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Technical Notice V1.0 / 01.09

Page 69 / 100

Model CSW 2000/2400 11

Chapter contents

This chapter contains information specific to the CSW 2000 and CSW 2400 models. It covers all topics
associated with installation, commissioning, tuning and maintenance of these models.

For reasons of clarity, only the CSW 2000 model is described in the current chapter. However, all
of the explanations apply in a similar fashion to the CSW 2400 model.

11.1

Description

11.1.1 Overall view

(1)

Programmable controller display (optional, visible after opening the door)

(2)

Thermostat display

(3)

Breakdown indicator lamp (red)

(4)

Main power switch

Fig. 11-1 : CSW 2000 type chiller (front view)

(2)

(3)

(4)

(1)

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Summary of Contents for CSSW 50

Page 1: ...INDUSTRIAL REFRIGERATION UNITS TECHNICAL NOTICE V1 0...

Page 2: ...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 f...

Page 3: ...ion 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 Ov...

Page 4: ...he 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 Handli...

Page 5: ...SW 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 6...

Page 6: ...rmostat 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 Descr...

Page 7: ...nance 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...

Page 8: ...Page 8 100 Technical Notice V1 0 01 09 Table of contents...

Page 9: ...ded 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 com...

Page 10: ...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 softwa...

Page 11: ...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 item 1 item 2 item 3 1 1 7 T...

Page 12: ...r 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 potentia...

Page 13: ...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 reassemb...

Page 14: ...Page 14 100 Technical Notice V1 0 01 09 1 Introduction...

Page 15: ...rty 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 suitab...

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 S...

Page 17: ...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: ...ole 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...

Page 19: ...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...

Page 20: ...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 Refrig...

Page 21: ...ted with installation commissioning tuning and maintenance of these models For reasons of clarity only the CSW 80 model is described in the current chapter However all of the explanations apply in a s...

Page 22: ...al Notice V1 0 01 09 3 Model CSW 50 65 80 4 Cooling liquid outlet 5 Cooling liquid return inlet 6 Refilling port 7 Visual water level indicator 8 Electric power connector Fig 3 2 CSW 80 type chiller r...

Page 23: ...emperature C 22 22 Outlet temperature C 20 20 Flow rate l min 8 8 Maximum input temperature C 38 38 Description Units CSW 50 CSW 65 80 Power input kW 0 4 0 6 Maximum amperage A 2 5 3 Start up amperage...

Page 24: ...input kW 0 16 0 16 Amperage A 0 70 0 70 Rotation t min 2900 2900 Power supply V x ph x Hz 230 x 1 x 50 230 x 1 x 50 Stainless steel reservoir l 7 7 Inlet outlet couplings 3 4 3 4 Description Units CSW...

Page 25: ...ction diameter at least equal to that indicated in the technical characteristics See section 3 1 2 Technical specifications on page 23 3 3 2 Electrical connections ELECTROCUTION The machine cabinet mu...

Page 26: ...4 Commissioning The unit has been checked tuned and tested in our workshops A Make the hydraulic and electrical connections B Fill the reservoir with liquid C Start up the machine 1 D Check the rotati...

Page 27: ...ning and maintenance of these models For reasons of clarity only the CSW 100 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 150 model 4...

Page 28: ...emperature C 22 22 Outlet temperature C 20 20 Flow rate l min 8 8 Maximum input temperature C 38 38 Description Units CSW 100 CSW 150 Power input kW 0 8 1 0 Maximum amperage A 6 5 6 5 Start up amperag...

Page 29: ...input kW 0 16 0 16 Amperage A 0 70 0 70 Rotation t min 2900 2900 Power supply V x ph x Hz 230 x 1 x 50 230 x 1 x 50 Stainless steel reservoir l 8 8 Inlet outlet couplings 3 4 3 4 Description Units CSW...

Page 30: ...ction diameter at least equal to that indicated in the technical characteristics See section 4 1 2 Technical specifications on page 28 4 3 2 Electrical connections ELECTROCUTION The machine cabinet mu...

Page 31: ...connections B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 4 5 Specific tuning 4 5 1 Draining the reservoir A Disconnect the o...

Page 32: ...Page 32 100 Technical Notice V1 0 01 09 4 Model CSW 100 150...

Page 33: ...maintenance of these models For reasons of clarity only the CSW 200 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 300 model 5 1 Descr...

