8
Filling System
To avoid possible damage to the heaters, DO
NOT energize the heater until the system is
filled with fluid.
To Fill Using Expansion Tank
The expansion tank should be the highest point in the
system. Simply fill the fluid in the expansion tank, while
monitoring the air-bleed valves for complete fill. After
filling by gravity, run pump and re-monitor air-bleed
valves for any remaining air pockets.
To Fill Using Pump
1. On systems equipped with a float switch on the
expansion tank it will be necessary to bypass this
switch until the system is filled in order to oper-
ate the pump. After system is filled remove bypass
jumper to obtain protection of float switch. This
switch will shut the system down in the event of a
low liquid level or loss of heat transfer liquid thus
preventing damage to system.
2. During filling operation, heater setpoint should be
set to ambient temperature. If heater on/off switch
option is installed, switch should be on OFF posi-
tion.
3. Close the system inlet gate valve and open the out-
let and fill line (option) gate valves and heater bleed
valve on all heaters. Prime the pump by pouring
approximately 1 pint to 1 quart (1 L) of fluid through
any inlet valve located above pump.
4. The system is then filled directly from the 55 gallon
(208 L) drum(s) by connecting a hose to fill line and
inserting it into the drum.
5. Next energize the pump to pull the fluid into the
complete system and up into the expansion tank.
When the fluid reaches the heater bleed valve, it
should then be closed, and accordingly the bleeds
on the customer’s process closed when the fluid
reaches them. The fill line remains open until the
expansion tank sight glass indicates being 1/3 full.
After the system is filled, shut down the pump and
close the fill valve. Open system inlet valve.
6. Turn master circuit breaker off. Bleed air from all
lines (including one located above pump) and re-
close all bleed valves.
7. The temperature limiting device located inside the
control panel should be checked to insure man-
ual reset buttons are in the closed position. They
should be set approximately 50˚F (28˚C) higher
than the process control during normal operation.
8. Close control box door and turn circuit breaker
on. Start pump – do not be alarmed if the pump is
noisy during the initial start-up operation since it is
due to air in the system.
9. Bleed out all air by opening bleeder valves. The
pump should become quiet.
During the initial start-up operation, the liquid
level in the expansion tank must be checked
continually. This level should not exceed the
three-quarter mark on the glass nor drop be-
low the one-quarter mark. Note: If abnormal
expansion of fluid is detected, this is probably
due to a pocket of air still present in the sys-
tem. Check all bleed valves for air, and bleed
if necessary. If problem continues, de-energize
pump and bleed again.
10. Excessive air in the system will cause the heat
transfer liquid to back up into the expansion tank,
thus evacuating the heating chamber or chambers.
If this happens, shut the system down, bleed off air
and allow liquid to return to the heating chamber.
If pump continues to be noisy and cavitates or if
abnormal expansion persists there is excessive air
in the system.
11. After the system has been completely charged and
free of air pockets, set process controller at the de-
sired temperature.