INSTALLATION, OPERATION & MAINTENANCE MANUAL
Contents
1. END VIEW TOP VIEW END VIEW FRONT VIEW NOTE All dimensions are in mm dimensions in brackets are in inches DIMENSIONS Blower amp motor assembly A B D E F G H Cooling coil 805 31 7 520 20 5 246 9 7 863 34 444 17 5 696 27 4 183 7 2 736 29 208 8 2 Control box I 805 31 7 520 20 5 246 9 7 863 34 444 175 696 27 4 183 72 736 9 208 8 2 805 31 7 520 20 5 246 9 7 863 34 444 17 5 696 27 4 183 2 736 9 208 8 2 Filter rack Unit mounting brackets 904 35 6 610 24 244 9 6 960 37 8 521 20 5 769 30 3 183 7 2 841 33 1 183 7 2 841 83 1 241 9 945 37 2 259 10 2 Duct connector 9 5 241 9 5 945 37 2 259 10 2 206 8 1 904 35 6 610 24 244 9 6 960 378 521 20 5 769 30 3 206 8 1 Drip lip 1011 39 8 762 30 318 12 5 1067 42 640 25 2 858 33 8 1011 39 8 762 30 318 12 5 1067 42 640 25 2 858 33 8 241 95 945 37 2 259 10 2 1194 47 762 30 368 14 5 1245 49 625 24 6 894 35 2 1194 47 762 30 368 14 5 1245 49 625 24 6 894 35 2 1194 47 762 30 368 145 1245 49 625 24 6 894 35 2 266 10 5 1155 45 5 292 11 5 266 10 5 1155 45 5 2922. FM SPEED CONNECTIONS SPFED MED HIMED IMED LOW COLOR 3LK VIO BLU VALVE PACKAGES VALVE PACKAGE 3 C for 2 pipe 2 One balancing valve 3 way motor valve gt 1 Two compression stop valves VALVE PACKAGE 3 D for 2 pipe 2 One balancing valve One 3 way motor valve gt 1 Two gate shut off valves 7 1 Two gate valves 2 One balancing 3 way motor valve DESCRIPTION PARTS LIST MODEL NUMBER VALVE PACKAGE 4 C for 4 pipe Four compression stop valves 2 Two balancing valves Two 3 way motor valves VALVE PACKAGE 4 D for 4 pipe 1 D 1 Four gate shut off valves 2 Two balancing valves c 3 Two 3 way motor valves CHILLER DWL02 03 04 DWLO06 08 DWL10 12 14 DWL16 18 DWL20 FAN DECK ASSEMBLY 800 089 75 800 089 711 800 089 72 800 089 73 800 089 76 BLOWER MOTOR 800 547 55 800 547 51 800 547 52 800 547 53 800 547 56 BLOWER WHEEL 800 711 50 800 711 541 800 711 52 800 711 53 800 711 53 VALVE PACKAGE 3 700 362 51 700 362 51 700 362 51 700 362 51 700 362 51 VALVE PACKAGE 3D 700 364 81 700 364 81 700 364 81 700 364 81 700 364 81 RETURN AIR FILTERS 800 249 43 800 249 39 800 249 38 800 249 36 800 24
3. NTC in housing Optional Remote Sensor 193720 m BASE PLATE THERMOSTAT 12 HOUSING PROTECTION OPTIONAL NOTE All dimensions are in mm INSTALLATION The complete shipment should be inspected for damage Any damage visible or concealed should be reported immedi ately to the delivery man or driver and noted on the shipping invoice Place unit in position and make sure that unit is level This is important to assure proper drainage and operation Slots provided in the mounting brackets should be used for installing the units ELECTRICAL Please ensure power supply V Ph Hz to the unit is as per unit nameplate requirements Caution Operation of the unit on improper power supply will result in damage to the unit Warning Before installation or servicing always TURN OFF all power to the unit There may be more than one disconnect switch Ensure all of them are turned off GROUND amp POWER WIRES Connect power wires as per wiring diagram Connect ground wire to the ground lug inside the control box MAINTENANCE COIL Coil may be cleaned by removing and brushing between fins with a stiff wire brush Brushing should be followed by cleaning with vacuum cleaner The coil may also be cleaned by using a high pressure air if compressed air source is available It should be pointed out that if air filters are used and periodically cleaned the coils will not be
