Troubleshooting guide

TABLE OF CONTENTS
MANUAL INDEX PAGE
1.0 INTRODUCTION...................................................................................................................................................................3
2.0 GENERAL INFORMATION
2.1 SAMPLE NOMENCLATURE.................................................................................................................................................4
2.2 RECEIVING, INSPECTION AND PACKAGING........................................................................................................................4
2.3 RIGGING AND UNCRATING.................................................................................................................................................5
2.4 LIMITATIONS......................................................................................................................................................................5
3.0 INSTALLATION
3.1 FOUNDATION.....................................................................................................................................................................6
( i.) Provide A Separate Floating Plinth..................................................................................................................................6
( ii.) Place The Unit On A Minimum 2½” Thick Cork Sheet ........................................................................................................7
( iii.) Support The Complete Unit On Spring Isolators. Request Factory To Provide
Correct Spring Isolators And Mounting Brackets At Base Units............................................................................................7
3.2 LOCATIONS.......................................................................................................................................................................7
3.3 CLEARANCE......................................................................................................................................................................7
Figure 3.3A: For Units With Single Side Return Air, WCPS 68B To 570B ......................................................................................8
Figure 3.3B: For Units With Single Side Return Air, WCPS 640B To 1520B...................................................................................9
3.4 UNPACKING AND UNCRATING..........................................................................................................................................10
3.5 BLOWER SECTION...........................................................................................................................................................10
3.5.1 Discharge Pattern ....................................................................................................................................................10
3.5.2 Duct Connections ....................................................................................................................................................10
Figure 3.5.1: Blower Discharge Pattern..........................................................................................................................11
Figure 3.5.2: Suggested Method For Connecting Supply Duct To Twin Blower Unit ..............................................................12
3.6 EVAPORATOR SECTION ...................................................................................................................................................12
Figure 3.6: Condensate Drain Trap .......................................................................................................................................12
3.7 CONDENSER SECTION.....................................................................................................................................................13
3.8 COOLING TOWER ............................................................................................................................................................13
Figure 3.8A: Cooling Tower Water Piping Schematic ...............................................................................................................14
Figure 3.8B: Unit Control On Water Flow ...............................................................................................................................14
Figure 3.8C: Alternate Unit Control On Water Flow..................................................................................................................14
4.0 OPERATION
4.1 SYSTEMS CAPACITY........................................................................................................................................................15
4.2 SYSTEM WATER FLOW ....................................................................................................................................................15
4.3 TEMPERATURE CONTROL................................................................................................................................................15
4.4 TEMPERATURE SETTING.................................................................................................................................................16
4.5 PHASE ROTATION............................................................................................................................................................16
4.6 CYCLE LIMIT RATE...........................................................................................................................................................16
4.7 HOT GAS BYPASS............................................................................................................................................................16
4.8 REFRIGERANT CIRCUIT AND COMPONENTS.....................................................................................................................17
Figure 4.8: Typical Refrigerant Piping And Components...........................................................................................................17
4.9 TYPICAL OPERATING SEQUENCE FLOW CHART...............................................................................................................18
4.10 START UP CHECKLIST.....................................................................................................................................................19
4.11 TYPICAL WIRING SCHEMATIC WITHOUT STARTER ...........................................................................................................20
4.12 TYPICAL WIRING SCHEMATIC WITH DOL..........................................................................................................................20
4.13 TYPICAL WIRING SCHEMATIC WITH AUTOTRANS.............................................................................................................21
5.0 MAINTENANCE
5.1 GENERAL ........................................................................................................................................................................22
5.2 SCHEDULE OF INSPECTION AND MAINTENANCE..............................................................................................................22
5.2.1 Monthly Inspection And Maintenance ........................................................................................................................22
5.2.2 Three Monthly Inspection And Maintenance...............................................................................................................22
5.2.3 Annual Inspection And Maintenance..........................................................................................................................22
5.3 CONDENSER MAINTENANCE............................................................................................................................................23
5.3.1 General....................................................................................................................................................................23
5.3.2 Condenser Cleaning.................................................................................................................................................23
5.3.3 Tube Replacement....................................................................................................................................................24
5.4 WATER TREATMENT........................................................................................................................................................24
5.5 TIGHTENING OF BEARING SET SCREW ............................................................................................................................24
5.6 PULLEY ALIGNMENT........................................................................................................................................................25
5.7 BELT TENSION INSPECTION GUIDE..................................................................................................................................25
5.8 TROUBLE-SHOOTING CHART...........................................................................................................................................27
5.9 SAMPLE LOG SHEET........................................................................................................................................................30