The Filling Procedure

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Aubrey McBride
5 years ago
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1 The Filling Procedure Model(s): ECO Series

2 What is needed! 1. Pump 2. 3 water hoses with metric adapters (found on the chiller pump) 3. Glycol (Premixed 37% of KKT Protect) 4. Hand tools 5. Pressure gauge 6. Chiller key 4/6/2016 Filling Procedure/ TSG Manager AF 2

3 Method of Filling What is The Push-Through Method? It is the most effective method for purging air out of the closed water loop system. The trap air will travel throughout the system and make its way back to the chiller by means of an external pump. The external pump is used to push through the chiller, IFP, and MRI system. In a form of a bypass at the chiller, a bucket is ran inline of the external pump to collect the purged glycol to be recirculated into the system. 4/6/2016 Filling Procedure/ TSG Manager AF 3

4 Connecting to the Chiller 1. Remove the pump compartment panel. 2. Connect the discharge port of the pump to the drain valve of the chiller via hose. 3. Connect inlet port of the pump to the glycol bucket via hose. 4. Connect a hose from the drain valve before the filter ball valve to the glycol bucket. 5. Verify connections 4/6/2016 Filling Procedure/ TSG Manager AF 4

5 Step 1 Remove pump compartment panel. Chiller key needed 4/6/2016 Filling Procedure/ TSG Manager AF 5

6 Step 2 Connect discharge port of the pump to the drain valve of the chiller via hose. 4/6/2016 Filling Procedure/ TSG Manager AF 6

7 Step 3 Connect inlet port of the pump to the glycol bucket via hose. 4/6/2016 Filling Procedure/ TSG Manager AF 7

8 Step 4 Connect a hose from the drain valve before the filter ball valve to the glycol bucket. 4/6/2016 Filling Procedure/ TSG Manager AF 8

9 Step 5 Verify connections 4/6/2016 Filling Procedure/ TSG Manager AF 9

10 Steps before filling 1. Verify the chiller is powered off! 2. Remove fuses from the 17F1 pump fused breaker! 3. Verify IFP is powered off! 4. Verify filter ball valve to the chiller is closed! 5. Verify all valves to the IFP are open. 6. Verify air bleeders are open. 7. Verify pipe run and check for any bypass loops installed on the contractors piping from the chiller to the IFP. (If installed, close the valve) 8. Verify chiller height from scanner. 9. Verify expansion tank nitrogen pressure. 4/6/2016 Filling Procedure/ TSG Manager AF 10

11 Step 1 Verify the chiller is powered off! 4Q1 should be on the 0 position 4/6/2016 Filling Procedure/ TSG Manager AF 11

12 Step 2 Remove fuses from the 17F1 pump fused breaker! 4/6/2016 Filling Procedure/ TSG Manager AF 12

13 Step 3 Verify IFP is powered off! 4F1 should be on the 0ff position 4/6/2016 Filling Procedure/ TSG Manager AF 13

14 Step 4 Verify filter ball valve is closed! Valve handle should be pointing upwards 4/6/2016 Filling Procedure/ TSG Manager AF 14

15 Step 5 Verify all valves to the IFP are open. 4/6/2016 Filling Procedure/ TSG Manager AF 15

16 Step 6 Verify all air bleeders are open. IFP, Chiller, and Water Loop 4/6/2016 Filling Procedure/ TSG Manager AF 16

17 Step 7 Verify pipe run and check for any bypass loops installed on the contractors piping from the chiller to the IFP. (If installed, close the valve) Ball valve handle should be positioned away from flow 4/6/2016 Filling Procedure/ TSG Manager AF 17

18 Step 8 Verify chiller height from scanner. Important factor in determining IFP static fill 4/6/2016 Filling Procedure/ TSG Manager AF 18

19 Step 9 Verify expansion tank nitrogen pressure! The reserve and operating tank should be pressurized at 0.6 Bar. Remove cap and check with a pressure gauge. 4/6/2016 Filling Procedure/ TSG Manager AF 19

