Marksa CSO Series User manual
INDUSTRIAL REFRIGERATION UNITS
TECHNICAL NOTICE CSO/CPO
V1.1 - 10.14
Page 2 / 86 Technical Notice CSO/CPO V1.1 / 10.14
Identification
Marksa SA
Industrial Refrigeration
39, avenue du Technicum
CH-2400 Le Locle
Tel.: +41 32 933 55 55
Fax: +41 32 931 15 65
Translated from original French Notice.
Version Date Comments
1.0 09.03.12 First Edition
1.1 21.10.14 Minor modifications (Omron
E5CC thermostat and pro-
grammable controller)
Correspondance
All correspondence regarding our products must provide the serial
number. The serial number is located on the identification plate fixed
on the refrigeration unit.
CSO
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 CSO/CPO V1.1 / 10.14 Page 3 / 86
Table of contents
1 Introduction .................................................................................................................... 7
1.1 Foreword ........................................................................................................................................... 7
1.2 Typographical conventions ............................................................................................................... 8
1.2.1 Description ......................................................................................................................... 8
1.2.2 Command........................................................................................................................... 8
1.2.3 Procedure........................................................................................................................... 8
1.2.4 Cross reference.................................................................................................................. 8
1.2.5 List of items ........................................................................................................................ 8
1.2.6 Troubleshooting.................................................................................................................. 9
1.2.7 Warnings ............................................................................................................................ 9
1.2.8 Recommendation and Note.............................................................................................. 10
2 Generalities .................................................................................................................. 11
2.1 Appropriate usage .......................................................................................................................... 11
2.2 Safety and usage precautions ........................................................................................................ 11
2.2.1 Importance of the safety instructions................................................................................ 11
2.2.2 Safety ............................................................................................................................... 11
2.2.3 Graphic symbols............................................................................................................... 12
2.3 CSO/CPO principles of operation ................................................................................................... 13
2.3.1 Basic schematic ............................................................................................................... 13
2.4 Models and available options ......................................................................................................... 14
2.4.1 List of models ................................................................................................................... 14
2.4.2 Available options .............................................................................................................. 14
3 CPO 140 model............................................................................................................. 15
3.1 Description ...................................................................................................................................... 15
3.1.1 Front view......................................................................................................................... 15
3.1.2 Technical specifications ................................................................................................... 16
3.2 Handling ......................................................................................................................................... 18
3.3 Installation ...................................................................................................................................... 18
3.3.1 Hydraulic connections ...................................................................................................... 18
3.3.2 Electrical connections....................................................................................................... 18
3.4 Commissioning ............................................................................................................................... 18
4 CPO 310 - CSO 300 models......................................................................................... 19
4.1 Description ...................................................................................................................................... 19
4.1.1 Front view......................................................................................................................... 19
4.1.2 Rear view ......................................................................................................................... 20
4.1.3 Technical specifications ................................................................................................... 21
4.2 Handling ......................................................................................................................................... 23
4.3 Installation ...................................................................................................................................... 23
4.3.1 Hydraulic connections ...................................................................................................... 23
4.3.2 Electrical connections....................................................................................................... 23
4.4 Commissioning ............................................................................................................................... 24
Page 4 / 86 Technical Notice CSO/CPO V1.1 / 10.14
Table of contents
5 CSO 500/800 models.................................................................................................... 25
5.1 Description ...................................................................................................................................... 25
5.1.1 Front view......................................................................................................................... 25
5.1.2 Rear view ......................................................................................................................... 26
5.1.3 Technical specifications.................................................................................................... 27
5.2 Handling .......................................................................................................................................... 29
5.3 Installation ....................................................................................................................................... 29
5.3.1 Hydraulic connections ...................................................................................................... 29
5.3.2 Electrical connections....................................................................................................... 29
5.4 Commissioning ............................................................................................................................... 30
6 CPO 510/810 models.................................................................................................... 31
6.1 Description ...................................................................................................................................... 31
6.1.1 Front view......................................................................................................................... 31
6.1.2 Rear view ......................................................................................................................... 32
6.1.3 Technical specifications.................................................................................................... 33
6.2 Handling .......................................................................................................................................... 35
6.3 Installation ....................................................................................................................................... 35
