Cooline DWL SERIES, DWL02, DWL03, DWL04, DWL06 Installation, Operation & Mainenance Manual

INSTALLATION,

OPERATION

&

MAINTENANCE

MANUAL

CONCEALED CHILLED WATER FAN COIL UNITS

'DWL' SERIES

Part Number: 800-213-51 (Rev.-01)

INDEX

Contents Page

General information .................................................................................................................................. 2

Warranty terms......................................................................................................................................... 2

Inspection procedure ................................................................................................................................ 2

Model decoding ........................................................................................................................................ 3

Options ..................................................................................................................................................... 3

Installation procedures ............................................................................................................................. 4

Location of indoor units ............................................................................................................................ 4

Site preparation ........................................................................................................................................ 4

Unit installation ......................................................................................................................................... 4

Piping connection ..................................................................................................................................... 5

Condensate drain connection ................................................................................................................... 5

Unit dimensions ........................................................................................................................................ 6

Dimensional data - coil connections ......................................................................................................... 7

Typical wiring diagram ........................................................................................................................... 8-9

Valve packages ...................................................................................................................................... 10

Parts list ................................................................................................................................................. 10

Thermostat operation & specification data ........................................................................................ 11-12

Installation .............................................................................................................................................. 13

Electrical ................................................................................................................................................. 13

Maintenance ........................................................................................................................................... 13

Servicing instructions ............................................................................................................................. 14

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

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

All 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:
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.

2

MODEL DECODING

1, 2 & 3

BASIC (SERIES)

DWL : COOLINE

CHILLED
WATER
FAN COIL
UNIT

4 & 5

SIZE

(x 100 CFM)

02
03
04
06
08
10
12
14
16
18
20

6

ELECTRICAL

SUPPLY (V-Ph-Hz)

B : 220/240-1-50

7

COIL

A :

3 ROW CHILLED
WATER

J :

3 ROW CHILLED
WATER + 1 ROW

HEAT

B :

4 ROW CHILLED
WATER

K :

4 ROW CHILLED
WATER + 1 ROW

HEAT

8

HEATER

NO HEATER

N :
D :2 kW
E :3 kW
G:5 kW

N :

NO HEATER

E :3 kW
G:5 kW
J :7 kW
M: 10 kW

9

ACCESSORIES

N : STANDARD

A :

3C VALVE PACKAGE
(COOL ONLY)

B :

3D VALVE PACKAGE
(COOL ONLY)

J :

4C VALVE PACKAGE
(HEAT & COOL)

K :

4D VALVE PACKAGE

(HEAT & COOL)

10

FIN

A : ALUMINUM

FIN

B : COATED

ALUMINUM
FIN

C : COPPER FIN

11

COIL

CONNECTION

R : RH SIDE,

STANDARD
(FACING AIR
DIS­CHARGE)

L : LH SIDE,

OPTIONAL
(FACING AIR
DIS­CHARGE)

12

FILTER

N : NONE

A :

ALUMINUM

(1/2" THICK)

13

OPTION

N :

STANDARD

UNIT

OPTIONS

ELECTRIC HEATERS

The heater element is of the resistance open coil type. Thermal overheat cut-outs and fusible links are provided to shut­off power to heaters in case of airflow failure. The 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 (3C & 3D for two pipe system and 4C & 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 & heating. This thermostat can be supplied loose through separate Kit number.

TYPICAL THERMOSTAT

3

INSTALLATION PROCEDURES

A. Location of Indoor units

The Indoor FCU should be ideally located in a plenum
or false 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 obstructing
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.

C. 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).

- Fit and tighten the nuts at the 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
from the 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.

FIGURE - 1

REQUIRED INDOOR UNIT CLEARANCES

FIGURE - 2

Note: Always leave 7 to 8 cm extra length in the

threaded rod below the lower nut/washer.

FIGURE - 3

4

D. Piping connection

MODEL NUMBER

DWL 02
DWL 03
DWL 04
DWL 06
DWL 08
DWL 10
DWL 12
DWL 14
DWL 16
DWL 18
DWL 20

SWEAT CONNECTION

WATER INLET WATER OUTLET

1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"

1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"

Note: The water lines must be installed level in both the horizontal & vertical plane.

Insulation of pipes

The pipe insulation should cover both inlet & outlet pipes as shown below.

