 55
8.3 Installation........................................................................................................................................ 55
8.3.1 Hydraulic connections ......................................................................................................55
8.3.2 Electrical connections....................................................................................................... 55
8.3.3 Filling the reservoir ........................................................................................................... 55
8.4 Commissioning ................................................................................................................................ 56
8.5 Specific tuning ................................................................................................................................. 56
8.5.1 Draining the reservoir ....................................................................................................... 56

Technical Notice V1.0 / 01.09 Page 5 / 100
Table of contents
9 Model CSW 2000/2400 ................................................................................................. 57
9.1 Description....................................................................................................................................... 57
9.1.1 Overall view...................................................................................................................... 57
9.1.2 Technical specifications ...................................................................................................59
9.2 Handling .......................................................................................................................................... 61
9.3 Installation ....................................................................................................................................... 61
9.3.1 Hydraulic connections ......................................................................................................61
9.3.2 Electrical connections....................................................................................................... 61
9.3.3 Filling the reservoir ........................................................................................................... 61
9.4 Commissioning ................................................................................................................................ 62
9.5 Specific tuning ................................................................................................................................. 62
9.5.1 Draining the reservoir ....................................................................................................... 62
9.6 Close the drainage tap once the reservoir is empty. ....................................................................... 62
10 Model CSW 3000/3500/4700 ........................................................................................ 63
10.1 Description....................................................................................................................................... 63
10.1.1 Overall view...................................................................................................................... 63
10.1.2 Technical specifications ................................................................................................... 65
10.2 Handling .......................................................................................................................................... 67
10.3 Installation ....................................................................................................................................... 67
10.3.1 Hydraulic connections ...................................................................................................... 67
10.3.2 Electrical connections....................................................................................................... 67
10.3.3 Filling the reservoir ........................................................................................................... 67
10.4 Commissioning ................................................................................................................................ 68
10.5 Specific tuning ................................................................................................................................. 68
10.5.1 Draining the reservoir ....................................................................................................... 68
10.6 Close the drainage tap once the reservoir is empty. ....................................................................... 68
11 Tuning and maintenance............................................................................................. 69
11.1 Control settings................................................................................................................................ 69
11.1.1 Thermostat ....................................................................................................................... 69
11.2 Maintenance .................................................................................................................................... 71
11.2.1 Periodic maintenance....................................................................................................... 71
11.2.2 Safety ............................................................................................................................... 71
11.2.3 Maintenance table ............................................................................................................ 71
11.2.4 Weekly maintenance ........................................................................................................71
11.2.5 Monthly maintenance .......................................................................................................71
11.2.6 Annual maintenance......................................................................................................... 72

