Kooltronic DP Series User manual

Keep This Manual

With Air Conditioner

AIR CONDITIONER

OPERATOR'S MANUAL

CAUTION

BEFORE INSTALLING AND

USING THIS AIR CONDITIONER,

IT IS IMPORTANT THAT THIS

MANUAL BE READ AND

UNDERSTOOD THOROUGHLY

KOOLTRONIC, INC.

30 Pennington-Hopewell Road

Pennington, NJ 08534

609•466-3400

FAX: 609 • 466-1114

www.kooltronic.com

900-039-51 (1/19)

(CDR: 20131)

DP SERIES

KA4C2DP17L

Find additional information on

this model at kooltronic.com or

use the Technical Documents

QR code below.

Technical

Documents

TABLE OF CONTENTS

Page

I. Introduction 2

II. Incoming Inspection 3

III. Product Handling 3

IV. Product Identification and Nameplate 4

V. Principles of Operation 5 - 8

VI. Pre-Installation Testing 8 - 9

VII. Specific Model Data 9 - 13

Mounting

Drawings and Dimensions

Technical Data

Major Component Replacements

Standard Features

VIII. Maintenance 14 - 15

IX. Trouble Shooting 15 - 16

X. Warranty 17

NOTE: Wiring Schematics are available on the specific model page of the Kooltronic website.

I. Introduction

Kooltronic Air Conditioners are designed to provide a cool, dehumidified environment for your electronic

components. There are models to fit virtually all sizes and shapes of electronics enclosures, in

capacities ranging from 1,000 to 30,000 BTU/H. Our "closed-loop" design also ensures that your

components will not be exposed to hot, dirty operating conditions.

This Manual provides you with the necessary general information for properly installing and operating

standard Kooltronic Air Conditioners. Technical data and mounting instructions are presented on pages

9 through 13.

II. Incoming Inspection

Kooltronic Air Conditioners are designed, built and packaged to withstand the shock and vibration normally

associated with shipment by common carriers. Occasionally improper handling during shipping causes damage.

Such handling could include unbanding of palletized shipments, failing to respect "This Side Up" arrows, rough

handling, falling off conveyors, excessive vibration, crushing, etc. Therefore, a thorough inspection should be

done upon receipt of all shipments. Any carton tears, dents, scratches, loose articles or evidence of oil are signs

of damage and should be noted on the Freight Bill. Cartons should be opened promptly and the units inspected

for CONCEALED DAMAGE. Kooltronic Air Conditioners must be delivered in the proper mounting position to

assure that damage to the compressor has not occurred during shipping. Any Kooltronic Air Conditioner that is

delivered removed from the banded pallet, lying down or double stacked should be refused.

An immediate claim MUST be filed with the freight carrier and an inspection requested. Retain all packing

materials. Kooltronic cannot assume responsibility for Consignee's failure to file a timely freight claim.

III. Product Handling:

1) Do not attempt to operate your Kooltronic Air Conditioner until you read and thoroughly understand this

Manual. See section VI PRE-INSTALLATION TESTING.

2) Before operating the Kooltronic Air Conditioner be certain that it is placed in its correct mounting position.

This Air Conditioner is designed to operate in a vertical position only. This placement must be done

a minimum of 5 minutes prior to operating in order to allow the compressor oil to drain to the compressor

sump area.

CAUTION

3) Before operating this unit, all electrical wiring must be checked to assure the proper connection to the

correct power source. Minimum circuit ampacity should be at least 125% of the amperage found on the

nameplate for the corresponding voltage. Do not exceed the maximum fuse size found on the nameplate.

4) We do not recommend that Air Conditioners be shipped to their final destination attached to an enclosure.

In the event that the Air Conditioner needs to be shipped attached to an enclosure it is strongly

recommended that proper support be provided for the Air Conditioner. Excessive vibration can occur if Air

Conditioners are not properly supported when shipped on enclosures, increasing the potential for internal

damage and voiding the warranty.

5) PROCEDURE FOR PROPER PACKING AND SHIPMENT OF KOOLTRONIC AIR

CONDITIONERS:

■Keep Air Conditioner in proper upright position indicated by arrow markers.

