Emerson Preparing the System for Filling, Filling the XDF with COOLANT-WATER or Glycol

Filling the XDF with Coolant—Water or Glycol

6.0FILLING THE XDF WITH COOLANT—WATER OR GLYCOL

6.1Preparing the System for Filling

It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the coolant and fouling of the drycooler piping (IF USED). The system should be flushed thoroughly using a mild cleaning solution or high-quality water and then completely drained before charging with coolant.

Cleaning new systems is just as important as cleaning old ones. New systems might be coated with oil or a protective film; dirt and scale are also common. Any residual contaminants could adversely affect the heat transfer stability and performance of your system. In many cases, in both old and new sys- tems, special cleaners are needed to remove scale, rust and hydrocarbon foulants from pipes, mani- folds and passages. Clean heat transfer surfaces are important in maintaining the integrity of the cooling system. For more information on cleaners and degreasers, contact your sales representative.

Calculate the internal volume of the system as closely as possible. See Table 6 and Table 3 for unit volumes. Use volume in Table 6 for glycol piping volumes.

6.1.1XDF Water/Glycol Cooled Unit Volume

The water/glycol cooled XDF’s coolant capacity is 0.56 of a gallon (2.1 liters). In closed systems, addi- tional coolant will be required for the piping. Refer to Table 6 for required amounts for various piping sizes.

Table 6 Volume in standard Type “L” copper piping

Diameter (in.)		Volume
Outside	Inside	Gal/Ft	L/M
1/2	0.123	0.008	0.01
5/8	0.555	0.012	0.15
3/4	0.666	0.018	0.22
7/8	0.785	0.025	0.31
1-1/8	1.025	0.043	0.53

6.1.2Filling the System with Water or Glycol

When filling the XDF with either water or glycol, keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to remove. (Anti-foam additives are available and may be consid- ered.)

1.Open all operating systems to the loop.

2.With the top vent(s) open, fill the system from the bottom of the loop. This will allow the coolant to push the air out of the top of the system, minimizing trapped air.

3.Fill to approximately 80% of calculated capacity.

Fill slowly from this point, checking fluid levels until the system is full.

NOTE

For glycol solution preparation and periodic testing, follow manufacturer's recommendations. Do not mix products of different manufacturers.

30