Page 6 / 100 Technical Notice V1.0 / 01.09
Table of contents
12 Options..........................................................................................................................73
12.1 List of the options............................................................................................................................. 73
12.2 Air filter (A)....................................................................................................................................... 75
12.2.1 Description of the option................................................................................................... 75
12.2.2 Maintenance ..................................................................................................................... 75
12.2.3 Breakdowns...................................................................................................................... 75
12.3 By-pass (J)....................................................................................................................................... 76
12.3.1 Description of the option................................................................................................... 76
12.3.2 Maintenance ..................................................................................................................... 76
12.3.3 Breakdowns...................................................................................................................... 76
12.4 Distributor (D) .................................................................................................................................. 77
12.4.1 Description of the option................................................................................................... 77
12.4.2 Maintenance ..................................................................................................................... 77
12.4.3 Breakdowns...................................................................................................................... 77
12.5 400V power supply (E) .................................................................................................................... 77
12.5.1 Description of the option................................................................................................... 77
12.5.2 Maintenance ..................................................................................................................... 77
12.5.3 Breakdowns...................................................................................................................... 77
12.6 Water-flow controller (F) .................................................................................................................. 78
12.6.1 Description of the option................................................................................................... 78
12.6.2 Maintenance ..................................................................................................................... 78
12.6.3 Breakdowns...................................................................................................................... 78
12.7 Hot gas bypass (G).......................................................................................................................... 79
12.7.1 Description of the option................................................................................................... 79
12.7.2 Thermostat ....................................................................................................................... 80
12.7.3 Maintenance ..................................................................................................................... 81
12.7.4 Breakdowns..................................................................................................................... 81
12.8 Pre-heating kit (H)............................................................................................................................ 82
12.8.1 Description of the option................................................................................................... 82
12.8.2 Maintenance ..................................................................................................................... 82
12.8.3 Breakdowns...................................................................................................................... 82
12.9 Thermal insulation (I) ....................................................................................................................... 83
12.9.1 Description of the option................................................................................................... 83
12.9.2 Maintenance ..................................................................................................................... 83
12.9.3 Breakdowns...................................................................................................................... 83
12.10 Differential thermostat (L) ................................................................................................................ 83
12.10.1 Description of the option................................................................................................... 83
12.10.2 Maintenance..................................................................................................................... 83
12.10.3 Breakdowns...................................................................................................................... 83
12.11 Chassis sur roulettes (M)................................................................................................................. 83
12.11.1 Description of the option................................................................................................... 83
12.11.2 Maintenance..................................................................................................................... 83
12.11.3 Breakdowns...................................................................................................................... 83
12.12 Contrôle de niveau (N)..................................................................................................................... 84
12.12.1 Description of the option................................................................................................... 84
12.12.2 Maintenance..................................................................................................................... 84
12.12.3 Breakdowns...................................................................................................................... 84
12.13 Circuit d’eau sous pression (P)........................................................................................................ 85
12.13.1 Description of the option................................................................................................... 85
12.13.2 Maintenance..................................................................................................................... 85
12.13.3 Breakdowns...................................................................................................................... 85
12.14 Reinforced pump (R) ....................................................................................................................... 86
12.14.1 Description of the option................................................................................................... 86
12.14.2 Maintenance..................................................................................................................... 86
12.14.3 Breakdowns...................................................................................................................... 86
12.15 LP/HP safety pressure controllers (S) ............................................................................................. 87

Technical Notice V1.0 / 01.09 Page 7 / 100
Table of contents
12.15.1 Description of the option................................................................................................... 87
12.15.2 Maintenance..................................................................................................................... 87
12.15.3 Breakdowns...................................................................................................................... 88
12.16 Timer (T) .......................................................................................................................................... 88
12.16.1 Description of the option................................................................................................... 88
12.16.2 Maintenance..................................................................................................................... 88
12.16.3 Breakdowns...................................................................................................................... 88
12.17 Electric valve and solenoid (W) ....................................................................................................... 88
12.17.1 Description of the option................................................................................................... 88
12.17.2 Maintenance..................................................................................................................... 88
12.17.3 Breakdowns...................................................................................................................... 88
12.18 High temperature alarm (Y) ............................................................................................................. 89
12.18.1 Description of the option................................................................................................... 89
12.18.2 Maintenance..................................................................................................................... 89
12.18.3 Breakdowns...................................................................................................................... 89
13 Breakdowns.................................................................................................................. 91
13.1 Warnings.......................................................................................................................................... 91
13.2 Checks............................................................................................................................................. 91
13.2.1 Pressure checks............................................................................................................... 91
13.3 Breakdowns ..................................................................................................................................... 92
13.3.1 Le groupe ne fonctionne pas............................................................................................ 92
14 Appendix....................................................................................................................... 95
14.1 Compliance...................................................................................................................................... 95
14.1.1 Directives.......................................................................................................................... 95
14.1.2 Identification plate ........................................................................................................... 95
14.2 Disposal of the product .................................................................................................................... 96
14.2.1 General remarks............................................................................................................... 96
14.2.2 Preparation....................................................................................................................... 96
14.3 Maintenance sheet ......................................................................................................................... 97
14.4 Technical data sheet........................................................................................................................ 98
14.5 Compliance documents ................................................................................................................... 99

Page 8 / 100 Technical Notice V1.0 / 01.09
Table of contents

Technical Notice V1.0 / 01.09 Page 9 / 100
Introduction 1
Chapter contents
This chapter contains basic information on the structure and the specifications of the document, and on
the documentation.
1.1 Foreword
This manual is intended for all users of a Marksa refrigeration unit. It contains all the information ne-
cessary for installation, commissioning, periodic maintenance and repair.
This manual was compiled by the Marksa SA company with the same care as your refrigeration unit and
is therefore an inseparable component. If you have any questions or do not completely understand any
point, please contact your retailer immediately or contact us directly.