Page 34: ...25 25 Outlet temperature C 20 20 Flow rate l min 8 10 Maximum input temperature C 38 38 Description Units CSW 200 300 CSW200E 300E Power input kW 1 70 1 70 Maximum amperage A 9 3 25 Start up amperage...

Page 35: ...kW 0 16 0 25 Amperage A 0 70 0 80 Rotation t min 2900 2900 Power supply V x ph x Hz 230 x 1 x 50 400 x 3 x 50 Stainless steel reservoir l 21 21 Description Units CSW 200 300 CSW200E 300E Width mm 435...

Page 36: ...tion diameter at least equal to that indicated in the technical characteristics See section 5 1 2 Technical specifications on page 34 5 3 2 Electrical connections ELECTROCUTION The machine cabinet mus...

Page 37: ...ctions B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 5 5 Specific tuning 5 5 1 Draining the reservoir A Put a container under...

Page 38: ...Page 38 100 Technical Notice V1 0 01 09 5 Model CSW 200 300...

Page 39: ...covers all topics associated with ins tallation commissioning tuning and maintenance of these models 6 1 Description 6 1 1 Overall view 1 Programmable controller display optional 2 Thermostat display...

Page 40: ...W 1200 Heat load kW 5200 Inlet temperature C 24 Outlet temperature C 20 Flow rate l min 15 Maximum input temperature C 38 Description Units CSW 400 Power input kW 2 5 Maximum amperage A 7 5 Start up a...

Page 41: ...15 Total pressure bar 2 5 Power input kW 0 37 Amperage A 1 80 Rotation t min 2900 Power supply V x ph x Hz 400 x 3 x 50 Stainless steel reservoir l 35 Inlet outlet couplings 3 4 Description Units CSW...

Page 42: ...ion diameter at least equal to that indicated in the technical characteristics See section 6 1 2 Technical specifications on page 40 6 3 2 Electrical connections ELECTROCUTION The machine cabinet must...

Page 43: ...tions B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 6 5 Specific tuning 6 5 1 Draining the reservoir A Put a container under...

Page 44: ...Seite 44 100 Technical Notice V1 0 01 09 6 Model CSW 400...

Page 45: ...and maintenance of these models For reasons of clarity only the CSW 800 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 600 model 11 1...

Page 46: ...00 5 Output circuit pressure gauge on request 6 Electric power connector on request 7 Cooling liquid return inlet 8 Cooling liquid outlet 9 Refilling port 10 Drainage tap 11 Visual water level indicat...

Page 47: ...load kW 7500 Inlet temperature C 25 Outlet temperature C 20 Flow rate l min 20 Maximum input temperature C 38 Table 11 1 Description Units CSW 600 800 Power input kW 3 Maximum amperage A 9 5 Start up...

Page 48: ...sure bar 1 5 Power input kW 0 37 Amperage A 1 8 Rotation t min 2900 Power supply V x ph x Hz 400 x 3 x50 Stainless steel reservoir l 55 Inlet outlet couplings 3 4 Table 11 5 Description Units CSW 600...

Page 49: ...ction diameter at least equal to that indicated in the technical characteristics See section 7 1 2 Technical specifications on page 71 11 3 2 Electrical connections ELECTROCUTION The machine cabinet m...

Page 50: ...ions B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 11 5 Specific tuning 11 5 1 Draining the reservoir A Put a container under...

Page 51: ...g and maintenance of these models For reasons of clarity only the CSW 1000 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 900 CSW 1300...

Page 52: ...ice V1 0 01 09 11 Model CSW 900 1000 1300 1700 5 Electric power connector 6 Cooling liquid return inlet 7 Cooling liquid outlet 8 Visual water level indicator 9 Drainage tap Fig 11 2 CSW 1000 type chi...

Page 53: ...e C 27 25 27 Outlet temperature C 20 20 20 Flow rate l min 20 35 35 Maximum input temper ature C 38 38 38 Table 11 1 Description Units CSW 900 1000 CSW 1300 CSW1700 Power input kW 4 4 5 5 5 Maximum am...

Page 54: ...in 20 35 35 Total pressure bar 2 2 5 2 5 Power input kW 0 37 0 37 0 37 Amperage A 1 8 1 8 1 8 Rotation t min 2900 2900 2900 Power supply V x ph x Hz 400 x 3 x 50 400 x 3 x 50 400 x 3 x 50 Stainless st...

