Marksa CPO 1010 Technical Notice Download Page 45

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Technical Notice CSO/CPO V1.1 / 10.14

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Tuning and maintenance 8

8.2

Maintenance

8.2.1

Periodic maintenance

Regular maintenance by competent personnel makes it possible to ensure reliable and efficient ope-
ration of the refrigeration unit.

8.2.2

Safety

LECTROCUTION

AND

SERIOUS

INJURY

Always disconnect the power supply of the unit before any maintenance operation.

There is a significant risk of burns from contact with the copper piping.

8.2.3

Maintenance table



See section “9 Options” on page 47 for the maintenance of various options.

8.2.4

Weekly maintenance

Check that the oil is at the maximum visual indicator's level.

8.2.5

Monthly maintenance

Check for fouling of the air condenser.

If necessary, blow compressed air through the exhaust fan from the outlet port of the exhaust fan.

Restart the unit by switching it back on.

Interval

Weekly

Monthly

Annually

Check oil

Check for fouling of the air condenser

Check the bearing clearance of the exhaust
fan motor

Clean the exhaust fan blades

Check the refrigerating and hydraulic cir-
cuits and pump, if available (option)

Summary of Contents for CPO 1010

Page 1: ...INDUSTRIAL REFRIGERATION UNITS TECHNICAL NOTICE CSO CPO V1 1 10 14...

Page 2: ...dence 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 th...

Page 3: ...fety 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...

Page 4: ...ng 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 Elect...

Page 5: ...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 Differ...

Page 6: ...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 1...

Page 7: ...ntended 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...

Page 8: ...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 Rep...

Page 9: ...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...

Page 10: ...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 menda...

Page 11: ...operty 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 sui...

Page 12: ...Technical Notice CSO CPO V1 1 10 14 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...

Page 13: ...il 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 Custo...

Page 14: ...ntly 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...

Page 15: ...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 14...

Page 16: ...apacity 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 St...

Page 17: ...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...

Page 18: ...te 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 specific...

Page 19: ...llation 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 fashio...

Page 20: ...86 Technical Notice CSO CPO V1 1 10 14 4 CPO 310 CSO 300 models 4 1 2 Rear view Fig 4 2 CPO 310 type chiller rear view 5 Cooling liquid outlet 6 Electric power connector 7 Cooling liquid return inlet...

Page 21: ...d kW 4 355 4 355 Inlet temperature C 24 24 Outlet temperature C 20 20 Max input temperature C 38 C 38 C Description Unit CPO 310 CSO 300 Power input kW 1 5 1 5 Maximum amperage A 5 6 5 6 Start up ampe...

Page 22: ...er characteristics Description Unit CPO 310 CSO 300 Min flow rate l min 30 30 Inlet outlet coupling diameter 3 4 3 4 Description Unit CPO 310 CSO 300 Width mm 470 600 Height mm 700 600 Depth mm 570 60...

Page 23: ...aust fan With these precautions both ventilation and maintenance access will be made easier 4 3 1 Hydraulic connections Except where specifications state otherwise the connections between the refriger...

Page 24: ...ioning The unit has been checked tuned and tested in 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...

Page 25: ...ation commissioning tuning and maintenance of these models For reasons of clarity only the CPO 500 model is described in the current chapter However all of the explanations apply in a similar fashion...

Page 26: ...Technical Notice CSO CPO V1 1 10 14 5 CSO 500 800 models 5 1 2 Rear view Fig 5 2 CSO 500 type chiller inner view 5 Safety pressure controllers LP HP 6 Cooling liquid return inlet 7 Cooling liquid out...

Page 27: ...1 5 1 5 Heat load kW 6 5 9 4 Inlet temperature C 25 27 Outlet temperature C 20 20 Max input temperature C 38 C 38 C Description Unit CSO 500 CSO 800 Power input kW 2 5 2 5 Maximum amperage A 6 5 6 5...