Page 10 / 100 Technical Notice V1.0 / 01.09
1 Introduction
1.1 Typographical conventions
The following styles are used in this manual.
1.1.1 Description
This style, use in conjunction with illustration numbers, is preceded with the corresponding numbers:
Example:
(1) First element
(2) Second element
(3) Etc...
1.1.2 Command
Any software command, button, function key, window, icon, option, tab, checkbox, selection box, article,
menu, tool bar, field and section used in this document is represented by a bold italic font.
Example:
The Exit command allows to quit the software.
1.1.3 Procedure
Each procedure step to be carried out step-by-step by the user is preceded by a letter.
Example
A. Open the drawer.
B. Put the microplate into position as shown.
C. Close the drawer.
1.1.4 Procedure result
A procedure result is shown by the following symbol .
Example
A. Click on the Parameters button.
The parameter window is displayed.

Technical Notice V1.0 / 01.09 Page 11 / 100
Introduction 1
1.1.5 Cross reference
This style is used to helps the user find complementary information linked to the current subject.
Example:
See section “4.2.4 Sensor Board Positioning” on page 47.
1.1.6 List of items
This style is used in order to display a list of elements.
Example:
•item1;
•item2;
•item3.
1.1.7 Troubleshooting
The complete description of the error message, the explanation and the remedy appear as follows:
Problem
- Explanation, possible cause
✔Remedy

Page 12 / 100 Technical Notice V1.0 / 01.09
1 Introduction
1.1.8 Warning
Depending on the importance of the warning and the associated risks, three warning styles are defined.
The safety aspects are used in accordance with the requirements contained in the following norms:
• ANSI Z535.4;
• ISO 3864, ISO 3864-1:2002, and ISO3864-2:2004.
1.1.8.1 Danger
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
The main risk is shown in capitals under the symbol WARNING .The mention of a risk does not exclude
anyway the presence of subsidiary risks.
Example
ELECTROCUTION
Never touch unisolated electrical wire. A contact with conductors may cause an electrocution.
1.1.8.2 Warning
Used to indicate a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Example
Always disconnect the power supply cable before working inside the device. A contact with live
conductors may cause an electrocution.
1.1.8.3 Caution
Used to indicate a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
Example
If the mirror is broken, do not handle it with unprotected hands because of risks of cut.
The use of the sign CAUTION without triangle means there is a risk of minor damage, but no possible
injury.
Example
The use of other cleaning agents or hard objects may damage the ID-Pipetor EP-5. Do not use
others cleaning agents or products prior to consult Marksa SA and to receive the agreement.
1.1.9 Recommendation and Note
When additional information is necessary and its non-respect conduct to minor inconveniences, recom-
mendations and notes are presented.
1.1.9.1 Recommendation
Used to designate a preferred procedure or a recommended usage. Marksa SA declines any responsi-
bility in case of non-respected recommendations.

Technical Notice V1.0 / 01.09 Page 13 / 100
Introduction 1
Example
For more information, contact either your DiaMed AG representative or the manufacturer direct-
ly.
1.1.9.2 Note
Used to give a general or purely informative remark.
Example
The housing reassembly must follow the reverse order of the disassembly.