Page 55: ...oss section diameter at least equal to that indicated in the technical characteristics See section 8 1 2 Technical specifications on page 71 11 3 2 Electrical connections ELECTROCUTION The machine cab...

Page 56: ...connections B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 11 5 Specific tuning 11 5 1 Draining the reservoir A Put a containe...

Page 57: ...and maintenance of these models For reasons of clarity only the CSW 2000 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 2400 model 11...

Page 58: ...ice V1 0 01 09 11 Model CSW 2000 2400 5 Electric power connector optional 6 Output circuit pressure gauge 7 Cooling liquid outlet 8 Cooling liquid return inlet 9 Drainage tap Fig 11 2 CSW 2000 type ch...

Page 59: ...re C 27 28 Outlet temperature C 20 20 Flow rate l min 40 40 Maximum input temperature C 42 42 Description Units CSW 2000 CSW 2400 Power input kW 8 0 9 0 Maximum amperage A 16 18 Start up amperage A 50...

Page 60: ...wer input kW 0 37 0 37 Amperage A 1 2 1 2 Rotation t min 2900 2900 Power supply V x ph x Hz 400 x 3 x 50 400 x 3 x 50 Stainless steel reservoir l 145 145 Inlet outlet couplings 1 1 Description Units C...

Page 61: ...section diameter at least equal to that indicated in the technical characteristics See section 9 1 2 Technical specifications on page 71 11 3 2 Electrical connections ELECTROCUTION The machine cabinet...

Page 62: ...tions B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 11 5 Specific tuning 11 5 1 Draining the reservoir A Put a container unde...

Page 63: ...s For reasons of clarity only the CSW 3000 model is described in the current chapter However all of the explanations apply in a similar fashion to the CSW 3500 and CSW 4700 models 11 1 Description 11...

Page 64: ...Page 70 100 Technical Notice V1 0 01 09 11 Model CSW 3000 3500 4700 7 Cooling liquid outlet 8 Cooling liquid return inlet Fig 11 2 CSW 3000 type chiller rear view 7 8...

Page 65: ...l min 75 75 115 Maximum input temperature C 42 42 42 Description Units CSW 3000 CSW 3500 CSW 4700 Power input kW 12 0 13 0 15 0 Maximum amperage A 24 26 28 Start up amperage A 75 80 90 Line fuse A T...

Page 66: ...1 Amperage A 1 6 1 6 2 6 Rotation t min 2800 2800 2900 Power supply V x ph x Hz 400 x 3 x 50 400 x 3 x 50 400 x 3 x 50 Stainless steel reservoir l 145 145 405 Inlet outlet couplings 1 1 2 1 1 2 2 Desc...

Page 67: ...s section diameter at least equal to that indicated in the technical characteristics See section 13 1 2 Technical specifications on page 71 11 3 2 Electrical connections ELECTROCUTION The machine cabi...

Page 68: ...nections B Fill the reservoir with liquid C Start up the machine 1 D Check the rotation direction of the pump and the exhaust fan 11 5 Specific tuning 11 5 1 Draining the reservoir A Put a container u...

Page 69: ...y the value of the selected parameter 4 DOWN def button Decrease the displayed setting s value Go to the following parameter 11 1 1 2 Indications on the display COMP 1 Led indicates that the com press...

Page 70: ...tore the new value and move on to display the following parameter F Press on the PRG key to store the new value and terminate the parameter modification procedures In order to exit without saving the...

Page 71: ...4 Weekly maintenance A Check that the liquid is at the maximum level of the visual indicator An electrical level detector can be installed as an option B Restart the unit by switching it off and back...

Page 72: ...ents are either 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...

Page 73: ...A Air filter X X X X J By pass O O O O O O O O D Distributor O O O O O O O O E 400 V power supply O X X X X X F Water flow con troller O O O O O O O O G Hot gas bypass O O O O O O O O H Pre heating ki...

Page 74: ...olenoid O O O O O O Y Programma ble problem recovery controller O O O O X X Z High tempera ture alarm O O O O O O O O Abb Option CSW 50 65 80 CSW 100 150 CSW 200 300 CSW 400 CSW 600 800 CSW 900 1000 1...