6.3.1 Hydraulic connections ...................................................................................................... 35
6.3.2 Electrical connections....................................................................................................... 35
6.4 Commissioning ............................................................................................................................... 36
7 CPO 1010 - CSO 1000/1300/1700 models................................................................... 37
7.1 Description ...................................................................................................................................... 37
7.1.1 Front view......................................................................................................................... 37
7.1.2 Rear view ......................................................................................................................... 38
7.1.3 Technical specifications.................................................................................................... 39
7.2 Handling .......................................................................................................................................... 41
7.3 Installation ....................................................................................................................................... 41
7.3.1 Hydraulic connections ...................................................................................................... 41
7.3.2 Electrical connections....................................................................................................... 41
7.4 Commissioning ............................................................................................................................... 42
Technical Notice CSO/CPO V1.1 / 10.14 Page 5 / 86
Table of contents
8 Tuning and maintenance............................................................................................. 43
8.1 Tunings ........................................................................................................................................... 43
8.1.1 Thermostat ....................................................................................................................... 43
8.2 Maintenance ................................................................................................................................... 45
8.2.1 Periodic maintenance....................................................................................................... 45
8.2.2 Safety ............................................................................................................................... 45
8.2.3 Maintenance table ............................................................................................................ 45
8.2.4 Weekly maintenance ........................................................................................................45
8.2.5 Monthly maintenance .......................................................................................................45
8.2.6 Annual maintenance......................................................................................................... 46
9 Options ......................................................................................................................... 47
9.1 List of the options ........................................................................................................................... 47
9.1.1 Air filter (A) ....................................................................................................................... 48
9.1.2 Cleanable heat exchanger (B).......................................................................................... 49
9.1.3 Pump (C) .......................................................................................................................... 51
9.1.4 Distributor (D) .................................................................................................................. 52
9.1.5 400 V Power supply (E)....................................................................................................52
9.1.6 Flow rate controller (F) ..................................................................................................... 53
9.1.7 Hot gas bypass (G) .......................................................................................................... 54
9.1.8 Pre-heating kit (H) ............................................................................................................ 60
9.1.9 Differential thermostat (L)................................................................................................. 61
9.1.10 Frame on casters (M) ....................................................................................................... 61
9.1.11 LP/HP safety pressure controllers (S) .............................................................................. 62
9.1.12 Timer (T).......................................................................................................................... 64
9.1.13 Pressure gauge (V) .......................................................................................................... 64
9.1.14 Programmable troubleshooting logic controller (Y) .......................................................... 65
9.1.15 High temperature alarm (Z) .............................................................................................. 78
10 Troubleshooting........................................................................................................... 79
10.1 Warnings ......................................................................................................................................... 79
10.2 Checks ............................................................................................................................................ 79
10.2.1 Pressure checks............................................................................................................... 79
10.3 Failures ........................................................................................................................................... 80
10.3.1 The unit is not operating................................................................................................... 80
Page 6 / 86 Technical Notice CSO/CPO V1.1 / 10.14
Table of contents
11 Appendix....................................................................................................................... 83
11.1 Compliance ..................................................................................................................................... 83
11.1.1 Directives.......................................................................................................................... 83
11.1.2 Identification plate ............................................................................................................ 83
11.2 Disposal of the product ................................................................................................................... 84
11.2.1 General remarks............................................................................................................... 84
11.2.2 Preparation ....................................................................................................................... 84
11.3 Technical file ................................................................................................................................... 84
11.4 Maintenance sheet ......................................................................................................................... 85
11.5 Compliance certificat ...................................................................................................................... 86
Technical Notice CSO/CPO V1.1 / 10.14 Page 7 / 86
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 8 / 86 Technical Notice CSO/CPO V1.1 / 10.14
1 Introduction
1.2 Typographical conventions
The following styles are used in this manual.
1.2.1 Description
This style, used in conjunction with illustration numbers, is preceded with the corresponding numbers:
Example
(1) First element
(2) Second element
(3) Etc.
1.2.2 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 On button allows actuating the unit
1.2.3 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. Replace the defective component.
C. Close the drawer.
1.2.3.1 Procedure result
A procedure result is shown by the following symbol .
Example
A. Set the main switch to OFF.
The device's electric power is switched off
1.2.4 Cross reference
This style is used to help the user find complementary information linked to the current subject.
Example
See section “1.2.4 Cross reference” on page 8.
1.2.5 List of items
This style is used in order to display a list of elements.