Page 14 / 100 Technical Notice V1.0 / 01.09
1 Introduction

Technical Notice V1.0 / 01.09 Page 15 / 100
Generalities 2
Chapter contents
This chapter contains generic information applicable to all refrigeration unit models. In particular, it
contains instructions concerning safety as well as practical and theoretical information.
2.1 Appropriate usage
The refrigeration unit is intended to be used to maintain the ambient temperature of a machine tool. It
can be only be used by trained and authorised personnel.
The instructions contained in this user manual must be carefully respected, specifically those concerning
safety.
2.2 Safety and usage warnings
2.2.1 Importance of the safety instructions
The safety and protection instructions appearing in this manual must be respected to avoid injury, da-
mage to property and environmental pollution. In the same manner, the legal conditions, accident pre-
vention and environmental protection measures, as well as the technical regulations for guaranteeing
safe and suitable working conditions applicable in your country and on the specific installation site of the
refrigeration unit must be respected.
The use of the refrigeration unit in any other manner than described in this manual may void the
guarantee.
2.2.2 Safety
Leave free space of at least 0.5m in front of the intake and 1m in front of the exhaust fan.
As the cooling process is reliant on the circulation of air, sufficient space on each side and above
the refrigeration unit must be planned to ensure that the exhaust fan does not repeatedly recycle
the same air.
The maximum allowable ambient temperature is 38°C for the intake.
The minimum acceptable ambient temperature is 5°C. Below this limit, the operation of your re-
frigeration unit will be disrupted.

Page 16 / 100 Technical Notice V1.0 / 01.09
2 Generalities
2.2.3 Graphic symbols
The following symbols may be present on your refrigeration unit:
Symbol Description
Risk of electrocution
Risk of burns
Table 2-1: Symbols



Technical Notice V1.0 / 01.09 Page 17 / 100
Generalities 2
2.3 Operation
2.3.1 Basic schematic
2.3.1.1 Direct cooling of the tank
Fig. 2-1 : Basic schematic
TH
BP - HP
(7)(6)(4)(3)(2)(1)
(8) (9) (10) (11) (12) (14)(13)
(5)

Page 18 / 100 Technical Notice V1.0 / 01.09
2 Generalities
2.3.1.2 Legend
(1) Pump
(2) Temperature probe
(3) Thermostat
(4) Compressor
(5) Safety pressure controller (an option on the CSW100)
(6) Exhaust fan
(7) Condenser
(8) Temperate water inlet
(9) Cold water outlet
(10) Reservoir
(11) Evaporator
(12) Pressure regulator
(13) Dehumidifier
(14) Cooling circuit
2.3.2 Principles of operation
The whole range of water chillers supply chilled water (9) continuously at a constant temperature.
The chilling is accomplished in the following manner: An HFC refrigerant of either R134A (tetrafluo-
roethane) or R407C types is compressed (4) then chilled in a condenser (7).
A pressure regulator (12) causes a drop in pressure which leads to a drop in temperature. The drop in
temperature is transmitted to the water contained in the reservoir (19) through a heat exchanger (11).
The cold water leaves the reservoir (9) to chill the end use equipment and then returns back to the re-
servoir (8).

Technical Notice V1.0 / 01.09 Page 19 / 100
Generalities 2
2.3.3 Separated tank and refrigeration units
For refrigeration units of greater capacity, the refrigerant liquid returned is stored in a reservoir (10) then
pumped (1) and chilled (11) before being returned back to the cooling circuit (8)..
Fig. 2-2 : Basic schematic
TH HPBP
(7)(6)(4)(3)(2)(1)
(8) (9) (10) (11) (12) (14)(13)
(5)

Page 20 / 100 Technical Notice V1.0 / 01.09
2 Generalities
2.4 Models and available options
The CSW range of industrial water chillers covers several models, classified according to their capacities
and available options.
The following models are currently available:
Various options are available.
See section “12.1 List of the options” on page 73.
The options are referenced as initials in the product name, just after the reference to its class.
Example
CSW 100 NRV
With:
N : Water-level control
R : Reinforced pump
V : Visual water-level indicator
Model Capacity Refrigerant
gas Model Capacity Refrigerant gas
CSW 50 0.5 kW 134A CSW 800 7.8 kW 407C
CSW 65 0.65 kW 134A CSW 900 9.3 kW 407C
CSW 80 0.8 kW 134A CSW 1000 9.7 kW 407C
CSW 100 1 kW 134A CSW 1300 12 kW 407C
CSW 150 1.5 kW 134A CSW 1700 16.4kW 407C
CSW 200 3 kW 134A CSW 2000 20 kW 407C
CSW 300 3 kW 134A CSW 2400 24 kW 407C
CSW 400 4 kW 407C CSW 3000 30 kW 407C
CSW 600 6 kW 407C CSW 3500 35 kW 407C
Table 2-2: List of models