Page 75: ...The filters can be either metallic or synthetic 12 2 2 Maintenance 12 2 2 1 Metallic filters Metallic filters should be cleaned monthly during the regular monthly maintenance procedure 12 2 2 2 Synthe...

Page 76: ...ort of the refrigeration unit the bypass is engaged and reinjects the liquid into the reservoir in order to avoid damages in the external circuit 12 3 2 Maintenance The bypass is regulated in the fact...

Page 77: ...n several circuits 12 4 2 Maintenance No special maintenance procedures 12 4 3 Breakdowns No special breakdown procedures 12 5 400V power supply E 12 5 1 Description of the option A 400V power supply...

Page 78: ...to provide a delay in order to avoid the display of disruptive errors during the start up of the refrigeration unit 12 6 2 Maintenance No special maintenance procedures 12 6 3 Breakdowns Faulty flow...

Page 79: ...the option The hot gas bypass option makes it possible to precisely maintain the liquid temperature by eliminating disruptive starting up and powering down of the compressor Precision in the order of...

Page 80: ...anual mode is activated STOP Alight The device is stopped RMT remote Alight Remote control is activated AT auto tuning Flashes during automatic regulation of the PID 4 A M key Selection between manual...

Page 81: ...r r 12 7 2 3 Activation of auto tuning A Hold down the button 1 for more than one se cond B Press once on 2 C Hold down the button 1 for more than one se cond to go to level 1 D Press on 2 to activate...

Page 82: ...might be too cold particularly useful when pre hea ting the machine or when the refrigeration unit s are located outside the building A safety thermostat 2 protects the tank from inadequacies in the h...

Page 83: ...kdowns No special breakdown procedures 12 10 Differential thermostat L 12 10 1 Description of the option In non air conditioned environments the differential thermostat makes it possible to automatica...

Page 84: ...an alarm is shown on the programmable control ler display and or on the visual display located on the front panel It is recommended to fill the tank up to the visual display level 12 12 2 Maintenance...

Page 85: ...eral bars 12 13 2 Maintenance Maintenance and required checking are reduced The circuit is pressurised Eliminate the pressure before any intervention on the customer s coo ling circuit Open the draina...

Page 86: ...12 14 1 Description of the option A reinforced pump makes it possible to ensure better liquid circulation during significant load losses coo ling of spindles for example 12 14 2 Maintenance No special...

Page 87: ...The pressure 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 significantly excess of pr...

Page 88: ...Description of the option The timer programmable clock makes it possible to stop the unit outside of its normal operating hours and restart it if necessary 12 16 2 Maintenance No special maintenance p...

Page 89: ...icates 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 b...

Page 90: ...Page 90 100 Technical Notice V1 0 01 09 12 Options...

Page 91: ...is motive in mind we do advise you to entrust such work to a qualified refrigeration engineer 13 2 Checks 13 2 1 Pressure checks It is highly recommended to entrust any intervention to a specialist re...

Page 92: ...3 1 The unit doesn t work Looking for the cause of the breakdown A Check the power supply for the unit B Check that the safety switch 10Q1 is in position 1 power on for the unit C Check the pump circu...

Page 93: ...at the compressor is running The compressor is powered on but doesn t work The internal compressor safety switch has been activated Cut off the power supply Let the unit cool off may take several hour...

Page 94: ...lean the exhaust fan or replace 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 F...

Page 95: ...nt with directive 98 37 CE from the European Parliament and Council on June 22nd 1998 relating to the unification of the legislation of member states regarding machinery For further details please ref...

Page 96: ...cation of such parts must be pre cisely detailed in the request 14 2 2 Preparation A Completely drain the hydraulic circuit into an clearly identified empty container B As regards the refrigeration ga...

Page 97: ...Appendix 14 14 3 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 details M...

Page 98: ...ata sheet This notice being common to several refrigeration unit models the information specific to your model ap pears in a separately delivered technical data file This file contains the following e...

Page 99: ...Technical Notice V1 0 01 09 Page 99 100 100 Appendix 14 14 5 Compliance documents...

Page 100: ...3 44 with directive 73 23 and with directive CEM EMV 89 336 with amendments 92 31 We declare that this machine are in conformity KONFORMIT TSERKL RUNG Wir MARKSA S A av du Technicum 42 2400 Le Locle e...

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