4. Electric shock hazard and or serious injury from rotating parts can result from improper handling and servicing Only skilled and trained technicians should attempt at installing and servicing these units CAUTION Improper handling and operating procedures might adversely affect the proper functioning of the unit Please read carefully this manual before operating the unit MODEL DECODING 12 amp 3 4 amp 5 6 7 8 9 10 11 12 13 BASIC SERIES SIZE ELECTRICAL COIL HEATER ACCESSORIES FIN COIL FILTER OPTION x 100 CFM SUPPLY V Ph Hz CONNECTION DWL COOLINE 02 220 240 1 50 A 3 ROW CHILLED NO HEATER N STANDARD A ALUMINUM SIDE N NONE N STANDARD WATER 93 AET A 3C VALVE PACKAGE b ee hin W 8 A ALUMINUM FAN COIL 0 3 ROW CHILLED E 3 kW COOL ONLY COATED DIS 1 2 THICK UNIT 06 WATER 1 ROW G 5 kw ALUMINUM CHARGE 08 HEAT B 3D VALVE PACKAGE FIN 10 NOHEATER COOL ONLY HE 45 C COPPER FIN OPTIONAL 3 kW J 4C VALVE PACKAGE FACING AIR 14 4 ROW CHILLED 6 5 kw HEAT amp COOL DIS 16 WATER Da CHARGE 18 CHILLED K 4D VALVE PACKAGE HEAT amp COOL 20 WATER 1 Row M 10 KW Ton HEAT OPTIONS ELECTRIC HEATERS The heater element is of the resistance open coil type Thermal overheat cut outs and fusible links are provided to shut off power to heaters in case of airflow failure The
5. uv 414 16 3 427 16 8 427 16 8 TYPICAL SCHEMATIC WIRING DIAGRAM HEAT COOL MODELS ELECTRIC HEATER LEGEND AUXILIARY TERMINAL BLOCK CAPACITOR CONTROL RELAY ELECTRIC VALVE COOLING FAN MOTOR LUG GROUND HEATER CONTACTOR HEATER HIGH VOLTAGE TERMINAL BLOCK LINE OR LINE 1 LINE 2 OR NEUTRAL OVER HEAT THERMOSTAT FIELD WIRING FACTORY WIRING NOTES Refer to for 5 1 POWER SUPPLY 220 240V 1PH 50Hz 2 MOTORS THERMALLY PROTECTED 3 4 HVTB IS NOT REQUIRED FOR HEATER MODELS 4 USE HEATER AS PER OPTION REQUIRED IF EV amp HEATERS ARE FACTORY IN STALLED PLEASE READ DASHED LINE AS CONTINUOUS LINE 5 USE COPPER CONDUCTORS ONLY FM SPEED CONNECTIONS MED HI MED MED L0 18 BLU ORN TYPICAL SCHEMATIC WIRING DIAGRAM HEAT COOL MODELS HOT WATER LEGEND AUXILIARY TERMINAL BLOCK CAPACITOR CONTROL RELAY ELECTRIC VALVE COOLING ELECTRIC VALVE HEATING FAN MOTOR LUG GROUND HIGH VOLTAGE TERMINAL BLOCK LINE OR LINE 1 LINE 2 OR NEUTRAL FIELD WIRING FACTORY WIRING NOTES 1 POWER SUPPLY 220 240V 1PH 50Hz 2 MOTORS THERMALLY PROTECTED 3 USE COPPER CONDUCTORS ONLY 4 1 EV amp EV1 ARE FACTORY INSTALLED PLEASE READ DASHED LINE AS CONTINUOUS LINE Speed Connections
6. that the electrical power is disconnected Avoid spilling any liquid on the thermostat Always allow for 1 to 2 minutes before activating different commands 13 SERVICING INSTRUCTIONS os gt e S oo o lt Blower deck holding bolt Blower deck_ Bottom panel Note 1 Required indoor unit access clearances are shown as hatched area 2 Free sevice access should be available from the bottom of the unit for removing amp servicing the blower motor deck 3 Servicing instructions a Remove the bottom panel b Support the blower deck while unscrewing the 4 blower deck holding bolts and bring down the blower deck 14
7. the threaded rod below the lower nut washer FIGURE 1 REQUIRED INDOOR UNIT CLEARANCES 2 7 FIGURE 2 Me FIGURE 3 D Piping connection SWEAT CONNECTION WATER INLET WATER OUTLET DWL 02 1 2 1 2 DWL 03 1 2 1 2 DWL 04 1 2 1 2 DWL 06 1 2 1 2 DWL 08 1 2 1 2 DWL 10 1 2 1 2 DWL 12 1 2 1 2 DWL 14 1 2 1 2 DWL 16 1 2 1 2 DWL 18 1 2 1 2 DWL 20 1 2 1 2 Note The water lines must be installed level in both the horizontal amp vertical plane MODEL NUMBER Insulation of pipes The pipe insulation should cover both inlet amp outlet pipes as shown below WATER