WATER IN

WATER OUT

WATER OUT

WATER OUT

INSULATION

INSULATION

NO NOYES

WATER INWATER IN

E. Condensate Drain connection

- Use PVC Class 3 material for the condensate drain piping (3/4") as per figure-4.

- Provide a "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

5

DIMENSIONS

MODELS: DWL02 - DWL20

D

4

I

5

A

H

2

3/4" NPT(14TPI)
DRAIN TUBE.

0.5"

B

E

7

END VIEW TOP VIEW

G

C

FRONT VIEW

1

6

1.0"

END VIEW

F

3.5"

3

7.0"

NOTE: All dimensions are in mm (dimensions in brackets are in inches).

MODEL

DWL02 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)
DWL03 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)
DWL04 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)
DWL06 904 (35.6) 610 (24) 244 (9.6) 960 (37.8) 521 (20.5) 769 (30.3) 183 (7.2) 841 (33.1) 206 (8.1)
DWL08 904 (35.6) 610 (24) 244 (9.6) 960 (37.8) 521 (20.5) 769 (30.3) 183 (7.2) 841 (33.1) 206 (8.1)
DWL10 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DWL12 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DWL14 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DWL16 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)
DWL18 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)
DWL20 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)

ABCDEFGH I

DIMENSIONS

1. Blower & motor assembly

2. Cooling coil

3. Control box

4. Filter rack

5. Unit mounting brackets

6. Drip lip

7. Duct connector

6

INLET
OUTLET

DIMENSIONAL DATA - COIL CONNECTIONS

MODELS: DWL02, 03 & 04 (VERTICAL COIL)

LH SIDERH SIDE

MODELS: DWL06 - DWL20 (INCLINED COIL)

INLET
OUTLET

MODEL

AB CD

DWL02 225 (8.9) 237 (9.3) 32 (1.3) 176 (6.9) 3 264 (10.4) 275 (10.8) 1
DWL03 225 (8.9) 237 (9.3) 32 (1.3) 176 (6.9) 3 264 (10.4) 275 (10.8) 1
DWL04 225 (8.9) 237 (9.3) 32 (1.3) 176 (6.9) 3 264 (10.4) 275 (10.8) 1
DWL06 313 (12.3) 324 (12.8) 32 (1.3) 178 (7) 3 351 (13.8) 362 (14.3) 1
DWL08 313 (12.3) 324 (12.8) 32 (1.3) 178 (7) 3 351 (13.8) 362 (14.3) 1
DWL10 313 (12.3) 324 (12.8) 83 (3.3) 227 (8.9) 3 351 (13.8) 362 (14.3) 1
DWL12 313 (12.3) 324 (12.8) 83 (3.3) 227 (8.9) 3 351 (13.8) 362 (14.3) 1
DWL14 319 (12.6) 330 (13) 83 (3.3) 227 (8.9) 4 357 (14) 368 (14.5) 1
DWL16 376 (14.8) 389 (15.3) 129 (5) 273 (10.8) 4 414 (16.3) 427 (16.8) 1
DWL18 376 (14.8) 389 (15.3) 129 (5) 273 (10.8) 4 414 (16.3) 427 (16.8) 1
DWL20 376 (14.8) 389 (15.3) 129 (5) 273 (10.8) 4 414 (16.3) 427 (16.8) 1

NOTE: All dimensions are in mm (dimensions in brackets are in inches).

CHILLED WATER COIL

LH SIDERH SIDE

HOT WATER COIL

No. OF ROWS

7

EF

No. OF ROWS

TYPICAL SCHEMATIC WIRING DIAGRAM

HEAT/COOL MODELS - ELECTRIC HEATER

ATB AUXILIARY TERMINAL BLOCK

CAP CAPACITOR

CR CONTROL RELAY

EV ELECTRIC VALVE (COOLING)

FM FAN MOTOR

GND LUG GROUND

HC HEATER CONTACTOR

HTR HEATER

HVTB HIGH VOLTAGE TERMINAL BLOCK

L/L1 LINE OR LINE 1

L2/N LINE 2 OR NEUTRAL

OHT OVER HEAT THERMOSTAT
_ _ _

1. POWER SUPPLY, 220/240V-1PH-50Hz.

2. MOTORS THERMALLY PROTECTED.

3. HVTB IS NOT REQUIRED FOR HEATER
MODELS.

4. USE HEATER AS PER OPTION REQUIRED.
IF EV & HEATERS ARE FACTORY IN­STALLED, PLEASE READ DASHED LINE AS
CONTINUOUS LINE.

