ClimaCool UCR 30, 50 and 70 tons Manual - Manual (Page 17)

17
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Filling the Water System
It is imperative that the water systems are free from debris
prior to initial operation. See page 18– Water Treatment 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.
We recommend the following sequence 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 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
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.
We recommend the following sequence 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 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
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
We recommend the following sequence 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 modular chillers 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.
5. Step 4 should be repeated until there is no more debris being
collected by the strainer.
6. Open all water isolation valves inside each module equipped
with manual or automatic water isolation valves (see step
7 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, 4 and 5 until there is no more
debris being collected by the strainer.
7. 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, 4 and 5 until there is no more debris being
collected by the strainer.
Starting the Pumps
Follow 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 19-20 – 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
the need to clean the strainers.