IN WATER OUT WATER OUT WATER OUT INSULATION A WATERN WATER IN INSULATION YES NO NO E Condensate Drain connection Use PVC Class 3 material for the condensate drain piping 3 4 as per figure 4 Provide P trap immediately at the condensate drain connection Run your piping avoiding bends and elbows Pitch the piping away from the unit with 2 100 slope If the pipe is routed though a room or an unconditioned space insulate to avoid condensation on its outer walls FIGURE 4 DIMENSIONS MODELS DWL02 DWL20 3 4 NPT 14TPI DRAIN TUBE
8. 11 5 266 10 5 1155 45 5 292 11 5 1011 39 8 762 50 318 12 5 1067 42 640 25 2 858 33 8 DIMENSIONAL DATA CONNECTIONS MODELS DWL02 03 amp 04 VERTICAL COIL INLET O OUTLET RH SIDE INLET O OUTLET LH SIDE CHILLED WATER COIL HOT WATER COIL A B C D No OF ROWS E F No OF ROWS 225 8 9 237 9 3 32 1 3 176 6 9 264 10 4 275 10 8 225 8 9 237 9 3 32 1 3 176 6 9 264 10 4 275 10 8 225 8 9 237 9 3 32 13 176 6 9 264 10 4 275 10 8 313 12 3 324 12 8 32 1 3 178 7 351 13 8 362 14 3 313 12 3 324 12 8 32 1 3 178 7 351 13 8 362 14 3 313 12 3 324 12 8 83 3 3 227 8 9 351 13 8 362 14 3 324 12 8 83 3 3 227 8 9 351 13 8 362 14 3 319 12 6 330 13 83 3 3 227 8 9 357 14 368 14 5 376 14 8 389 15 3 129 5 273 10 8 414 16 3 427 16 8 313 12 3 376 14 8 389 15 3 129 5 273 10 8 414 16 3 376 14 8 389 15 3 129 5 NOTE dimensions are in mm dimensions in brackets are in inches 273 10 8 BRR IR WO W
9. 9 36 THERMOSTAT 800 646 20 800 646 20 NOTE For 4C amp 4D type valve package order 2 x 3C amp 2 x 3D valve packages 10 800 646 20 800 646 20 800 646 20 THERMOSTAT OPERATION amp SPECIFICATION DATA OPERATING INSTRUCTIONS SYMBOL FUNCTION OFF mode switch position COOL mode switch position FAN mode switch position HEAT mode switch position Temperature set button increasing Temperature set button decreasing LOW fan speed switch position MEDIUM fan speed switch position HIGH fan speed switch position FUNCTION COOLING MODE Position the switch S1 to COOL mode function Set desired temperature setting by pressing the or button to increase or decrease the set value displayed on the LCD of the thermostat Fan speeds can be selected by positioning the switch S2 to LOW speed MEDIUM speed HIGH speed HEATING MODE Position the switch S1 to HEAT mode function Set desired temperature setting by pressing the or button to increase or decrease the set value displayed on the LCD of the thermostat Fan speeds can be selected by positioning the switch S2 to LOW speed MEDIUM speed HIGH speed FAN MODE Position the switch S1 to FAN mode function Fan speeds can be selected by positioning the switch S2 to LOW speed MEDIUM speed HIGH speed UNIT OFF Positi
10. INSTALLATION OPERATION amp MAINTENANCE MANUAL CONCEALED CHILLED WATER FAN COIL UNITS DWL SERIES INDEX Contents Page General information LSE 2 ENCARTA 2 Inspection procedure eret ed peeled ure AR 2 Model decoding corni e Pepe e 3 Goin ea ie ened 3 Installation procedures nid 4 Eocation of iridoor Untere eee Pret ete e T e d e e rr e eee 4 Site preparations a i e ced nci seem DU 4 Unitinstallatior ot EE 4 2 ooo eie eee ctr Fuel e o ota EEE 5 Condensate drain connection 5 Unit dimensions dee eda ede s 6 Dimensional data coil connections cienia e NE Ri 7 Typical wiring Glagram EE 8 9 Valve packages inne daniel init ein 10 Parts list iare di p n eR 10 Thermostat operation amp specification data essen 11 12 RR te ee Rn REESE 13 Electrical ee RE enn RSS 13 Maintenance i fete eT 13 Servicing Instructions da 14 CONTINUING RESEARCH RESULT
