20 Work Instructions

20.1 Active Cooling System

Vision RFD Systems are shipped with a ready-to-use mixture in the cooling system acting as a
coolant during operation. The coolant enables the equipment to withstand temperatures down to
-13°C during storage and transport. No particular hazards are known.

Admissible anti-freeze agent: Solarliquid L

(blue colored)

NOTE
The ready to use compound can be ordered with P/N 267751 (10 liters).

CAUTION
Top up only the ready to use compound in such units, which are already filled with
the specific cooling liquid.

WARNING
When working with any of the anti-freeze agents you must wear protective gloves
and safety goggles.

Ziehm Vision RFD / Ziehm Vision RFD 3D 20-1

280495/280757 - EN - 2022-03-01
20 Work Instructions

20.2 Filling / Draining of the Cooling System

20.2.1 General

20.2.1.1 Requirements

The filling has to be done very carefully, otherwise an immaculate function is not ensured. If it is
not done correctly, the pump might be damaged and the desired radiation time is not achieved.

Required tool: Additionally required:

Ventilation hose Bucket
(for draining the cooling circuit)
Funnel
Cooling liquid, ready to use compound

Funnel

Bucket

Ventilation hose
(example) Additionally
required
parts
Fig. 20-1 Required parts for maintaining the cooling system general

20-2 Ziehm Vision RFD / Ziehm Vision RFD 3D

280495/280757 - EN - 2022-03-01
 20 Work Instructions

20.2.1.2 Flow Scheme with Flow Sensor

Pressure Flow Sensor

control valve

Maximum level indicator max

(cooling circuit drained)

Expansion tank Heat exchanger

(Fan not shown)

Minimum level indicator min

(cooling circuit filled)

Drain valve
Flow

Return

Drain hose
Coolant pump

Swivel harnes

Filter

Cooling of
Generator
final stage

Cooling of
generator oil

Fig. 20-2 Liquid cooling flow scheme

Ziehm Vision RFD / Ziehm Vision RFD 3D 20-3

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20 Work Instructions

20.2.1.3 Starting the Pump Manually

In 20/25 kW systems, the pump is always running as soon as the system has started up.
To stop the pump, disconnect the pump or turn off the system.

Pump connector

Fig. 20-3 Disconnecting liquid pump

20.2.2 Filling the Cooling Circuit with Cooling Liquid

NOTE
Be sure the cooling circuit is completely drained before performing this step
( Ch. 20.2.4, p. 20-5).

In order to fill the cooling circuit, remove the pressure control valve and fill cooling liquid into the
expansion tank to the maximum level indicator by using a funnel. Start the pump. The cooling liq-
uid will be pumped into the cooling circuit now.
Air bubbles will appear from the return and the liquid level inside the expansion vessel will
decrease. When no more air bubbles return and the level has settled, the cooling circuit is com-
pletely filled. The liquid level now has to be about in the middle between the max and min indicator.
Do not top up cooling liquid to the max indicator when the cooling circuit is filled.
Install the pressure control valve again.

20-4 Ziehm Vision RFD / Ziehm Vision RFD 3D

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 20 Work Instructions

20.2.3 Checking the Circulation

Cooling liquid circulation can be monitored by the liquid stream from the return inside the expan-
sion tank.

20.2.4 Draining the Cooling Circuit

The cooling liquid can be pumped down to the expansion tank by using the ventilation hose.
Remove the pressure control valve, start the pump and insert the ventilation hose to the flow like
shown below. Air will be pumped into the cooling circuit and the cooling liquid will be pumped down
to the expansion tank. The liquid level in the expansion tank will increase. as soon as air bubbles
appear from the return, the cooling circuit is completely drained. Turn off the coolant pump. All the
cooling liquid is inside the expansion tank now.
Now, for example, the generator or the swivel harness may be changed without risk of spilling
cooling liquid.
Also the liquid level can be checked or topped up to the maximum respectively.
This procedure may also be used if you are not sure if the cooling circuit is completely drained.

Fig. 20-4 Usage of the ventilation hose

Ziehm Vision RFD / Ziehm Vision RFD 3D 20-5

280495/280757 - EN - 2022-03-01
20 Work Instructions

If the ventilation hose is removed while the pump is running, the cooling circuit will be filled again
like described above ( Ch. 20.2.2, p. 20-4).

20.2.5 Draining the Cooling System

Drain the cooling circuit like described above.

Put a bucket underneath the drain hose and open the drain valve.
The cooling liquid now is drained to the bucket.
The cooling system is completely drained now.
Close the drain valve.
Install the pressure control valve.
The system is not to be used now. Label the unit visibly:
Cooling System drained – Unit not ready for operation.
Do not switch on!

20.3 Checking the Liquid Level

The liquid level must not be below the min indicator of the expansion tank.
If the level is below min or if you want to top up cooling liquid, drain the cooling circuit as described
above, 20/25 kW systems ( Ch. 20.2.4, p. 20-5). When the cooling liquid has been pumped
down completely to the expansion tank, you may top up cooling liquid to the max indicator of the
expansion tank.
Fill the cooling circuit again by running the coolant pump without using the ventilation hose.
Install the pressure control valve when finished.

20.4 Replacing the Cooling Liquid

If cooling liquid needs to be topped up and the system is not filled with the specified ready to use
compound yet ( Ch. 20, p. 20-1), the cooling liquid needs to be replaced completely.
Drain the cooling system like described above.
Fill the cooling system with the specific ready to use compound like described above.

20-6 Ziehm Vision RFD / Ziehm Vision RFD 3D

280495/280757 - EN - 2022-03-01
 Document type: Technical Service Information

General Technical Information

6.14.Cooling fan and heat exchanger

Check the cooling fan at the cooling circuit mechanically for proper function and clean the blades of the
cooling fan and the cooling fins of the heat exchanger

6.15.Cooling circuit

Drain the cooling liquid completely and fill clear water into the cooling circuit until the MAX level of the
coolant expansion tank is reached. Flush the cooling system for 5 minutes with clear water. Drain the
rinsing liquid completely see Technical Service Manual, chapter Liquid Cooling System

Dispose of the coolant and inline filter, in which substances containing lead may have
accumulated over time, the rinsing liquid used and cleaning agents, e.g. cleaning
cloths, in accordance with the applicable local guidelines for the disposal of substances
containing lead

Replace the inline filter in the cooling circuit

Refill the cooling circuit with coolant liquid to the target fill level see Technical Service Manual, chapter
Liquid Cooling System

Check the flow rate of the cooling circuit at systems with flow meter by controlling the system logfile for
errors regarding the flow rate (e.g. E1146; E1177; E1178 etc.)

Check the flow rate of the cooling circuit at systems without flow meter by observing a constant inlet of the
coolant fluid into the reservoir without air bubbles

Check the adhesive surface of the cooling tank for impermeability

19_2210_Maintenance_Instruction_Ziehm_Vision_RFD_motorized_EN_D.doc page 24 of 54
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