ClimaCool UCA 20, Installation, Operation And Maintenance Manual

Page: 24 / 92

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22
It is imperative that the water systems are free from
debris prior to initial operation. See Water Treatment
for a comprehensive list of precautions on page 22.
Filling, Purging and Leak Testing the System
After the water systems have been properly installed,
˜‹•—ƒŽŽ›‹•’‡ –ƒŽŽŒ‘‹–•ˆ‘”–‹‰Š–‡••Ǥˆ–Š‡ Š‹ŽŽ‡”‹•–‘
be installed in an existing system, the cleanliness of the
‡š‹•–‹‰•›•–‡ ƒ„‡Œ—†‰‡†ˆ”‘–Š‡‘’‡”ƒ–‹‰ ‘†‹–‹‘•
‘ˆ–Š‡’”‡•‡–ƒ Š‹‡•Ǥ–‹•‰‘‘†’”ƒ –‹ ‡–‘ƪ—•Šƒ†ǡ
ideally, to acid wash the existing system before connecting
a new chiller.
Š‡ˆ‘ŽŽ‘™‹‰‡–Š‘†‹•”‡ ‘‡†‡†–‘ƤŽŽƒ†Ž‡ƒ Š‡ 
the water system for modules WITH Water Isolation Valves:
1.
Close all water isolation valves inside each module
which isolate the individual heat exchangers.
2.
Ensure that all drain valves are closed and that all water
main isolation valves are opened.
3.
Š‡•›•–‡•Š‘—Ž†„‡ƤŽŽ‡†™‹–Š Ž‡ƒ™ƒ–‡”•‡–
through the strainers and the system checked for leaks.
4.
Once the main water lines and the chiller headers are
ƤŽŽ‡†™‹–Š Ž‡ƒ™ƒ–‡”ǡ’—”‰‡ƒ†”‡’‡ƒ––Š‡ƤŽŽ‹‰
process at least three times.
5. ŽŽ‘†—Ž‡•ƒ”‡‡“—‹’’‡†™‹–ŠΧdzƤŽŽƒ†ƪ—•Š˜ƒŽ˜‡•
with lines teed into the inlet and outlet connections into
and out of each heat exchanger. Ensure these ¾” valves
are
CLOSED .
6.
Open the water isolation valves inside each modular
Š‹ŽŽ‡”ƒ†”‡’‡ƒ––Š‡ƤŽŽ‹‰’”‘ ‡••ǡ–Š‹•–‹‡ƒŽ•‘
checking for leaks inside each module.
7.
‘ŽŽ‘™‹‰–Š‡ƤƒŽƤŽŽ‹‰ƒ†Ž‡ƒ Š‡ ‹‰’”‘ ‡†—”‡ǡ
air should be purged from the system.
Š‡ˆ‘ŽŽ‘™‹‰•›•–‡‹•”‡ ‘‡†‡†–‘ƤŽŽƒ†Ž‡ƒ
check the water system for modules WITHOUT Water
Isolation Valves:
1.
Ensure that all drain valves are closed.
2. ŽŽ‘†—Ž‡•ƒ”‡‡“—‹’’‡†™‹–ŠΧdzƤŽŽƒ†ƪ—•Š˜ƒŽ˜‡•
with lines teed into the inlet and outlet connections into
and out of each heat exchanger. Ensure these ¾” valves
are
CLOSED .
3.
Š‡•›•–‡•Š‘—Ž†„‡ƤŽŽ‡†™‹–Š Ž‡ƒ™ƒ–‡”•‡–
through the strainer and the system checked for leaks.
4.
Once the main water lines and the chiller headers are
ƤŽŽ‡†™‹–Š Ž‡ƒ™ƒ–‡”ǡ’—”‰‡ƒ†”‡’‡ƒ––Š‡ƤŽŽ‹‰
process at least three times.
5. ‘ŽŽ‘™‹‰–Š‡ƤƒŽƤŽŽ‹‰ƒ†Ž‡ƒ Š‡ ‹‰’”‘ ‡†—”‡ǡ
air should be purged from the system.
Cleaning the System
The following method is recommended to properly clean
the water systems:
1.
Before cleaning the system, install a temporary
bypass line between the main supply and return water
headers of both chilled and condenser water systems
when possible. Open the main header bypass lines to
†‹˜‡”––Š‡‹‹–‹ƒŽ™ƒ–‡”ƪ‘™ƒ”‘—†–Š‡‘†—Ž‡Š‡ƒ–
‡š Šƒ‰‡”•—–‹Ž›‘—ƒ”‡ ‘Ƥ†‡––Š‡ ‹” —Žƒ–‹‰™ƒ–‡”
is mostly pure.
2.
Provided 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
˜ƒŽ˜‡••‘–Š‡‹‹–‹ƒŽ™ƒ–‡”ƪ‘™„›’ƒ••‡•ƒŽŽ‘†—Ž‡
heat exchangers.
3.
It is mandatory to run the pumps with the strainers in
place (see Starting the Pumps section below for proper
pump startup). All external hydronic branches should be
open to all devices in the system.
4.
Pressure drop across the strainer must be observed
and as pressure change reaches 50% of the initial read,
strainers must be isolated and cleaned.
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 (described in step
͕Ȍ‹–‹•”‡ ‘‡†‡†–‘†”ƒ‹‘—––Š‡‹‹–‹ƒŽƤŽŽ‘ˆ™ƒ–‡”
–‘Š‡Ž’ƪ—•Š‘—–†‡„”‹•ǤŽ‘•‡‘ơ–Š‡ƒ‹Š‡ƒ†‡”„›’ƒ••
Ž‹‡•”‡ˆ‡””‡†–‘‹•–‡’͕ƒ†‘’‡–Š‡ƪ‘™–‘–Š‡ƒ‹
water headers. Repeat steps 3 and 4 until there is no
more debris being collected by the strainers.
6.
If bypass lines are not installed (described in step 1) and
the modules are
NOT equipped with water isolation
˜ƒŽ˜‡•ǡ‹–‹•”‡ ‘‡†‡†–‘†”ƒ‹‘—––Š‡‹‹–‹ƒŽƤŽŽ‘ˆ
™ƒ–‡”–‘Š‡Ž’ƪ—•Š‘—–†‡„”‹•Ǥ‡‘˜‡ƒ† Ž‡ƒ–Š‡
•–”ƒ‹‡”•„‡ˆ‘”‡”‡ƤŽŽ‹‰ƒ†’—”‰‹‰–Š‡•›•–‡ƒ‰ƒ‹Ǥ
Repeat steps 3 and 4 until there is no more debris being
collected by the strainers.
Starting the Pumps
Follow the manufacturer’s recommendations when starting
–Š‡’—’•ˆ‘”–Š‡Ƥ”•––‹‡ǤŠ‡•›•–‡•Š‘—Ž†„‡ Š‡ ‡†
for leaks and air purged with the pumps in operation. The
pressure drop across the heat exchangers will give a good
‹†‹ ƒ–‹‘‘ˆƪ‘™–Š”‘—‰Š–Š‡•›•–‡ȋ‡‡˜ƒ’‘”ƒ–‘”
Water Pressure Drop Charts on page 25). This should be
immediately checked against the expected pressure drop
ˆ‘”–Š‡ƪ‘™”ƒ–‡”‡“—‹”‡†Ǥ
If the pressure drop begins to
ˆƒŽŽƒ†–Š‡ƪ‘™”ƒ–‡‹•ˆƒŽŽ‹‰ǡ–Š‹• ‘—Ž†‹†‹ ƒ–‡–Š‡‡‡†
to clean the strainers.
Filling the Water System