ClimaCool IOM FLEX SERIES - Manual (Page 14)

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12
FILLING THE WATER SYSTEMS
It is imperative that the water systems are free from
debris prior to initial operation. See the page 15 -
Water Treatment section for a comprehensive list of
precautions.
Filling, Purging and Leak Testing the System
After the water systems have 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 flush the existing system and ideally,
to acid wash the system before connecting a new chiller.
We recommend the following sequence to fill and leak check
the water systems:
1. Close all isolation valves inside each modular chiller.
2. Ensure that all drain valves are closed and that all water
main isolation valves are opened.
3. The system should be filled with clean water send through
a strainer and the system checked for leaks.
4. Once the main water lines and the chiller headers are
filled with clean water, purge and repeat the filling process
several times.
5. Open the isolation valves inside each modular chiller and
repeat the filling process, this time also checking for leaks
inside each module.
6. Following the final filling 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. If possible, install a temporary bypass line between the
supply and return water lines of both water systems prior
to cleaning the system.
2. Close all isolation valves inside each modular chiller
before engaging the main water pumps.
3. The pumps should be run with the strainer in place (see the
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. Finally, open all isolation valves inside each modular
chiller and repeat step 4 and 5.
If it is not possible to install the bypass line in step 1 above,
it is recommended to drain out the initial fill of water to help
flush out debris. The chiller isolating valves should be closed
to prevent debris from being washed into the chiller as the
water drains out. Before refilling and purging the system
again, the strainers should be removed and cleaned. This
action should be repeated until there is no more debris being
collected by the strainer.
Starting the Pumps
Follow manufacturer's recommendations when staring the
pumps for the first 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 flow through the system (see page 34). This
should be immediately checked against the expected pressure
drop for the flow rate required. If the pressure drop begins to
fall and the flow rate is falling, this could indicate the need to
clean the strainers.
Filling the Water System Pre-Start Up