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Summary of Contents for Glen Dimplex Koolant Koolers WO2-2-5000
- Page 1 User Manual Original Instructions 800.968.5665 | dimplexthermal.com...
- Page 2 Table of Contents ATTENTION This manual provides the user, installer and maintenance technician the technical information for installation, operation and routine maintenance to ensure smooth operation and long-lasting operation of the CHILLER. This manual has been written with general guidelines and specifications for this platform of chillers.
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Page 3: Table Of Contents
Table of Contents Table of Contents Table of Contents ................................ i List of Figures ................................iii List of Tables ................................iv Important Safety Instructions ........................... 1 Introduction ............................... 2 Specifications ..............................3 Labels ................................. 4 Installation Guidelines ............................5 Exterior Components ..........................5 Overall Dimensions ............................ -
Page 4: Table Of Contents
Table of Contents Troubleshooting ............................26 Refrigeration High Pressure Switch ......................27 Maintenance ............................27 7.6.1 Suggested maintenance checklist....................27 Internal Components ............................30 Units Equipped with a Tank Heater ......................34 Spare Parts List ..............................35 Maintenance ..............................36 Pump Removal ............................ -
Page 5: List Of Figures
List of Figures List of Figures Figure 1: Exterior Components ..........................5 Figure 2: Exterior Components (Electrical Enclosure Side) ..................5 Figure 3: WO2-2-5000 Overall Dimensions ....................... 6 Figure 4: WO2-2-7500 / WO2-2-10000 Overall Dimensions ..................6 Figure 5: WO2-2-5000 / WO2-2-7500 / WO2-2-10000 Required Clearances ............8 Figure 6: Internal Access ............................ - Page 6 List of Tables List of Tables Table 1: Medical Chiller Capacities ..........................2 Table 2: Specifications ............................... 3 Table 3: Labels ................................4 Table 4: Chiller Air Intake and Exhaust Requirements ....................7 Table 5: Standard Fitting Losses in Equivalent Feet of Pipe ..................15 Table 6: Chiller Plumbing Connections ........................
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Page 7: Important Safety Instructions
Important Safety Instructions Important Safety Instructions This manual contains important safety instructions that should be followed during the installation and maintenance of the chiller. Read this manual thoroughly before attempting to install or operate this unit. Failure to follow the instructions in this document may damage the equipment, cause hazardous conditions and void the warranty. -
Page 8: Introduction
Introduction Introduction WO-2-2-( ) outdoor chillers are designed to supply water/glycol as coolant to remove heat from process equipment and reject it to the air through a vapor compression refrigeration cycle. The chiller features: • Dual refrigeration circuits ▪ Over 99% system uptime ▪... -
Page 9: Specifications
Specifications Specifications Table 2: Specifications WO2-2-5000 WO2-2-5000 WO2-2-7500 WO2-2-7500 WO2-2-10000 WO2-2-10000 Criterion Standard Low Ambient Standard Low Ambient Standard Low Ambient Electrical Input power 460V, 3Phase, 60Hz 61 A 64 A 64 A 66 A MOPD 70 A 70 A SCCR 5 kA Refrigeration... -
Page 10: Labels
Labels Labels Table 3: Labels Symbol Description Symbol Description Caution Fan Do No Remove Starts Guards Automatically Tank Level High Prop65 Warning Tank Level Low Tank Drain Fluid Outlet Fluid Inlet Arc Flash Arc Flash Warning Warning Made in USA... -