■Pack Air Conditioner in an appropriate carton (preferably original carton if possible), with

adequate internal protective packaging, making sure carton is marked and is kept in correct

upright position.

■For local, controlled transportation, strap carton to a secure part of truck to prevent falling or

sliding, minimize vibration, etc.

■For common carrier shipment, band unit(s) securely to a pallet. Unpalleted shipment risks

severe damage which voids the warranty.

Kooltronic Air Conditioners must be operated in their proper mounting position. If attempts are

made to operate a unit that is not in its designed mounting position, permanent compressor

damage will occur. This action will void the warranty. To avoid compressor damage do not tip the

unit more than 45° from its proper mounting position.

IV. Product Identification and Nameplate

Each Kooltronic Air Conditioner includes an identification nameplate. This nameplate provides:

qModel Number

wSerial Number

eElectrical power characteristics

rMaximum and minimum ambient operating temperatures

tCooling capacity

yType and amount of refrigerant required for recharging

uDesign Pressure

iMaximum Fuse Size

oManufacturing Order Number

aUnderwriters Laboratories Inc. Listed or Recognized Marks and NEMA ratings

We recommend you copy this information from your unit.

qwo When ordering parts, specify the Model Number, Serial Number & MFG. Order Number.

eBefore operating, be sure that the power source matches these requirements.

r Make sure that these parameters are met. Failure to do so may result in permanent damage to the unit.

ALL MOTORS ARE THERMALLY PROTECTED

VIOLATES WARRANTY

UNAUTHORIZED SERVICE OR MODIFICATION

SERVICE AIR FILTER REGULARLY

OUTDOOR USE

COMPARTMENT ONLY

NEMA/EEMAC/UL50 BY UNDERWRITERS LABORATORIES, INC.

TYPE 1 SPECIAL PURPOSE AIR CONDITIONER EQUIPMENT

TYPE 3R & 12 INTERFACE TO THE ELECTRICAL ENCLOSURE ONLY

NEMA/EEMAC/UL50 BY UNDERWRITERS LABORATORIES, INC.

SPECIAL PURPOSE AIR CONDITIONER

FUSE SIZE

MAX.

HIGHLOW

Oz.REFRIGERANT

MAX.°FMIN.°F

AMBIENT TEMP.COOLING

ALLOW 5 MIN. BEFORE RESTARTING AFTER SHUTDOWN

Air Conditioner

DESIGN PRESSURE P.S.I.G.

MFG. ORDER NO.

KOOLTRONIC, INC. PENNINGTON, NJ

MANUFACTURED BY:

COOLING BTU

F.L.A.PH.FREQ.VOLTS

SERIAL NUMBERMODEL NUMBER

LISTED 84H7

SPECIAL PURPOSE

AIR CONDITIONER

eeee rr

uu i

y Use of incorrect type or amount of refrigerant will adversely affect performance and may damage the unit.

V. Principles of Operation

Kooltronic Air Conditioners are required when the equipment operating

temperature must be kept near or lower than the ambient room temperature,

and/or the cabinet must be sealed from dust, fumes, oil, corrosives and

other contaminants. These Air Conditioners utilize a "Closed-Loop Cooling

System" to ensure optimum performance of the installed components.

Closed-Loop cooling seals the electronic enclosure from hostile elements in

the environment. Two separate circulation systems are employed. The

internal system cools and dehumidifies the air inside the cabinet, totally

isolating the sensitive electronics and other components from the

environment. The external system uses circulating ambient air or water to

discharge the heat removed from the electronics. The heat is dissipated

from the enclosure by means of the vapor compression refrigeration cycle.

This takes place in a hermetically-sealed refrigeration system, utilizing

either an air-cooled or water-cooled condenser heat exchanger. The warm

air inside the enclosure is drawn through the evaporator coil where it is

cooled, dehumidified and returned.

Any enclosure moisture accumulated on the evaporator coil is collected in

the condensate tray and removed through the drain tube to the condensate

evaporator. Condensate evaporates in the condensate evaporator and is

released to the ambient air by the condenser impeller.

The heat removed through the evaporator coil is transferred by the compressed refrigerant to the condenser coil. Ambient

air is then passed through the condenser coil, where it absorbs the heat and is then discharged to the environment.