Page 28: ...Other characteristics Description Unit CSO 500 CSO 800 Min flow rate l min 45 70 Inlet outlet coupling diameter 1 1 Description Unit CSO 500 CSO 800 Width mm 600 600 Height mm 600 600 Depth mm 600 600...

Page 29: ...st fan With these precautions both ventilation and maintenance access will be made easier 5 3 1 Hydraulic connections Except where specifications state otherwise the connections between the refrigerat...

Page 30: ...ning The unit has been checked tuned and tested in 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 d...

Page 31: ...s sociated with installation commissioning tuning and maintenance of these models For reasons of clarity only the CPO 510 model is described in the current chapter However all of the explanations appl...

Page 32: ...Page 32 86 Technical Notice CSO CPO V1 1 10 14 6 CPO 510 810 models 6 1 2 Rear view Fig 6 2 CPO 510 type chiller rear view 4 Pump option 5 Cooling liquid outlet 6 Cooling liquid return inlet 4 5 6...

Page 33: ...5 Heat load kW 6 5 9 4 Inlet temperature C 25 27 Outlet temperature C 20 20 Max input temperature C 38 C 38 C Description Unit CPO 510 CPO 810 Power input kW 2 5 2 5 Maximum amperage A 6 5 6 5 Start u...

Page 34: ...Other characteristics Description Unit CPO 510 CPO 810 Min flow rate l min 45 70 Inlet outlet coupling diameter 1 1 Description Unit CPO 510 CPO 810 Width mm 550 550 Height mm 900 900 Depth mm 600 600...

Page 35: ...st fan With these precautions both ventilation and maintenance access will be made easier 6 3 1 Hydraulic connections Except where specifications state otherwise the connections between the refrigerat...

Page 36: ...ning The unit has been checked tuned and tested in 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 d...

Page 37: ...ssociated with installation commissioning tuning and maintenance of these models For reasons of clarity only the CPO 1010 model is described in the current chapter However all of the explanations appl...

Page 38: ...O V1 1 10 14 7 CPO 1010 CSO 1000 1300 1700 models 7 1 2 Rear view Fig 7 2 CPO 1010 type chiller rear view 4 Pump option 5 Cooling liquid return inlet 6 Cooling liquid outlet 7 Outlet circuit pressure...

Page 39: ...ature C 27 27 27 27 Outlet temperature C 20 20 20 20 Max input temperature C 38 C 38 C 38 C 38 C Description Unit CPO 1010 CSO 1000 CSO 1300 CSO 1700 Power input kW 4 5 4 5 4 5 5 5 Maximum amperage A...

Page 40: ...0 CSO 1700 Min flow rate l min 90 90 110 150 Inlet outlet coupling diameter 1 1 1 4 1 1 4 1 1 4 Description Unit CPO 1010 CSO 1000 CSO 1300 CSO 1700 Width mm 700 700 700 700 Height mm 1300 1300 1300 1...

Page 41: ...he exhaust fan With these precautions both ventilation and maintenance access will be made easier 7 3 1 Hydraulic connections Except where specifications state otherwise the connections between the re...

Page 42: ...ommissioning The unit has been checked tuned and tested in 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 ro...

Page 43: ...ameter 3 SET button Sets the setpoint Displays the selected parameter s value 4 DOWN def button Decreases the displayed data Goes to the next parameters 8 1 1 2 Indications on the display COMP 1 Led i...

Page 44: ...displayed E Press on the SET 3 button again to store the new value and move on to display the following parameter F Press on the PRG 1 key to store the new value and terminate the parameter modificat...

Page 45: ...8 2 3 Maintenance table See section 9 Options on page 47 for the maintenance of various options 8 2 4 Weekly maintenance A Check that the oil is at the maximum visual indicator s level 8 2 5 Monthly m...

Page 46: ...omponents are broken damaged ice encrusted or fouled exhaust fan condenser Due to a lack of gas or operation of the unit at an evaporation temperature which is too low the heat exchangers can become i...

