Check Filling Level in Cooling Unit

Interval

Component

200 Hours Operating time

Cooling unit

Small quantities of cooling water can be lost from the cooling circuit through evaporation. Losses amounting to several litres per week, however, indicate leaks.

For manufacturer's documentation on the cooling unit, see Subsuppliers' Information (ZI) from "BKW".

For structure of the cooling unit, see the media diagram (MP).

Procedure

Check level at the filling level indicator.

If the filling level has decreased substantially since the last inspection, the hydraulic equipment must be checked for leakages.

For procedure see: "Inspection of Fluid Equipment"

If the cooling water level is below the centre of the min-max range, top up cooling water.

For procedure see: "Replenish Cooling Water"

Cooling Unit
1. Filler opening
2. Fill level display

Replenish Cooling Water

Cooling water:
Only a mixture of the following components may be used as cooling water.

Manufacturer Mixing ratio water: Antifrogen N
Demineralised water According to DIN ISO 3696, Quality 3 (or better).
Antifrogen N Anti - freeze with anti - corrosive action
Clariant GmbH D - 65840 Sulzbach Tel.: 06196/ 757 - 8807 www.antifrogen.de
65:35 Percent by volume = 62:38 Percent by weight This is equivalent to frost protection downto - 22\n°C.

The proportion of Antifrogen N in the cooling circuit must never drop below 20 % ! Below 20 % ,the anti - bacterial effect is reversed and bacteria can multiply extensively in the cooling circuit. Always keep the mixing ratio within the following limits:

Minimum of Antifrogen N Target value Maximum of Antifrogen N
Water: Antifrogen N in percentage by volume 70:30 65:35 60:40
Water: Antifrogen N in percentage by weight 67:33 62:38 57:43
Frost protection - 17\n°C - 22\n°C - 26\n°C

Determine the mixture ratio in the cooling circuit using a frost protection tester before toppingup the cooling water and depending on the test result, add pure Antifrogen N, a mixture or pure water. This procedure is described below.

Handling demineralised water and auxiliary materials:

  • Store demineralised water only for a few days and only in plastic containers.
  • To prevent contamination, demineralised water must not come into contact with the skin or soiled objects.
  • Pumps, hoses, containers and other auxiliary materials,that are used for handling demineralised water or Antifrogen N may not come into contact with other media such as oil or cooling lubricant.

Safety precautions for Antifrogen N:

  • Antifrogen N is harmful to the health if swallowed. If swallowed accidentally, seek medical treatment!
  • Do not inhale fumes.
  • Avoid any contact with eyes, skin or clothing. Wear solvent resistant gloves andtight - fitting safety goggles.
  • Remove contaminated clothing immediately. For First Aid measures following contact with the body or inhalation, see Safety Datasheet.
  • Do not allow undiluted or large volumes of Antifrogen N to penetrate ground water, running water or sewerage systems.
  • Furthermore, observe the safety instructions on the product packaging.

    • Ladder

    Clean glass for collecting cooling water sample

    Clean anti-freeze tester for Antifrogen N, HELLER No.01.019174

    Clean vessel for preparing the mixture

    Clean equipment for filling (jug, funnel)

    For safety data sheet on anti-corrosion agents, see Subsuppliers Information (ZI) from "Clariant".

    Procedure

    Fill with cooling water through the filling opening up to the maximum mark on the filling level indicator.

    Screw on filling opening cover.

    Operate the machine for 1 hour to mix the cooling water.

    Check the mixing ratio again and adjust as necessary.

    Cooling Unit
    1. Filler opening
    2. Fill level display

    Taking Cooling Water Sample

    Step 1:

    Maintenance area / safety door opened and secured to prevent closing.

    Step 2:

    Machine switched off at main switch and secured against being switched on again. This switches off the cooling unit.

    Step 3:

    Unscrew cover on filling opening.

    Cooling Unit
    1. Filler opening
    2. Fill level display

    Step 4:

    Unlock side panel of cooling unit (2 locks) and remove.

    Step 5:

    Remove safety cap from hose. Guide the hose into a glass beaker. Open the drain cock and remove approx. 100 ml cooling water.

    Step 6:

    Close drain cock and seal the end of the hose with the safety cap. Place the hose inside the cooling unit. Attach side panel of the cooling unit.

    Determine Mixture Ratio

    Step 1:

    Fill anti-freeze tester:

    • Open valve.
    • Hold anti-freeze tester with tube in the cooling water sample.
    • Fully compress suction bulb.
      • Hold the anti-freeze tester in a vertical position and extract cooling water: Release the suction bulb slowly at first to prevent the formation of air bubbles. Air bubbles result in inaccurate measurements. When measuring chamber is approx. 1/3 full, you can release the suction bulb.
    • Close the valve.

    Step 2:

    Any air bubbles that have formed can be removed by tapping your finger lightly against the measuring chamber.

    Step 3:

    Read off measuring result.

    • Hold the ant-freeze tester vertically.
    • The scale value at the level of the pointer indicates the anti-freeze rating in °C.

    Step 4:

    Drain the anti-freeze tester into the glass:

    • Open valve.
    • Repeatedly compress the suction bulb until the measuring chamber is completely empty.

    Step 5:

    Clean the anti-freeze tester by repeatedly sucking up and pumping out warm water.

    Step 6:

    Empty glass and clean with warm water.