Page 11: Installation Guidelines
Installation Guidelines Installation Guidelines Exterior Components DOORS BLOCKER / DOOR BOLTS (EACH SIDE) FANS LOWER DOORS INTAKE FILTERS Figure 1: Exterior Components MAIN POWER DISCONNECT FLUID INLET 2” FPT TANK LEVEL HIGH FLUID OUTLET 2” FPT TANK LEVEL LOW TANK DRAIN Figure 2: Exterior Components (Electrical Enclosure Side) -
Page 12: Overall Dimensions
Installation Guidelines Overall Dimensions 87.7” 44.0” 134.5” Figure 3: WO2-2-5000 Overall Dimensions 96.5” 44.0” 134.5” Figure 4: WO2-2-7500 / WO2-2-10000 Overall Dimensions... -
Page 13: Location Considerations
Installation Guidelines Location Considerations The chiller must be installed with enough clearance for service and for unrestricted air intake and exhaust. The chiller must be located sufficiently close to the process to ensure adequate flow rate of coolant by not exceeding the capabilities of the chiller’s pumps. -
Page 14: Figure 5: Wo2-2-5000 / Wo2-2-7500 / Wo2-2-10000 Required Clearances
Installation Guidelines OBSTRUCTION OBSTRUCTION MINIMUM 8FT VERTICAL CLEARANCE MINIMUM 3FT CLEARANCE ON DOOR SIDE MINIMUM 6FT CLEARANCE ON FILTER SIDE OBSTRUCTION Figure 5: WO2-2-5000 / WO2-2-7500 / WO2-2-10000 Required Clearances... -
Page 15: Checking For Shipping Damage
Installation Guidelines Checking for Shipping Damage Upon delivery of the chiller, verify that the shipment matches the bill of lading. Inspect the chiller immediately for signs of shipping damage both visible and concealed. Damaged crating likely indicates damage to the chiller and may require the removal of the panel and/or air filter(s) for further inspection. -
Page 16: Installation
Installation Installation Internal Access AIR FILTER RETAINERS BLOCKER BLOCKER AIR FILTER AIR FILTER AIR FILTER AIR FILTER DOOR DOOR DOOR DOOR LOWER DOOR RETAINERS Figure 6: Internal Access... -
Page 17: Figure 7: Removal Or Doors & Blockers
Installation 3/8” DOOR BOLT 3/8” BLOCKER BOLT DOOR BLOCKER Figure 7: Removal or Doors & Blockers... -
Page 18: Figure 8: Removal Of Lower Doors
Installation LATCHES Figure 8: Removal of Lower Doors... - Page 19 Installation To access the chiller’s internal components (Refer to, Figure 6, Figure 7, Figure 8): • From the air intake/filter side 1. Use a slotted screwdriver to turn the quarter-turn Air Filter Retainer fasteners above the Air Filters counterclockwise. 2. Gently lift the Air Filter upward by its mesh and then pull outward to remove the filter. 3.
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Page 20: Connections
Installation Connections 6.2.1 Electrical WARNING This procedure involves a risk of electric shock that could cause property damage, injury and/or death. All electrical connections should be performed only by properly trained and certified electricians wearing proper protective gear and using properly insulated tools. -
Page 21: Coolant Plumbing
Installation 6.2.2 Coolant plumbing The chiller must not be installed more than 65 feet above the heat exchangers and cryro compressor. The chiller pumps can deliver up to 165 feet of head. The heat exchangers and cryro compressor are rated at 230 feet maximum. -
Page 22: Coolant Reservoir Filling
Installation WARNING All plumbing connections should be performed only by properly trained and certified operators wearing proper protective gear and using appropriate tools. Failure to correctly install plumbing fittings can lead to leaks, loss of coolant, and/or water damage to nearby equipment. NOTICE Ferrous and galvanized steel fittings are incompatible with the coolant. - Page 23 Installation NOTICE The chiller will require more coolant than the volumes listed above to fill the connecting hoses and the chillers internal plumbing components. Additional coolant will most likely be required if the chiller is being commissioned for the first time after the pumps have begun running as this coolant will fill any empty plumbing components.
