Glen Dimplex Koolant Koolers WO2-2-5000 User manual

Original Instructions 800.968.5665 | dimplexthermal.com
User Manual

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. Always refer to your CHILLER’s specific
drawings that have shipped with the unit. When
contacting the factory for service or replacement parts
reference your CHILLER’s serial and model numbers.
These can be found on the data tag on the CHILLER or
on the data pack information that shipped with the
unit.
Information Subject to Change
While every effort has been made to ensure the
accuracy and completeness of the information
presented in this document, Dimplex Thermal
Solutions assumes no responsibility and disclaims all
liability for damages resulting from the use of this
information or for any errors or omissions.

Table of Contents
i
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.................................................................................................................................... 6
Location Considerations ............................................................................................................................ 7
Checking for Shipping Damage.................................................................................................................. 9
Transportation........................................................................................................................................... 9
Uncrating ................................................................................................................................................... 9
Installation....................................................................................................................................................... 10
Internal Access......................................................................................................................................... 10
Connections............................................................................................................................................. 14
6.2.1 Electrical .......................................................................................................................................... 14
6.2.2 Coolant plumbing ............................................................................................................................ 15
Coolant Reservoir Filling.......................................................................................................................... 16
Installation Checklist................................................................................................................................ 18
Operation......................................................................................................................................................... 19
Initial Startup........................................................................................................................................... 19
7.1.1 Temperature control ....................................................................................................................... 19
Controller................................................................................................................................................. 20
7.2.1 Initialization of Controller:............................................................................................................... 20
7.2.2 Starting the System: ........................................................................................................................ 20
7.2.3 Enabling Devices:............................................................................................................................. 20
7.2.4 Changing the Setpoint: .................................................................................................................... 21
7.2.5 Viewing Alarms................................................................................................................................ 21
7.2.6 Sequence of Operation:................................................................................................................... 21

Table of Contents
ii
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......................................................................................................................................... 36
Revisions...................................................................................................................................................... 37
Appendix A (Plumbing)............................................................................................................................................ 38
Appendix B (Pump Curve)........................................................................................................................................ 39
Appendix C (Refrigeration) ...................................................................................................................................... 40
WO2-2-5000 ........................................................................................................................................................ 40
WO2-2-7500 ........................................................................................................................................................ 41
WO2-2-10000 ...................................................................................................................................................... 42
Appendix D (Warranty)............................................................................................................................................ 43
Warranty Coverage.............................................................................................................................................. 43
What is Included.................................................................................................................................................. 43
What is Not Included........................................................................................................................................... 43
Appendix E (General Warranty Procedures) ........................................................................................................... 44
Warranty Work.................................................................................................................................................... 44
Warranty Parts .................................................................................................................................................... 44
Appendix F (Factory Contact) .................................................................................................................................. 45
Service Support Team.......................................................................................................................................... 45
Parts Department ................................................................................................................................................ 45
Appendix G (Chiller Registration) ............................................................................................................................ 46
Why register your chiller? ................................................................................................................................... 46

List of Figures
iii
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.......................................................................................................................................... 10
Figure 7: Removal or Doors & Blockers................................................................................................................... 11
Figure 8: Removal of Lower Doors .......................................................................................................................... 12
Figure 9: Reservoir Visual Level Indicator Marks .................................................................................................... 16
Figure 10: Controller Restart Warning .................................................................................................................... 22
Figure 11: Controller Home Page ............................................................................................................................ 22
Figure 12: Controller Main Menu Pg1 ..................................................................................................................... 23
Figure 13: Controller Main Menu Pg2 ..................................................................................................................... 23
Figure 14: Controller Main Menu Pg3 ..................................................................................................................... 23
Figure 15: Controller On/Off Menu......................................................................................................................... 24
Figure 16: Controller Pump Enable/Disable Menu.................................................................................................. 24
Figure 17: Controller Setpoint Menu....................................................................................................................... 25
Figure 18: Controller Alarm Menu........................................................................................................................... 25
Figure 19: WO2-2-5000 Air Filter Side..................................................................................................................... 30
Figure 20: Door Side ................................................................................................................................................ 31
Figure 21: WO2-2-7500 Air Filter Side..................................................................................................................... 32
Figure 22: WO2-2-10000 Air Filter Side................................................................................................................... 33
Figure 23: Tank Heater ............................................................................................................................................ 34
Figure 24: Tank Heater Control Box ........................................................................................................................ 34
Figure 25: Pump Removal........................................................................................................................................ 36