5. USE COPPER CONDUCTORS ONLY.

LEGEND

FIELD WIRING

FACTORY WIRING

NOTES

8

TYPICAL SCHEMATIC WIRING DIAGRAM

HEAT/COOL MODELS - HOT WATER

ATB AUXILIARY TERMINAL BLOCK

CAP CAPACITOR

CR CONTROL RELAY

EV ELECTRIC VALVE (COOLING)

EV1 ELECTRIC VALVE (HEATING)

FM FAN MOTOR

GND LUG GROUND

HVTB HIGH VOLTAGE TERMINAL BLOCK

L/L1 LINE OR LINE 1

L2/N LINE 2 OR NEUTRAL
_ _ _

1. POWER SUPPLY, 220/240V-1PH-50Hz.

2. MOTORS THERMALLY PROTECTED.

3. USE COPPER CONDUCTORS ONLY.

4.IF EV & EV1 ARE FACTORY INSTALLED,
PLEASE READ DASHED LINE AS CONTINUOUS
LINE.

LEGEND

FIELD WIRING

FACTORY WIRING

NOTES

9

VALVE PACKAGES

VALVE PACKAGE 3-C (for 2-pipe)

Two compression stop valves

1

One balancing valve

2

One 3-way motor valve

3

VALVE PACKAGE 3-D (for 2-pipe)

Two gate shut off valves

1

One balancing valve

2

One 3-way motor valve

3

VALVE PACKAGE 4-C (for 4-pipe)

Four compression stop valves

1

Two balancing valves

2

Two 3-way motor valves

3

VALVE PACKAGE 4-D (for 4-pipe)

Four gate shut off valves

1

Two balancing valves

2

Two 3-way motor valves

3

1

FCU

2

3

CHILLER

Two gate valves

1

One balancing valve

2

One 3-way motor valve

3

1

PARTS LIST

MODEL NUMBER

DESCRIPTION

DWL02/03/04 DWL06/08 DWL10/12/14 DWL16/18 DWL20

FAN DECK ASSEMBLY 800-089-75 800-089-71 800-089-72 800-089-73 800-089-76

BLOWER MOTOR 800-547-55 800-547-51 800-547-52 800-547-53 800-547-56

BLOWER WHEEL 800-711-50 800-711-51 800-711-52 800-711-53 800-711-53

` VALVE PACKAGE (3C) 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 800-249-43 800-249-39 800-249-38 800-249-36 800-249-36

THERMOSTAT 800-646-20 800-646-20 800-646-20 800-646-20 800-646-20

NOTE: For 4C & 4D type valve package, order 2 x 3C & 2 x 3D valve packages.

10

THERMOSTAT OPERATION & SPECIFICATION DATA

OPERATING INSTRUCTIONS

+

-

+

°C

-

FUNCTIONSYMBOL

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

OPERATING PROCEDURE

FUNCTIONSWITCH POSITION
COOLING MODE

+

-

+

-

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 (+) & (-)
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.

- 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

- Position the switch S1 to OFF position to turn off the unit.

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 : 230V + 10%; AC 50/60 Hz
Operating ambient : 00C to 400C
Temperature range : 50C to 300C
Selectivity of set value : 0.5K
Display range (actual value) : 0... + 400C
Selectivity of actual value : 0.1K
Hysteresis : ~0.5K
Switching current at 250 VAC : 3 (2)A
Maximum fan current : 6 (3)A
Sensor system : NTC (in housing)

Optional Remote Sensor 193720

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

83

75

UP
OPEN

135.5

127

194

160

92

HOUSING PROTECTION (OPTIONAL)BASE PLATE

28.6

6

0

85

120

105

THERMOSTAT

NOTE: All dimensions are in mm.

12

INSTALLATION

The complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immedi­ately 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 & 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 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 excep­tional 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 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

&

rs

e

w

o

l

b

r

o

f

s

s

e

c

c

A

M

C

95

Blower deck holding bolt

SERVICING INSTRUCTIONS

r

o

t

o

m

M

C

30

50

C

M

M

C

0

5

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 & 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