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Page 24: Installation Checklist
Installation Installation Checklist • Transport and Location of Chiller Chiller has been unpacked and inspected for visual damage from shipping. Required clearance for intake and exhaust air has been maintained around the chiller. Required clearance for service access has been maintained around the chiller. •... -
Page 25: Operation
Operation Operation Initial Startup WARNING Risk of improper startup. Failing to complete the installation checklist could cause damage to the chiller. The following startup procedures must be adhered to in sequence. This outline should be used as a checklist for the initial startup and for subsequent startups if the chiller is taken out of service for a prolonged period. -
Page 26: Controller
Operation Controller 7.2.1 Initialization of Controller: When the unit is first powered up after a download it goes through a self-test and requires a reboot after initialization. Cycle power to the controller if the message in Error! Reference source not found. is displayed. W hen the controller has finished its initial self-test, the Home Page will be displayed. -
Page 27: Changing The Setpoint
Operation 7.2.4 Changing the Setpoint: To change the setpoint: • Press the “Prg” key and the main menu will be displayed • Highlight the menu labeled “B. SETPOINT” and press the “Enter” key. The page will look similar to Error! R eference source not found. -
Page 28: Figure 10: Controller Restart Warning
Operation Figure 10: Controller Restart Warning Figure 11: Controller Home Page... -
Page 29: Figure 12: Controller Main Menu
Operation Figure 12: Controller Main Menu Pg1 Figure 13: Controller Main Menu Pg2 Figure 14: Controller Main Menu Pg3... -
Page 30: Figure 15: Controller On/Off Menu
Operation Figure 15: Controller On/Off Menu Figure 16: Controller Pump Enable/Disable Menu... -
Page 31: Figure 17: Controller Setpoint Menu
Operation Figure 17: Controller Setpoint Menu Figure 18: Controller Alarm Menu... -
Page 32: Troubleshooting
Operation Troubleshooting Table 7 Troubleshooting Service Guide Symptoms Possible Cause 1. Open disconnect switch 2. Tripped overloads Selector switch is in “ON” position & pump will not start. 3. Phase monitor fault 4. Low tank level 1. Improper rotation 2. No water in reservoir 3. -
Page 33: Refrigeration High Pressure Switch
Operation Refrigeration High Pressure Switch WARNING The refrigeration discharge lines may be extremely hot – avoid contact. Resetting of the refrigeration high pressure switch should only be performed by qualified personnel equipped with proper safety gear and tools. The chiller’s refrigeration circuit is equipped with a mechanical, high pressure switch that disengages (trips) the refrigeration circuit when dangerously high pressures occur to prevent damage to the refrigeration system. - Page 34 Operation 7.6.1.4 Inspect the quality of the coolant in the reservoir Access the coolant in the reservoir via the access cap. System fluid should be clean and free of contaminants. Test the glycol concentration level to ensure levels are within the rated conditions. Refill tank as needed with pre-mixed glycol to maintain proper concentration.
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Page 35: Table 8: Electrical Component Torque
Operation 7.6.1.7 Check all wiring for loose connections, chaffing or damage Turn off the main disconnect. Check all wiring inside of electrical panel and inside the chiller for loose or damaged wires. Tighten any loose terminals and replace any damaged wires. Table 8: Electrical Component Torque Component Torque (in-lb) -
Page 36: Internal Components
Internal Components Internal Components CIRCUIT 1 CIRCUIT 2 FAN 2 FAN 1 BRAZED PLATE HEAT EXCHANGER (USED FOR PRESSURE RELIEF VALVE BOTH CIRCUITS) CONDENSER COIL 2 CONDENSER COIL 1 TANK FILL CAP HIGH PRESSURE COMPRESSOR 1A COMPRESSOR 2A HIGH PRESSURE AIR VENT SWITCH CIRCUIT 1 SWITCH CIRCUIT 2... -
Page 37: Figure 20: Door Side
Internal Components PUMP 1 PUMP 2 FLOAT SWITCH Figure 20: Door Side... -
Page 38: Figure 21: Wo2-2-7500 Air Filter Side