List of Tables
iv
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.................................................................................................................... 15
Table 7 Troubleshooting Service Guide................................................................................................................... 26
Table 8: Electrical Component Torque .................................................................................................................... 29
Table 9: Spare Parts List .......................................................................................................................................... 35

Important Safety Instructions
1
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.
Only properly trained and qualified personnel should move, install, operate or service this equipment.
Adhere to all warnings, cautions and safety instructions on the unit and in this manual when installing, operating
or maintaining the unit. Follow all operating and user instructions.
WARNING
This unit may present arc flash and electric shock hazards that could cause injury
or death.
Open all local electric power disconnect switches and wear protective equipment
before working within the chiller cabinet.
Earth ground to unit must be provided, per NEC, CEC and local codes, as
applicable. Adhere to all other local codes as applicable.
The only way to isolate all power from the unit is to turn the chiller’s main
disconnect to its OFF position. This should only be performed when intending to
service the unit.
WARNING
The chiller has automatically starting, high-speed fans. Open all electric power
disconnect switches before working in the unit. Contact with fans when the chiller
is powered can cause injury or death.
Do not operate this unit with any cabinet panels or air filters removed.
CAUTION
Fan and pump motors, compressors, and refrigeration components can become
extremely hot during operation. Allow enough time for them to cool before
working within the unit. Wear protective gloves and arm protection when working
on or near hot components.
Only HVAC/R qualified technicians should be working on refrigeration
components.
NOTICE
Improper installation, application, and service practices can result in water leakage
from the unit, causing damage to property and equipment.
Do not locate unit directly above any equipment that could sustain water damage.
NOTICE
Improper storage can cause damage to the unit.
Keep the unit upright, protected from moisture, and prevent contact damage.

Introduction
2
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
▪50% capacity remains if one circuit is shut down
•Redundant horizontal centrifugal pump
▪Dual pumps provide complete redundancy in case of pump failure
▪Easy access panels and flanged plumbing connections streamline pump replacements
▪Automated pump rotation for increased longevity through load sharing
•Flow setter valve
▪Flow setter valve automatically adjusts internal pressure drop to compensate for varying
connecting pipe lengths while maintaining consistent flow
•Tank level switch
▪Tank level switch prevents the pumps from running dry
•Variable speed fans
▪Fans adjust rotational speed to provide optimal airflow through the condenser
•Flow switch
▪Flow switch ensures flow is maintained while the unit is running
Table 1: Medical Chiller Capacities
Model
Cabinet
Material
Coastal
Application?
(30 miles)
(Yes/No)
Tank and
Condenser
Heater?
(Yes/No)
Ambient
Range
(Min°F /
Max°F)
Capacity at
95°F
Ambient
kW/
(BTU/Hr)
Capacity at
Max
Ambient
kW/
(BTU/Hr)
WO2-2-5000-2P-NF-L-407C-M
Galvanized
No
No
-22 / 120
60 / 204720
49 / 167188
WO2-2-5000-2P-NF-L-407C-M
Galvanized
No
Yes
-40 / 120
60 / 204720
49 / 167188
WO2-2-5000-2P-NF-L-407C-M
Stainless
Yes
No
-22 / 120
60 / 204720
49 / 167188
WO2-2-7500-2P-NF-L-407C-M
Galvanized
No
No
-22 / 120
70 / 238840
WO2-2-7500-2P-NF-L-407C-M
Galvanized
No
Yes
-40 / 120
70 / 238840
WO2-2-7500-2P-NF-L-407C-M
Stainless
Yes
No
-22 / 120
70 / 238840
WO2-2-10000-2P-NF-L-407C-M
Galvanized
No
No
-22 / 104
94 / 320728
WO2-2-10000-2P-NF-L-407C-M
Galvanized
No
Yes
-40 / 104
94 / 320728
WO2-2-10000-2P-NF-L-407C-M
Stainless
Yes
No
-22 / 104
94 / 320728