11. S IN STEADY IMPROVEMENTS THEREFORE THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE GENERAL INFORMATION Thank you for your purchase of this equipment from the COOLINE Air Conditioners We trust that this unit will provide you with the proper Cooling Heating requirements for years to come However we would suggest that you read carefully this manual before you proceed with the installation and operation of this equipment and follow the instructions for a safe trouble free operation This unit has been tested to the extremes in terms of working conditions and successfully passed all the requirements of quality safety and performance WARRANTY TERMS of the DWL series of indoor fan coil concealed units are covered by the standard warranty terms against any manufacturer defect Should you encounter any problem that falls under the warranty terms please contact your nearest COOLINE representative INSPECTION PROCEDURES The moment you receive this unit check the packaging carton for any visible damage due to shipment and mishandling If you suspect any damage to the unit please call your nearest COOLINE representative After you open the carton make sure that there is no visible damage to the body Check the condition of the protective Styrofoam Manually rotate the blower wheels to make sure that it is running freely Inside every DWL packaging you will find DWL Concealed FCU 1 No Service Manual 1 No WARNING
12. bstructing in any way the movement of the installation personnel Clear the floor from all objects with sharp edges Remove liquid or slippery material from the installation site before proceeding Indoor unit installation Cut the top carton panel and mark it with a sketch simulating the FCU Use it as a template for positioning the unit and the corresponding mounting brackets hole slot Put the template against the ceiling and mark the corners Make sure that you leave at least 30 cm clearance from the rear and anther 50 cm from the right hand side of the unit when looking at the unit from the supply side as shown in figure 1 Mark the 4 holes Drill those 4 holes Insert the threaded rods using anchor bolts 8 mm Fitandtighten the nuts atthe loose end of each threaded rod as per the arrangement show in figure 2 Lift the FCU unit and insert the threaded rods into the mounting bracket slots Let it rest on the lower nut washer After you complete the electrical connections see corresponding sections Electrical Wiring and Thermostat Installation and Connection level the FCU and press it against the ceiling ensuring to separate it fromthe ceiling by inserting rubber cork pieces by further tightening action of the lower nut s For added security counter tighten the upper nut as shown in figure 3 Cut the extra length of the threaded rod and round the edges Note Always leave 7 to 8 cm extra length in
13. clogged up prematurely DRAIN PIPE Drain pipe should be checked before summer operation of unit If it is clogged steps should be taken to clear the debris so that condensate will flow out easily A standard pipe cleaner for 1 2 ID pipe may be used Periodic checks of the drain pipe should be taken during summer operation as there is a possibility of it becoming clogged with dirt FILTER CLEANING Remove access panel slide filter out of filter rack and clean as follows Tap filter on solid surface to dislodge heavy particles Wash under stream of hot water If filter has been put to excep tional service a mild solution of Sal Soda Tri Sodium Phosphate or any other