20 Filling the System 1. Power on the chiller! 2. Power on the IFP! 3. Verify that the 3 way valve at the IFP is open. 4. Power on external filling pump and open the drain valves. Perform The Push-Through Method. 5. Fill the system to static on the IFP. 6. After desired pressure, close the drain valves and power off the external pump. 4/6/2016 Filling Procedure/ TSG Manager AF 20

21 Step 1 Power on the chiller! 4Q1 should be on the I position. 17F1 should have the fuses removed! Powering on the chiller will ensure the chiller sends a signal to the IFP to activate the 3 way valve to the open position. This makes it easier to purge the system while performing The Push-Through Method. 4/6/2016 Filling Procedure/ TSG Manager AF 21

22 Step 2 Power on the IFP! 4F1 should be on the ON position 4/6/2016 Filling Procedure/ TSG Manager AF 22

23 Step 3 Verify that the 3 way valve at the IFP is open. Position should be at 9 4/6/2016 Filling Procedure/ TSG Manager AF 23

24 Step 4 Power on the external filling pump and open the drain valves. Perform The Push-Through Method. Allow the external pump to run for 5-10 minutes. Inspect the amount of air pouring out the hose. If a great amount of air remains pouring out, allow more time to circulate the external pump. It is important not to fully open both drain valves while performing The Push-Through Method, glycol may over-fill the glycol bucket. 4/6/2016 Filling Procedure/ TSG Manager AF 24

25 Step 5 Fill the system to static on the IFP. Chiller lower than the IFP panel or on the same level bar, Read at the IFP Limitation: 30m below IFP Chiller higher than the IFP panel bar, Read at the IFP Limitation: 10m above IFP 4/6/2016 Filling Procedure/ TSG Manager AF 25

26 Step 6 After desired pressure, close the drain valves and power off the external pump. 4/6/2016 Filling Procedure/ TSG Manager AF 26

27 Running the Pump, Venting the Air 1. Power off the chiller! 2. Add the fuses to the 17F1 pump fused breaker! 3. Close all air vents! 4. Power on the chiller! 5. Pump will begin to run. Allow the pump to run for minutes 6. Power off the chiller! 7. Open all air vents, purge the remaining air. 8. Clean the strainers! 9. Power on the chiller! 10. Verify operation! 4/6/2016 Filling Procedure/ TSG Manager AF 27

28 Step 1 Powered off the chiller! 4Q1 should be on the 0 position 4/6/2016 Filling Procedure/ TSG Manager AF 28

29 Step 2 Add the fuses to the 17F1 pump fused breaker! 4/6/2016 Filling Procedure/ TSG Manager AF 29

30 Step 3 Close all air vents! IFP, Chiller, and Water Loop 4/6/2016 Filling Procedure/ TSG Manager AF 30

31 Step 4 Power on the chiller! 4Q1 should be on the I position 4/6/2016 Filling Procedure/ TSG Manager AF 31

32 Step 5 Pump will begin to run. Allow the pump to run for minutes. 4/6/2016 Filling Procedure/ TSG Manager AF 32

33 Step 6 Powered off the chiller! 4Q1 should be on the 0 position 4/6/2016 Filling Procedure/ TSG Manager AF 33

34 Step 7 Open all air vents, purge the remaining air. If the pressure on the manometers drops. Repeat Steps 4-6 of Filling the System 4/6/2016 Filling Procedure/ TSG Manager AF 34

35 Step 8 Clean the strainers! Clean the filter strainer before the next-to last pass. The filter ball valve allows you to clean the strainers with minimal loss of glycol. Please be sure to clean the strainers at the IFP and chiller! 4/6/2016 Filling Procedure/ TSG Manager AF 35

36 Step 9 Power on the chiller! 4Q1 should be on the I position 4/6/2016 Filling Procedure/ TSG Manager AF 36

37 Step 10 Verify Operation! Pressure at the pump: bar. IFP Pressure differential: (Day Mode) 3-4 Bar (Night Mode) 1.4 Bar 4/6/2016 Filling Procedure/ TSG Manager AF 37

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