When the Kooltronic Air Conditioner is properly sized it should operate constantly and maintain 75°F to 115°F enclosure

temperature, depending on the ambient temperatures.

UNITS EQUIPPED WITH PROGRAMMABLE THERMOSTAT

For units equipped with Low Temperature Thermostat, see page 8.

CONTROL ACTION

The evaporator blower operates continuously. The compressor is cycled on

and off by the action from the factory preset programmable thermostat. A

pressure switch controls the on/off action of the condenser blower.

The regulation is performed according to the temperature measured by the

thermostat probe with a positive differential from the set point: if the

temperature increases and reaches set point plus differential the compressor

is started and then turned off when the temperature reaches the set point

value again.

In case of fault in the thermostat probe the start and stop of the compressor

are timed through preset parameters.

The programmable thermostat is located as shown in the upper right ISO illustration. WARNING: the programmable device

is preprogrammed and set at the factory. In the event changes are needed the following instructions can be used.

FRONT PANEL COMMANDS

FRONT PANEL LED INDICATORS

- To display target set point; in programming mode it selects a parameter or confirms an operation.

(UP) - To see the max. stored temperature; in programming mode it browses the parameter codes or increases the displayed value.

(DOWN) - To see the min. stored temperature; in programming mode it browses the parameter codes or decreases the displayed value.

- To switch the instrument off, if onF = oFF.

- Not enabled.

(DEF) - To start a manual defrost.

KEY COMBINATIONS

To lock and unlock the keyboard.

To return to the room temperature display.

To enter programming mode.

CONDENSER

AIR OUT

CONDENSER

AIR IN

SUPPLY

AIR OUT

RETURN

AIR IN

NOTE: REMOVE

TOP AND REAR

PANELS TO ACCESS

PROGRAMMABLE

THERMOSTAT

DP17L

Principles of Operation (con’t)

MAX AND MIN TEMPERATURE MEMORIZATION

HOW TO SEE THE MIN TEMPERATURE:

1) Press and release the down arrow key.

2) The “Lo” message will be displayed followed

by the minimum temperature recorded.

3) Press the down arrow key again or wait 5 seconds

to restore normal display.

HOW TO SEE THE MAX TEMPERATURE:

1) Press and release the up arrow key.

2) The “Hi” message will be displayed followed

by the maximum temperature recorded.

3) Press the up arrow key again or wait 5 seconds to

restore normal display.

HOW TO RESET THE MAX AND MIN TEMPERATURE

RECORDED:

1) Press the SET key for more than 3 seconds while the

max or min temperature is displayed. (rSt message

will be displayed.)

2) To confirm the operation, the “rSt” message starts

blinking and the normal temperature will be displayed.

MAIN FUNCTIONS

HOW TO SEE THE SETPOINT:

1) Press and immediately release the SET key.

The display will show the set point value.

2) Press and immediately release the SET key, or

wait 5 seconds to display the probe value again.

HOW TO CHANGE THE SETPOINT:

NOTE: The standard set point is 75°.

1) Press the SET key for more than 2 seconds to

change the set point value.

2) The value of the set point will be displayed and

the °C or °F LED starts blinking.

3) To change the set value push the up or down

arrow keys within 10 seconds.

4) To store the new set point value push the SET

key again, or wait 10 seconds.

HOW TO CHANGE A PARAMETER VALUE:

To change a parameter’s value, operate as follows:

1) Enter the Programming mode by pressing the

SET plus down arrow keys for 3 seconds (the

°C or °F LED starts blinking).

2) Select the required parameter. Press the SET

key to display its value.

3) Use up or down arrow keys to change its value.

4) Press SET to store the new value and move to

the following parameter. To exit, press SET and

the up arrow keys or wait 15 seconds without

pressing a key.

NOTE: The set value is stored even when the

procedure is exited by waiting for the time-out

to expire.

HOW TO LOCK THE KEYBOARD:

1) Press and hold the up and down arrow keys

simultaneously for more than 3 seconds.

2) The POF message will be displayed, and the

keyboard will be locked. At this point, it will only

be possible to see the set point or the MAX or

MIN temperature stored.

3) If a key is pressed more than 3 seconds, the

POF message will be displayed.