commercial solvent can be used Set filter on end with slots in frame down which allows it to drain Filters should dry thoroughly before reuse REPLACEMENT PARTS When writing for replacement parts refer to model number and serial number on the nameplate of the unit ROUTINE PREVENTIVE MAINTENANCE Clean the thermostat box with a dry soft cloth Remove the filter by either a Swinging away the knuckles on top of the filter rack then lifting the filter from the lower rack b Swinging away the knuckles on top of the filter rack then sliding the filter sideways C Clean the filter by a jet of air in the reverse return air direction d Inspect the condensate pipe for clogging SAFETY INSTRUCTIONS Warning Before you attend to any routine maintenance make sure
14. heaters are available as an option and can be installed at the blower outlet VALVE PACKAGES A variety of valve packages as a set are available as an option amp 3D for two pipe system and 4C amp 4D for four pipe systems These valves are supplied loose for field installations THERMOSTAT An attractive wall mount three speed thermostat with all required functions and features for safe and smooth operation which can be used for cooling amp heating This thermostat can be supplied loose through separate Kit number tx A 7 aM TYPICAL THERMOSTAT INSTALLATION PROCEDURES A Location of Indoor units The Indoor FCU should be ideally located in a plenum orfalse ceiling clearance cavity near the conditioned area where the access to the chilled water piping connection is easy Position the FCU in a way to avoid obstruction to return airflow supply air electrical cable connections condensate drain pipe and chilled water piping The required clearances are shown in figure 1 All dimensions are in cm B Site Preparation The site for the FCU installation should be free from any obstacle that can be hazardous to the installation personnel and or damaging to the unit Properly identify all existing building utilities such as electrical cables plumbing pipes sanitary hardware etc Make sure that live electrical cables are not hanging or running near the FCU proposed location or o
15. on the switch S1 to OFF position to turn off the unit Notes 1 Start up display When power is supplied to the thermostat the LCD indicates a flashing display of the standard set point value Press the amp button at the same time to change the display to ambient temperature 2 Set point adjustment When the or button is pressed the thermostat assumes the temperature set point setting mode and the present set point is displayed The displayed set point can now be adjusted in 0 5K steps to the required value After 3 seconds approx the actual temperature will then be displayed 11 PRODUCT DATA Part Number 800 646 20 Switches Fan speed high med low Heat Fan Cool Off Outputs Heat Cool Fan speed high med low Inputs Remote sensor optional TECHNICAL DATA Operating voltage Operating ambient Temperature range Selectivity of set value Display range actual value Selectivity of actual value Hysteresis Switching current at 250 VAC Maximum fan current Sensor system Switches Heat Off Cool Fan 3 Fan Speed Indicator lamps Cool Heat PHYSICAL DATA Color Polar white Material ABS plastic Protection class IP30 Plastic Weight 130 grams Accessories Base plate and screws Option Transparent wall mounted housing lockable with ventilation slit DIMENSIONS 230V 10 50 60 Hz 0 C to 40 5 C to 30 0 5K 0 40 C 0 1K 0 5 3 2 A 6 3 A
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