Example
•item 1 ;
•item 2 ;
•item 3.
Technical Notice CSO/CPO V1.1 / 10.14 Page 9 / 86
Introduction 1
1.2.6 Troubleshooting
The complete description, as well as the error message, the explanation and the remedy, appear as
follows:
Problem
- Explanation, possible cause
✔Remedy
1.2.7 Warnings
Depending on the importance of the warning and the associated risks, five warning styles are defined.
The "Danger", "Warning" and "Caution" warnings are defined in accordance with the requirements
contained in the following norms :
• ANSI Z535.4;
• ISO 3864, ISO 3864-1:2002 et ISO 3864-2:2004.
1.2.7.1 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.
1.2.7.2 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.
Page 10 / 86 Technical Notice CSO/CPO V1.1 / 10.14
1 Introduction
1.2.7.3 Caution
Used to indicate a potentially hazardous situation which, if not avoided, may result in minor injury or ma-
terial damage.
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 material damage, but no possible
injury.
Example
The unit must be transported flat and must not sustain any shocks.
1.2.8 Recommendation and Note
When additional information is necessary and its non-respect conduct to minor inconveniences, recom-
mendations and notes are presented.
1.2.8.1 Recommendation
The recommendation is used to designate a preferable procedure or a recommended usage.
Marksa SA declines any responsibility in case of non-respect of recommendations.
Example
Make sure the device is closed before starting it.
1.2.8.2 Note
Used to give a general or purely informative remark.
Example
The unit has been checked, tuned and tested in our workshops.
Technical Notice CSO/CPO V1.1 / 10.14 Page 11 / 86
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 used only 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 precautions
2.2.1 Importance of the safety instructions
The safety and protection instructions appearing in this manual must be respected to avoid injury,
damage to property and environmental pollution. In the same manner, the legal provisions, 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 provided 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 allowable ambient temperature is 5°C. Below this limit, the operation of your refri-
geration unit will be disrupted.
Technical Notice CSO/CPO V1.1 / 10.14 Page 13 / 86
Generalities 2
2.3 CSO/CPO principles of operation
The range of CSO/CPO chillers supplies chilled oil (10) continuously at a constant temperature. The
chilling is accomplished in the following manner: An HFC refrigerant of either R134A (tetrafluoroethane)
or R407C types is compressed (5) and then chilled in an air condenser (8). A pressure regulator (16)
causes a drop in pressure which leads to a drop in temperature. The drop in temperature is transmitted
to the oil contained in the unit through an evaporator (15).
The cold oil leaves the unit (10) to chill the end use equipment and then returns back to the unit.
2.3.1 Basic schematic
Fig. 2-1 : Basic schematic
(1) Customer pump (option C - only CPO)
(2) Temperature probe
(3) Thermostat
(4) Safety pressure controllers (LP/HP)
(5) Compressor
(6) Hot gas bypass (option G)
(7) Exhaust fan
(8) Air condenser
(9) Temperate liquid inlet
(10) Cold liquid outlet
(11) Pressure gauge (option V)
(12) Flow rate controller (option F)
(13) Safety thermostat (option H)
(14) Heater (option H)
(15) Evaporator (cleanable exchanger option B -
only CPO)
(16) Pressure regulator
(17) Liquid indicator
(18) Dehumidifier
(19) Liquid reservoir
(1) (2) (3) (5) (4) (7) (8)
(16) (17) (19)(13)(12)
(10)(9)
(4)
(14) (15) (18)
(6)
(11)
Page 14 / 86 Technical Notice CSO/CPO V1.1 / 10.14
2 Generalities
2.4 Models and available options
The CSO and CPO range of industrial oil chillers covers several models classified according to their ca-
pacities and available options.
On CPO models a pump can be added directly as an option in the unit, as well as a cleanable exchanger.
2.4.1 List of models
The following models are currently available:
2.4.2 Available options
Various options are available.
See section “9.1 List of the options” on page 47.
The options are referenced in the product name just after the reference to its class.