HOW TO UNLOCK THE KEYBOARD:

1) Press and hold the up and down arrow keys

simultaneously for more than 3 seconds until

the Pon message is displayed.

OPTIONAL MONITORING SYSTEM

TTL SERIAL LINE - FOR OPTIONAL MONITORING

SYSTEMS:

The optional TTL serial line, available through the

HOT KEY connector, allows through the use of

the external TTL/RS485 converter, connection of

this digital converter to a monitoring system that is

ModBUS-RTU compatible (X-WEB500/3000/300).

Connections are provided through an external 2-

position terminal block.

Principles of Operation (con’t)

RESETTING

If it becomes necessary to reset the unit, the factory settings are as follows:

PARAMETER DESCRIPTION VALUE UNIT RANGE

MINIMUM MAXIMUM

SEt Set Point 75 °F 60 95

Hy Differential 10 °F 1 45

dP4 Fourth probe display 0 -- -- --

dP3 Third probe display 0 -- -- --

dP2 Evaporator probe display 0 -- -- --

dP1 Room probe display 0 -- -- --

AFH Differential for temperature alarm recovery 2 °F 1 45

ALL Minimum temperature alarm 35 °F -67 120

ALU Maximum temperature alarm 120 °F 35 302

SHy Differential for auxiliary relay 5 °F 1 45

SAA Set point for auxiliary relay 115 °F -67 302

ACH Kind of action for auxiliary relay CL -- -- --

AC Anti-short cycle delay 2 min 0 50

odS Outputs delay at start up 0 min 0 255

P2P Evaporator probe presence n -- -- --

ot Thermostat probe calibration 0 °F -21 21

US Maximum set point 95 °F 75 302

LS Minimum set point 60 °F -67 75

Ptb Map code 7 -- 0 65535

rEL Software release 0 -- -- --

rSE Real set point 0 -- -- --

onF on/off key enabling ES -- -- --

PbC Kind of probe ntc -- -- --

Adr Serial address 1 -- 1 247

HES Differential for energy saving 0 °F -54 54

rrd Regulation restart with door open alarm y -- -- --

odc Compress status when open door no -- -- --

nPS Number of activation of pressure switch 15 -- 0 15

did Digital input alarm delay 5 min 0 255

i1F Digital input configuration EAL -- -- --

i1P Digital input polarity cL -- -- --

dAO Delay of temperature alarm at startup 00:00 h -- --

ALd Temperature alarm delay 0 min 0 255

ALc Temperature alarms configuration Ab -- -- --

ArP Probe selection for auxiliary alarm P1 -- -- --

dLy Display temperature alarm 00:00 min. 0 20

Lod Probe displayed P1 -- -- --

rES Resolution in -- -- --

CF Temperature measurement unit F -- -- --

CH Kind of action: heating cooling cL -- -- --

COF Compressor OFF time with faulty probe 4 min 0 255

COn Compressor ON time with faulty probe 20 min 0 255

O4 Fourth probe calibration 0 °F -21 21

P4P Fourth probe presence n -- -- --

O3 Third probe calibration 0 °F -21 21

P3P Third probe presence n -- -- --

OE Evaporator probe calibration 0 °F -21 21

V. Principles of Operation

UNITS EQUIPPED WITH LOW TEMPERATURE THERMOSTAT

Kooltronic Air Conditioners are required when the equipment

operating temperature must be kept near or lower than the ambient

room temperature, and/or the cabinet must be sealed from dust,

fumes, oil, corrosives and other contaminants. These Air

Conditioners utilize a "Closed-Loop Cooling System" to ensure

optimum performance of the installed components.

Closed-Loop cooling seals the electronic enclosure from hostile

elements in the environment. Two separate circulation systems are

employed. The internal system cools and dehumidifies the air

inside the cabinet, totally isolating the sensitive electronics and

other components from the environment. The external system uses

circulating ambient air or water to discharge the heat removed from

the electronics. The heat is dissipated from the enclosure by

means of the vapor compression refrigeration cycle. This takes

place in a hermetically-sealed refrigeration system, utilizing either

an air-cooled or water-cooled condenser heat exchanger. The

warm air inside the enclosure is drawn through the evaporator coil

where it is cooled, dehumidified and returned.