Page 47: ...ger B O O O O O C Pump C O O O O O D Distributor D O O O O O O O O O O O E 400 V Power sup ply E O X X X X X X X X X X F Flow rate control ler F X X X X X X X X X X X G Hot gas bypass G O O O O O O O...

Page 48: ...can be either metallic or synthetic 9 1 1 2 Maintenance Metallic filters Metallic filters should be cleaned monthly during the regular monthly maintenance procedure Synthetic filters Synthetic filter...

Page 49: ...10 14 Page 49 86 Options 9 9 1 2 Cleanable heat exchanger B 9 1 2 1 Description of the option Allows transporting the oil with particles larger than 500 l Fig 9 2 Cleanable heat exchanger 1 Cleanable...

Page 50: ...s of the refrigera ting circuit may be very hot in particular the copper pipings A Stop the unit B Unscrew the covers 2 of the heat exchanger Pay particular attention to the oil contained in the heat...

Page 51: ...talled in the CPO unit 2 If the pump is installed directly in the unit 2 prime before commissioning fill the oil pipe and drain 9 1 3 2 Maintenance A Annual control of the pump Traces of oil may indic...

Page 52: ...9 1 4 2 Maintenance No special maintenance procedures 9 1 4 3 Troubleshooting No special troubleshooting procedures 9 1 5 400 V Power supply E 9 1 5 1 Description of the option A 400V power supply mak...

Page 53: ...ide a delay in order to avoid the display of disruptive errors during the start up of the refrigeration unit 9 1 6 2 Maintenance No special maintenance procedures 9 1 6 3 Troubleshooting Faulty flow m...

Page 54: ...he option The hot gas bypass 1 option makes it possible to precisely maintain the liquid temperature by elimi nating disruptive starting up and powering down of the compressor Precision on the order o...

Page 55: ...h key Activation of autotuning A Press 4 for less than a second LAdJ displayed B Press the key 5 once At displayed C Press the key 7 The display goes from OFF to At 2 The Auto Tuning is activated this...

Page 56: ...roportional strip 0 9 I Total time 65 d Diversion time 11 Setting CN T 1 dU C SL H Max setpoint 35 SL L Min setpoint 20 CNTL PID S HC Stnd St OFF Orew d PtRN OFF ALt1 Type 1 alarm 1 ALH1 Hysteresis 1...

Page 57: ...adjusting settings 8 Up key adjusting settings Activation of autotuning A Press 4 for less than one second LAdJ displayed B Press the key 5 once At displayed C Press the key 8 the display changes fro...

Page 58: ...U C SL H Max setpoint 35 SL L Min setpoint 20 CNTL PID S HC Stnd St OFF Orew d PtRN OFF ALt1 Type 1 alarm 1 ALH1 Hysteresis 1 ALt2 Type 2 alarm 1 ALH2 Hysteresis 1 oiST Signal in mA 0 20 To access adv...

Page 59: ...Technical Notice CSO CPO V1 1 10 14 Page 59 86 Options 9 9 1 7 4 Maintenance No special maintenance procedures 9 1 7 5 Troubleshooting No special troubleshooting procedures...

Page 60: ...pre heating the machine or when the refrigeration unit s are located outside the building A safety thermostat 2 protects the tank from inadequacies in the heating system Do not change the safety therm...

Page 61: ...rigerant liquid temperature with respect to the ambient temperature 9 1 9 2 Maintenance No special maintenance procedures 9 1 9 3 Troubleshooting No special troubleshooting procedures 9 1 10 Frame on...

Page 62: ...controller 1 makes it possible to protect the compressor against any possible loss of gas in the refrigeration circuit LP and protects the compressor after any significant excess of pressure of the r...

Page 63: ...t the circuit Activation of the HP section Fouled heat exchanger Clean the heat exchanger and the air filters if fitted Ambient temperature is too high above the manufacturer s specified limit Insuffi...

Page 64: ...ts normal operating hours and restart it if necessary 9 1 12 2 Maintenance No special maintenance procedures 9 1 12 3 Troubleshooting No special troubleshooting procedures 9 1 13 Pressure gauge V 9 1...