Internal Components CIRCUIT 1 CIRCUIT 2 FAN 1 FAN 2 BRAZED PLATE HEAT EXCHANGER (USED FOR PRESSURE RELIEF VALVE BOTH CIRCUITS) CONDENSER COIL 1 CONDENSER COIL 2 HIGH PRESSURE HIGH PRESSURE TANK FILL CAP AIR VENT COMPRESSOR 1A SWITCH CIRCUIT 1 SWITCH CIRCUIT 2 COMPRESSOR 2A COMPRESSOR 2B... -
Page 39: Figure 22: Wo2-2-10000 Air Filter Side
Internal Components CIRCUIT 1 CIRCUIT 2 FAN 1 FAN 2 BRAZED PLATE HEAT EXCHANGER (USED FOR PRESSURE RELIEF VALVE BOTH CIRCUITS) CONDENSER COIL 1 CONDENSER COIL 2 HIGH PRESSURE HIGH PRESSURE TANK FILL CAP COMPRESSOR 1A COMPRESSOR 2A SWITCH CIRCUIT 2 SWITCH CIRCUIT 1 AIR VENT COMPRESSOR 1B... -
Page 40: Units Equipped With A Tank Heater
Internal Components Units Equipped with a Tank Heater Tank heaters are mounted on the front of the tank with an over temperature switch mounted directly above it. OVERTEMP SENSOR MOUNTING BULB TANK HEATER Figure 23: Tank Heater HEATER CONTROL BOX Figure 24: Tank Heater Control Box... -
Page 41: Spare Parts List
Spare Parts List Spare Parts List WO2-2-5000 WO2-2-5000 WO2-2-7500 WO2-2-7500 WO2-2-10000 WO2-2-10000 Description Standard Low Ambient Standard Low Ambient Standard Low Ambient Electrical Controller 4807776 Power Supply 5004669 Phase Monitor 5000472 Enclosure Heater 3835107 2-Pole Relay 5001058 1-Pole Relay 5001057 Pump MMP 5001241 Pump Contactor... -
Page 42: Maintenance
Maintenance Maintenance Pump Removal To remove pump: 1. Ensure power is disconnected 2. Access pumps from lower doors 3. Remove wiring 4. Close ball valve 5. Remove flange clamps 6. Remove 3/8” mounting bolts 7. Slide pump assembly out from retention tabs and remove FLANGE CLAMPS BALL VALVE 3/8”... -
Page 43: Revisions
Revisions Revisions Rev Description Date Initial Release B. Post 3/16/21 FN063 to ZN063 B. Post 4/27/21 Add spare parts list B. Post 7/15/21 Update WO2-2-7500 and WO2-2-10000 images B. Post 9/16/21... -
Page 44: Appendix A (Plumbing)
Appendix A (Plumbing) Appendix A (Plumbing) -
Page 45: Appendix B (Pump Curve)
Appendix B (Pump Curve) Appendix B (Pump Curve) -
Page 46: Appendix C (Refrigeration)
Appendix C (Refrigeration) WO2-2-5000 Appendix C (Refrigeration) WO2-2-5000... -
Page 47: Wo2-2-7500
Appendix C (Refrigeration) WO2-2-7500 WO2-2-7500... -
Page 48: Wo2-2-10000
Appendix C (Refrigeration) WO2-2-10000 WO2-2-10000... -
Page 49: Appendix D (Warranty)
Appendix D (Warranty) Appendix D (Warranty) Warranty Coverage Chiller warranty terms are full parts and labor coverage for 18 months from ship date or 12 months from chiller commissioning, whichever comes first. Parts and labor cover entire chiller up to the first external piping connection and conduit seal of electrical panel. -
Page 50: Appendix E (General Warranty Procedures)
Appendix E (General Warranty Procedures) Appendix E (General Warranty Procedures) Warranty Work Before doing any work on a chiller covered under warranty, call Dimplex Thermal Solutions (DTS) and explain the problem to one of our service technicians who can then determine the best course of action. DTS will not be obligated to pay for warranty service performed without our prior approval. -
Page 51: Appendix F (Factory Contact)
Appendix F (Factory Contact) Appendix F (Factory Contact) Hours of operation are 8:00 a.m. to 5 p.m. EST, Monday to Friday. Website: https://www.dimplexthermal.com Service Support Team • medicalservice@dimplexthermal.com • (800) 968-5665 ext. 710 • (269) 349-6800 Parts Department • partsdept@dimplexthermal.com •... -
Page 52: Appendix G (Chiller Registration)
Appendix G (Chiller Registration) Appendix G (Chiller Registration) The registration form must be submitted within 30 days of installation date or warranty coverage will be calculated from the date the chiller was shipped from the factory. http://www.dimplexthermal.com/service/register-chiller-location Register Your Chiller’s Site Location Why register your chiller? Dimplex Thermal Solutions chillers are sold across the globe, and often bundled with other manufacturers’... - Page 53 Appendix G (Chiller Registration)
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