Any enclosure moisture accumulated on the evaporator coil is

collected in the condensate tray and removed through the drain tube to the condensate evaporator. Condensate

evaporates in the condensate evaporator and is released to the ambient air by the condenser impeller.

The heat removed through the evaporator coil is transferred by the compressed refrigerant to the condenser coil.

Ambient air is then passed through the condenser coil, where it absorbs the heat and is then discharged to the

environment.

To help eliminate compressor cycling, a two stage thermostat is used in this unit, with a thermostat sensor located

in the return air stream of the enclosure. The first stage, which controls the compressor, has a set point of 64°F

(18°C).The second stage, which controls the condenser blower (fan), has a set point of 66°F (19°C). The first

stage has a temperature differential of 11°F (6°C), and the second stage has a temperature differential of 0.5°F.

When the return air temperature is above 70°F the air conditioner will run constantly. When the return air

temperature drops below 66°F the thermostat’s second stage will start to cycle the condenser blower and the

return air will fluctuate from 64°F to 70°F. In conditions of very low ambient temperature and low internal load the

return temperature could drop below 64°F. In this case the thermostat’s first stage will start to cycle the

compressor and the return air temperature will fluctuate from 63°F to 75°F. In reality this situation would occur

rarely, and then only for a short period of time. The advantage of a two stage thermostat is that it avoids

compressor cycling and controls the return air temperature to a very narrow temperature range of 6°F - from 64°F

to 70°F.

The heater kit consists of a heater, a heat control thermostat and a heater limiter. The heater control thermostat

is a bimetal disk with a fixed set point of 60°F. When the entering evaporator air temperature rises above 60°F

the heater shuts off, and when the evaporator air temperature falls below 40°F the heater will engage. The contact

points of the alarm thermostat are normally closed. If the entering evaporator air temperature exceeds 130°F the

alarm thermostat contacts open, and when the temperature drops below 130°F the contacts close.

VI. Pre-Installation Testing

Before mounting the air conditioner to the enclosure, test for proper operation. This will verify the shipping integrity

of the system. Please follow the steps below prior to installation.

CAUTION

CONDENSER

AIR OUT

CONDENSER

AIR IN

SUPPLY

AIR OUT

RETURN

AIR IN

DP17L

The air conditioner must be standing in its proper mounting position for a minimum of five

(5) minutes prior to testing. Failure to follow this procedure will cause permanent damage to

the compressor. To avoid compressor damage do not tip the unit more than 45° from its

proper mounting position.

1. Allow the unit to sit in a upright position at a room temperature of 65°F minimum, allowing the

system to warm-up. This is particularly important in winter months.

2. Refer to the nameplate for proper electrical voltage and current requirements. Then connect the

power cord to a properly grounded and fused electrical supply. Leave the electrical power off.

3. Note the factory thermostat setting which is 75°F.

4. Turn electrical power on.

5. Verify that the evaporator blower or fan is running.

6. Observe the temperature on the digital display. The thermostat must be set a minimum of 10°F

below this temperature for the compressor to operate (the factory setting is 75°F). Refer to page

6 for instructions on adjustment of the thermostat.

7. Operate the air conditioner for approximately ten (10) minutes. During this period no unusual

noise or vibration should be evident. Both the evaporator and condenser fans or blowers should

be delivering air through their respective discharge ports. The cool air discharged should be less

than 70°F when the room temperature is between 70 and 80°F. It is normal for the condenser

blower to cycle on/off during this period.

8. Turn off the electrical power source, and disconnect the air conditioner from the power source.

9. If any cover plug is removed to adjust the unit, make certain to put it back in place to maintain the

integrity of the closed-loop airflow system.

NOTE: Before shipment all Kooltronic Air Conditioners are subjected to a performance test.

VII. Specific Model Data

Mounting

The Kooltronic Special Purpose Air Conditioners KA4C2DP17L have been engineered to be installed easily. The

air conditioner is designed for two mounting options - external and internal. Prior to mounting, refer to page 11 for

the general arrangement drawings showing dimensions and locations of mounting holes and cutouts. Prior to

cutting or drilling, make sure that cutouts and mounting holes do not interfere with components inside the cabinet.