Page 65: ...ault display unit It is located on the front control panel or in the electrical unit Fig 9 11 Programmable troubleshooting logic controller front and right view 1 PLC identification 2 Main screen disp...

Page 66: ...amples of archives when the regulation function is used Main screen when the regulation function is used 3 Press the A key several times in succession to scroll through the messages on the display 4 O...

Page 67: ...Press the B key 1 several times in succession to locate the setting you wish to change The content of the Settings menu may vary depend ing on the program installed To find a setting use the settings...

Page 68: ...s active 1 Voltage present for an input Relay contact closed for an output Where the pixels around an input or output are not highlighted the corresponding input or output is inactive 2 Voltage not pr...

Page 69: ...ivity Fig 9 18 Display zoom B Examples of screens when the regulation function is used Press the key several times in succession to scroll through the various screens on the display Once you have scro...

Page 70: ...not used the display shows version and creation date or the Marksa SA contact details screen If the optionals flowmeters and or pressure switches are installed see section 9 1 14 6 with another examp...

Page 71: ...g flowmeters and or pressure switches must be installed A Examples of screens when the regulation function is used Press the key several times in succession to scroll through the various screens on th...

Page 72: ...ation key from September 2014 The analog flowmeters and or pressure switches must be installed B When the regulation function is not used the display shows version and creation date or the Marksa SA c...

Page 73: ...dicator lights up on the unit When the red indicator light is on the display shows the explanation in 3 languages In the event of a breakdown the fault that caused the problem is shown and remains sho...

Page 74: ...high temperature alarms delay at start up 1 200 seconds AdL Low temperature alarm delay at start up AdH High temperature alarm delay at start up c1 Probe calibration 3 ou C17 Refresh time of the senso...

Page 75: ...larm 10 C relative to set point St2 AH 2 High Temperature threshold alarm 10 C relative to set point St2 Ad 2 Low or high temperature alarms delay at start up 1 200 seconds AdL2 Low temperature alarm...

Page 76: ...display is frozen the red status light remains on the unit remains stopped To restart switch off the unit main power switch of the unit and then it is imperative to press the ESC key logic controller...

Page 77: ...th the various settings entitled macros See section 9 1 14 3 B key functions on page 67 This subject is covered here to give you an idea of the vocabulary and appearance of these settings when you enc...

Page 78: ...ates an incorrect operation of the device This information is forwarded to the device by the equipment being cooled An error is forwarded to the device in the event of overheating It may be caused by...

Page 79: ...e commend conferring this work to a qualified refrigeration engineer 10 2 Checks 10 2 1 Pressure checks It is strongly recommended to confer any intervention to a refrigeration engineering specialist...

Page 80: ...ocedures in dicated below If Option Y programmable problem re covery controller is installed Consult the display 1 10 3 1 The unit is not operating Look for the cause of the failure A Check the unit s...

Page 81: ...creasing in the concerned circuit Pump defective option Replace the pump F Check that the compressor is running The compressor is powered but doesn t work The internal compressor safety switch has bee...

Page 82: ...t fan or change it Condenser fouled Clean the condenser The thermostat no longer controls the compressor Faulty probe the alarm message Er on the thermostat display Replace the probe Faulty thermostat...

Page 83: ...conforms to the directive 2006 42 EC of the European Parliament and of the Council of May 17th 2006 relating to the unification of the legislation of member states regarding ma chinery For more infor...

Page 84: ...lic circuit in an empty container clearly identified B For the refrigeration gases you must use a company authorised for such activities C Extract the gas store it in a pressure resistant container ma...

Page 85: ...86 Appendix 11 11 4 Maintenance sheet The original blank maintenance sheet must be kept with this manual Whenever a maintenance intervention is required make a copy of it and then fill out the detail...

Page 86: ...Page 86 86 Technical Notice CSO CPO V1 1 10 14 11 Appendix 11 5 Compliance certificat...

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