Specifications
3
Specifications
Table 2: Specifications
Criterion
WO2-2-5000
Standard
WO2-2-5000
Low Ambient
WO2-2-7500
Standard
WO2-2-7500
Low Ambient
WO2-2-10000
Standard
WO2-2-10000
Low Ambient
Electrical
Input power
460V, 3Phase, 60Hz
FLA
61 A
64 A
89
MCA
64 A
66 A
93
MOPD
70 A
70 A
100
SCCR
5 kA
Refrigeration
Number of
Compressors
4
Compressor Motor
Power, each
5hp (3.7kW)
7.5hp (5.6kW)
10hp (7.5kW)
Refrigerant
R407c
Number of
Refrigeration
Circuits
2
Nominal
Refrigerant Charge
(Each Circuit)
29lb (13.2kg)
Plumbing
Number of Pumps
2
Pump Motor
Power
5.5hp (4.1kW)
Nominal Flow Rate
(36gpm Flowsetter
Configuration)
35gpm (132LPM)
Nominal Flow Rate
(26gpm Flowsetter
Configuration)
26gpm (98LPM)
Nominal Supply
Pressure
70 psi (4.8Bar)
Physical
Crated weight
3500lb (1588kg)
3750lb (1701kg)
4000lb (1814kg)
Uncrated weight
3400lb (1542kg)
3650lb (1656kg)
3900lb (1769kg)
Operational weigh
4300lb (1950kg)
4550lb (2064kg)
4800lb (2177kg)
Length
134.5” (3417mm)
Width
44.0” (1118mm)
Height
87.7” (2454mm)

Labels
4
Labels
Table 3: Labels
Symbol
Description
Symbol
Description
Caution Fan
Starts
Automatically
Do No Remove
Guards
Tank Level High
Prop65 Warning
Tank Level Low
Tank Drain
Fluid Outlet
Fluid Inlet
Arc Flash
Warning
Arc Flash Warning
Made in USA

Installation Guidelines
5
Installation Guidelines
Exterior Components
Figure 1: Exterior Components
Figure 2: Exterior Components (Electrical Enclosure Side)
LOWER
DOORS
AIR
INTAKE
FILTERS
BLOCKER / DOOR BOLTS
(EACH SIDE)
FLUID OUTLET 2” FPT
FLUID INLET 2” FPT
TANK DRAIN
TANK LEVEL HIGH
TANK LEVEL LOW
MAIN POWER
DISCONNECT
DOORS
FANS

Installation Guidelines
6
Overall Dimensions
Figure 3: WO2-2-5000 Overall Dimensions
Figure 4: WO2-2-7500 / WO2-2-10000 Overall Dimensions
134.5”
44.0”
87.7”
96.5”
44.0”
134.5”

Installation Guidelines
7
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. The following sections outline recommended installation practices. The
chiller has potential for misuse that could result in unplanned downtime. The main disconnect, drain, and field
installed service valves can be operated by unauthorized personnel. If unauthorized operation is a concern, then
a security fence should be provided to reduce the potential for misuse. Fencing must not obstruct airflow and
must leave room or be removable for service. The chiller’s air intake and exhaust clearances must adhere to the
following:
Table 4: Chiller Air Intake and Exhaust Requirements
Criterion
Value
Vertical clearance
≥ 8ft (2.4m)
Horizontal clearance (Door, Enclosure, and Rear Sides)
≥ 3ft (.9m)
Horizontal clearance (Air intake side)
≥ 6ft (1.8m)
Exhaust air must be freely discharged by the chiller’s fans. This air must not be recirculated to the air intake side
of the chiller. Avoid installing deflectors that redirect air to the air intake side of the chiller or installing ducting
that directly connects to the chiller’s top. The chiller uses axial fans that are not compatible with exhausting air
through ducting. Ducting increases the pressure drop of the fans severely and lowers the volumetric air flow.
NOTICE
Improper air intake and exhaust clearances can lead to reduced capacity, thermal
overloading of the fan motors and/or compressors, high pressure refrigeration
faults, and/or rendering the chiller inoperable.
If ducting must be installed at the chiller’s location a suitable duct auxiliary fan
must be provided. Consult the factory for guidelines and recommendations.
Make sure the unit is placed, on a level, hard surface. The chiller must be level or less than ½ inch of slope per 10
feet. Use shims to correct level if needed. If the chiller is mounted on a concrete slab, the slab should be 4-inch
thick and at least 5 feet x 12 feet. If the chiller is roof mounted, two I-beam runners are typically provided to
support the chiller feet at both ends. For rooftop mounting, chiller should be anchored through the mounting
holes provided in the feet. When the chiller is mounted above an office space, optional vibration mounting
springs can be used to isolate the chiller from the building structure.