Example
CPO 140 HC
With :
H : Pre-heating kit
C : Pump
CPO model Capacity Refrigerant
gas CSO model Capacity Refrigerant
gas
CPO 140 1.4 kW R 134A - - -
CPO 310 3 kW R 134A CSO 300 3 kW R 134A
CPO 510 5 kW R 407C CSO 500 5 kW R 407C
CPO 810 7.8 kW R 407C CSO 800 7.8 kW R 407C
CPO 1010 9.7 kW R 407C CSO 1000 9.7 kW R 407C
--- CSO 1300 12 kW R 407C
- - - CSO 1700 16.4 kW R 407C
Table 2-2: List of models
Technical Notice CSO/CPO V1.1 / 10.14 Page 15 / 86
CPO 140 model 3
Chapter contents
This chapter contains information specific to the CPO 140 model. It covers all topics associated with ins-
tallation, commissioning, tuning and maintenance of this model.
3.1 Description
3.1.1 Front view
Fig. 3-1 : CPO 140 type chiller
(1) Thermostat display
(2) Main power switch
(3) Visual failure indicator (red)
(1) (2)
(3)
Page 16 / 86 Technical Notice CSO/CPO V1.1 / 10.14
3 CPO 140 model
3.1.2 Technical specifications
3.1.2.1 Standard operating parameters
3.1.2.2 Electrical data
3.1.2.3 Air condenser
3.1.2.4 Evaporator
Description Unit CPO 140
Refrigerant Type R134A
Refrigerating capacity kW 1.4
Power consumption kW 0.7
Heat load kW 2.1
Inlet temperature °C 24
Outlet temperature °C 20
Max. input temperature °C 38°C
Description Unit CPO 140
Power input kW 0.8
Maximum amperage A 5
Start-up amperage A 13
Line fuse A T 10
Power supply V x ph x Hz 230 x 1 x 50
Description Unit CPO 140
Flow rate m3/h 580
Copper Alu w/ fins - X
Description Unit CPO 140
Pressure drops Pa 25
Stainless steel w/ rolled
plates
- X
Tubular stainless steel
(Cleanable)
-option
Technical Notice CSO/CPO V1.1 / 10.14 Page 17 / 86
CPO 140 model 3
3.1.2.5 Hydraulic circuit
3.1.2.6 Dimensions
3.1.2.7 Other characteristics
Description Unit CPO 140
Min. flow rate l/min 12.5
Inlet/outlet coupling diameter 3/4”
Description Unit CPO 140
Width mm 435
Height mm 520
Depth mm 550
Weight kg 4
Description Unit CPO 140
Standard colour Stainless steel
Sound rating
ISO 3741 – Lp
dB(A) 49
Page 18 / 86 Technical Notice CSO/CPO V1.1 / 10.14
3 CPO 140 model
3.2 Handling
The unit must be transported flat and must not
sustain any shocks.
3.3 Installation
The unit is normally installed close to the machine
being cooled, as indicated on the installation
plans.
During the installation, allow for a free space of
about 0.5 m around the refrigeration unit. This dis-
tance must be 1 m in front of the exhaust fan. With
these precautions, both ventilation and mainte-
nance access will be made easier.
3.3.1 Hydraulic connections
Except where specifications state otherwise, the
connections between the refrigeration unit and the
machine being cooled can be made with pipes
with a cross-section diameter at least equal to that
indicated in the technical specifications.
See section “3.1.2.5 Hydraulic circuit” on page 17.
3.3.2 Electrical connections
ELECTROCUTION
The machine cabinet must be disconnected
from power while connecting the cables.
Power cable installed with a 3m length (or accor-
ding to customer specifications).
3.4 Commissioning
Theunithasbeenchecked,tunedandtestedin
our workshops.
A. Make the hydraulic and electrical connections.
B. Make sure the oil circulates in the unit.
C. Start up the unit (1).
D. Check the rotation direction of the exhaust fan and
the pump, if available (option C).
Fig. 3-2 : Start-up
(1)
Technical Notice CSO/CPO V1.1 / 10.14 Page 19 / 86
CPO 310 - CSO 300 models 4
Chapter contents
This chapter contains information specific to the CPO 310 and CSO 300 models. It covers all topics as-
sociated with installation, commissioning, tuning and maintenance of these models.
For reasons of clarity, only the CPO 310 model is described in the current chapter. However, all
of the explanations apply in a similar fashion to the CSO 300 model.
4.1 Description
4.1.1 Front view
Fig. 4-1 : CPO 310 type chiller
(1) Programmable controller display (in option)
(2) Thermostat display
(3) Visual failure indicator (red)
(4) Main power switch
(1) (2) (3) (4)
This manual suits for next models
12
Table of contents