To avoid damaging your air conditioner, please read the following information before installation:

External Mounting

1. Place the supplied 1/2-inch gaskets on the two evaporator side cutouts as shown in the gasket drawing on page

8. The gaskets must start and end at the middle bottom of the cutouts. The gaskets must remain as one

continuous piece around the cutouts. Bend gaskets around the corners. Do not stretch the gaskets.

2. It is recommended that a lift truck be used for installation.

3. Attach the Mounting Plate to the enclosure using (3) 1/4-inch nuts, (3) sealing washers as a spacer and (3)

1/4-inch mounting nuts. Note that the mounting plate is not symmetrical. Be sure to install with the longer

section at the top and the shorter section at the bottom. Sealing washers must be placed against customer

enclosure (see External Mounting Drawing and Mounting Plate Detail on page 10).

4. Place the air conditioner on the lift truck. Insert a 1-inch (approximate) wooden block between the lift truck

bottom and the air conditioner bottom so that the angle between the unit mounting panel and the air conditioner

is about 10 degrees.

5. Adjust the lift truck height so that the air conditioner hook is located approximately 1/2-inch above the mounting

plate.

6. Route the power cord through the discharge (upper) air cutout.

7. Move the air conditioner toward the enclosure panel so that the gap between the hook and the enclosure is

about 1/2-inch.

8. Slowly move the lift truck down until the hook engages with the mounting plate. Continue to lower the lift truck.

The air conditioner will hang from the mounting plate flush against the mounting panel.

CAUTION

Internal Mounting

1. Place the supplied 1/2-inch gaskets on the two condenser side

cutouts as shown in the gasket drawing on page 8. The gaskets

must start and end at the middle top of the cutouts. The gaskets

must remain as one continuous piece around the cutouts. Bend

gaskets around the corners. Do not stretch the gaskets.

2. Remove the three #10 screws together with rubber washers

from the Rear Panel top.

3. Attach the supplied mounting angle to the Rear Panel top with the

three #10 screws and rubber washers (see Internal Mounting

Drawing).

4. It is recommended that 1/4-inch x 11/4-inch mounting studs be

used on the customer enclosure door or panel. If not, use the

hardware supplied for air conditioner mounting.

If the air conditioner is mounted to the cabinet door you must be sure that the door hinges

will support the additional weight of the air conditioner. Also be certain that when the door

is opened fully, the cabinet does not become unbalanced. The actual weight of the unit can

be found in the Technical Data on page 13.

EXTERNAL MOUNTING DRAWING

INSTALL THE MOUNTING PLATE W/STUDS

TO THE OUTSIDE WALL OF THE CUSTOMER'S

ENCLOSURE BEFORE INSTALLING A/C UNIT.

NOTE:

ENCLOSURE WALL

TYP. (3) PLACES

1/4'' NUT

CUSTOMER'S

ENCLOSURE

TYP. (3) PLACES

BOLT 1/4'' X 1-1/4''

RUBBER WASHER

MOUNTING PLATE

WITH STUDS

(SEE DETAIL

AT RIGHT)

TOP SECTION

OF A/C UNIT

BOTTOM SECTION

OF A/C UNIT

RUBBER WASHER

1/4'' NUT

TIGHTEN NUT TO

CLOSE GAP

MOUNTING PLATE DETAIL

MOUNTING

PLATE

WITH STUDS

MOUNTING PLATE IS NOT SYMMETRICAL.

INSTALL WITH LONGER SECTION AT THE

TOP AND SHORTER SECTION AT THE BOTTOM.

NOTE:

SHORTER

SECTION

AT BOTTOM

LONGER

SECTION

AT TOP

INTERNAL MOUNTING DRAWING

MOUNTING BRACKET

1/4'' NUT (3)

ENCLOSURE

WALL EXTERIOR

TOP SECTION

OF A/C UNIT

BOTTOM SECTION

OF A/C UNIT

RUBBER WASHER (3)

1/4'' BOLT OR STUD (3)

RUBBER WASHER (3)

1/4'' BOLT OR STUD (3)

1/4'' NUT (3)

9. Insert screws through the holes in the mounting plate bottom flange and the enclosure panel. Install sealing

washers and nuts on each screw from inside the enclosure and tighten (see External Mounting Drawing).

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