Applies To

• CW3 Climate Wizard
• CW-6S Climate Wizard

Issue

Water carryover (water droplets entering supply duct) may occur on initial start-up or commissioning of new coolers

Typically observed when:

• Pad Flush / Core Flush has been run for extended duration
• Unit has been operated in pump-only mode without draining
• Foam/residue develops on pads

Symptoms

• Water droplets in supply air
• Wet ductwork on startup
• Increased carryover at higher fan speeds (e.g. Speed 10)
• Issue persists after initial commissioning

Root Cause

Testing has confirmed:

• New cooler commissioning requires a 15-minute pad/core flush followed by a drain.
• Extended flushing (20+ minutes) generates foam from pad/core residues
• When the tank is not drained, foam remains on the pads
• Foam does not dissipate naturally and continues to affect operation
• This results in water pull-off into the supply air stream

Critical Requirement (Prevention)

✅ Always drain the tank after any Pad/Core Flush cycle

• Commissioning instructions require:
  • Run Core Flush (maximum 15 minutes)
  • Then open drain and fully drain reservoir
  • See commissioning section of product manual.

⚠️ Do NOT exceed 15 minutes flushing without draining

• Extended flush without draining directly contributes to foam formation and carryover

Rectification Procedure

Recommended Method

Repeat the following 3 times:

1. Run Pad Flush Continuously for a maximum of 5 minutes)
2. Perform Manual Tank Drain
3. Repeat

✔ This has been proven effective at removing foam and residue buildup

Menu Path (MagIQtouch Controller)

Settings → Cooler → Pad Flush → Continuously 

Settings → Cooler → Manual Drain

Controller functions reference:

• Pad Flush = pump-only operation
• Manual Drain = drains reservoir

Run Pad Flush Continuously– 4–5 minutes (no longer than 5 minutes)

Important Notes

1. Manual Drain is Critical

• The drain valve:
  • Removes contaminated water and residue from system

✔ Foam is only removed when physically drained from the reservoir
✔ Without draining, foam will persist and re-contaminate pads

2. Multiple Cycles Required

• Foam and residue can remain in:
  • Pad media (Chillcel)
  • Water distribution system
• Repeated short flush/drain cycles required to fully clean system

3. Post-Rectification Verification

After completing cycles:

• Run unit in COOL mode at Speed 10
• Confirm:
  • No water carryover
  • No droplets in supply air
  • Normal cooling operation

✔ Commissioning requires full-speed operation and performance confirmation:

4. Duct Moisture Consideration

• Residual moisture in ductwork may remain temporarily
• This is normal and will clear once system stabilises

Best Practice (Commissioning Guidance)

To avoid recurrence:

• Use Pad Flush only to:
  • Remove initial pad odours
• Limit initial flush duration to ≤15 minutes
• Always perform full drain immediately after flush
• Avoid extended pump-only operation without drain

Summary