Instruction Manual

15
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Filling the Water System
It is imperative that the water systems are free from debris
prior to initial operation. See Water Treatment - page 16 for
a comprehensive list of precautions.
Filling, Purging and Leak Testing the System
After the water system has been properly installed, a visual
inspection should be made to all joints for tightness. If
the chiller is to be installed in an existing system, the
cleanliness of the existing system can be judged from the
operating conditions of the present machines. The cooling
tower in particular should be inspected and cleaned if
required. It is a good practice to at least fl ush the existing
system and ideally, to acid wash the system before
connecting a new chiller.
The following sequence is recommended to fi ll and leak
check the water system for modules WITHOUT Water
Isolation Valves:
1. Ensure that all drain valves are closed and that all main
water header isolation valves (external to the system)
are opened.
2. All modules are equipped with 3/4” fi ll and fl ush valves
with lines teed into the inlet and outlet connections into
and out of the heat exchanger. Ensure these 3/4” valves
are CLOSED.
3. The system should be fi lled with clean water sent
through a strainer and the system checked for leaks.
4. Once the main water lines and the chiller headers are
fi lled with clean water, purge and repeat the fi lling
process several times.
5. Following the fi nal fi lling and leak checking procedure,
air should be purged from the system.
The following sequence is recommended to fi ll and leak
check the water system for modules WITH Water Isolation
Valves:
1. Close all water isolation valves inside each module
which isolate the individual heat exchanger.
2. Ensure that all drain valves are closed and that all water
main isolation valves (external to the system) are
opened.
3. The system should be fi lled with clean water sent
through a strainer and the system checked for leaks.
4. Once the main water lines and the chiller headers are
fi lled with clean water, purge and repeat the fi lling
process several times.
5. All modules are equipped with 3/4” fi ll and fl ush valves
with lines teed into the inlet and outlet connections into
and out of the heat exchanger. Ensure these 3/4” valves
are CLOSED.
6. Open the water isolation valves inside each modular
chiller and repeat the fi lling process, this time also
checking for leaks inside each module.
7. Following the fi nal fi lling and leak checking procedure,
air should be purged from the system.
Cleaning the System
The following sequence is recommended to properly clean
the water systems:
1. Whenever possible, install a temporary bypass line
between the main supply and return water header of
the chilled water system prior to cleaning the system.
Open the main header bypass lines to divert the initial
water fl ow around the module heat exchanger until you
are confi dent the circulating water is mostly pure.
2. Provided the main header bypass lines are installed,
close all water isolation valves inside all modules
equipped with manual or automatic water isolation
valves. If the modules are NOT equipped with water
isolation valves, we recommend installing 3-way main
header bypass valves so the initial water fl ow bypasses
all module heat exchangers.
3. The pumps should be run with the strainer in place (see
Starting the Pumps section for proper pump startup).
All external hydronic branches should be open to all
devices in the system.
4. After several hours of operation, the strainer should
be isolated and cleaned. Repeat until there is no more
debris being collected by the strainer.
5. Open all water isolation valves inside each module
equipped with manual or automatic water isolation
valves (see step 6 for modules NOT equipped with
water valves). If bypass lines are not installed as
described in step 1 above, it is recommended to drain
out the initial fi ll of water to help fl ush out debris.
Finally, close off the main header bypass lines referred
to in step 1 above, and open the fl ow to the main water
headers. Repeat steps 3 and 4 until there is no more
debris being collected by the strainer.
6. If bypass lines are not installed as described in step
1 above, and if the modules are NOT equipped with
water isolation valves, it is recommended to drain out
the initial fi ll of water to help fl ush out debris. Before
refi lling and purging the system again, the strainers
should be removed and cleaned. Repeat steps 3 and
4 until there is no more debris being collected by the
strainer.
Starting the Pumps
Follow the manufacturer’s recommendations when starting
the pumps for the fi rst time. The system should be checked
for leaks and air purged with the pumps in operation. The
pressure drop across the heat exchangers will give a good
indication of fl ow through the system (See page 17 - 18 –
Evaporator Water Pressure Drop Charts). This should be
immediately checked against the expected pressure drop
for the fl ow rate required. If the pressure drop begins to
fall and the fl ow rate is falling, this could indicate a need to
clean the strainers.