Installation Guidelines
8
Figure 5: WO2-2-5000 / WO2-2-7500 / WO2-2-10000 Required Clearances
MINIMUM 8FT VERTICAL CLEARANCE
OBSTRUCTION
OBSTRUCTION
MINIMUM 3FT CLEARANCE ON DOOR SIDE
OBSTRUCTION
MINIMUM 6FT CLEARANCE ON FILTER SIDE
OBSTRUCTION
MINIMUM 3FT CLEARANCE
OBSTRUCTION
MINIMUM 3FT CLEARANCE

Installation Guidelines
9
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. Any damage must be
reported to the shipping carrier and a copy of the damage claim submitted to your sales representative.
Transportation
The chiller is shipped with protective packing and wrapping that should remain in place until the unit is
transported to its final installation location. It is recommended that the chiller (crated or uncrated) be moved
with a forklift.
WARNING
The chiller is heavy and there is risk of tilting or falling when moved.
Transportation of the chiller must only be performed by trained and qualified
personnel using appropriate equipment.
Ensure that the chiller is securely positioned (tines of forklift spread as far as
permitted along the chiller’s long edge and extend thoroughly through the
opposite lifting face) before moving the chiller.
Improper handling or insecure lifting of the chiller during transportation can cause
it to tip and fall leading to injury or death.
Uncrating
The chiller is secured to the skid during shipping with screws. To remove the chiller from its skid:
1. Move the crated chiller as close as practical to its installation location.
2. Cut or unwrap the plastic shrink-wrap from the unit.
3. Uncrate the chiller by removing the screws holding the chiller to the skid.
4. Use a forklift to lift the chiller until its feet clear the top boards of the skid.
5. Pull the skid from under the chiller.
6. Lower the chiller onto the floor.

Installation
10
Installation
Internal Access
Figure 6: Internal Access
LOWER DOOR RETAINERS
BLOCKER
BLOCKER
AIR FILTER
AIR FILTER
AIR FILTER
AIR FILTER
DOOR
DOOR
DOOR
DOOR
AIR FILTER RETAINERS

Installation
11
Figure 7: Removal or Doors & Blockers
3/8” DOOR BOLT
3/8” BLOCKER BOLT
BLOCKER
DOOR

Installation
12
Figure 8: Removal of Lower Doors
LATCHES

Installation
13
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. For more access:
a. Use a wrench or socket to unscrew the Blocker Bolts located on the top of the unit. There
are four bolts per blocker, two bolts per door.
b. Grab the bottom of the Blocker and push upwards to disengage the hooks. Once hooks are
clear, pull the blocker outward to remove.
4. Reinstall in the opposite order when access is no longer required.
•From the door side
1. To access the pumps
a. Use a slotted screwdriver to turn the Lower Door Retainer on the left of the door clockwise, and
the Lower Door Retainer on the right counterclockwise.
b. Gently pull outward and lift to remove lower panels.
2. To access the coil and fans
a. Use a wrench or socket to unscrew the Door Bolts located on the top of the unit. There are two
bolts per door.
b. Lift the Door upward to disengage the hooks. Once the hooks are disengaged, pull the door
outward to remove the door.
c. Reinstall in the opposite order when access is no longer required.
NOTICE
The chiller must have all air filters and panels properly and securely installed when
operating. Failure to do so can result in refrigeration circuit faults that will
interrupt cooling to the system. When changing a pump, it is permissible to
remove the lower door while the unit is running if the pump has been disabled.

Installation
14
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.
Before attempting to make any electrical connections or disconnections to the
chiller:
•Verify that the chiller’s main disconnect handle is in the OFF position
•Verify that the incoming power to the chiller has been turned off
•Lock out and tag out main electrical connecting points
•Use a voltmeter to verify there is no incoming power to the chiller
Ensure that the supply power is enough to meet the chiller electrical requirements as found on the unit’s data
tag. The data tag is found on the front of the electrical enclosure. If a remote display is provided with the unit,
install the provided 150-foot communications cable between the chiller electrical panel and the remote display
location. For distances over 150 feet, an optional Long Distance Remote Display kit is required.
Connect power as follows:
1. Open the electrical enclosure by turning the main disconnect handle to the OFF position and releasing
the quarter-turn latches using a flathead screwdriver.
2. Use a step bit or knockout punch to install appropriate conduit fittings in the electrical enclosure.
WARNING
Take care to prevent any metal chips from falling on the electrical components in
the enclosure while installing conduit fittings. Metal chips can cause shorts in
electrical components and introduce arc flash hazards.
3. Wire mains power to the main disconnect. Wire the ground lead to the provided ground lug.
4. Close the electrical enclosure and fasten the quarter-turn latches.