Kooltronic P24 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

P24 SERIES

P28 SERIES

P36 SERIES

900-031-00

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 Label 4

V. Principles of Operation 5

VI. Pre-Installation Testing 6

VII. Specific Model Data 7 - 10

Mounting

Drawings and Dimensions

Technical Data

Major Component Replacements

Wiring Schematics

VIII. Maintenance 11-12

IX. Trouble Shooting 13

X. Accessories 14

XI. Warranty 15

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 7 through 10.

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.

All Air Conditioners containing an MM, NM, P, or V as part of the model number are designed to

operate in a vertical position only. All Air Conditioners containing an H, RT or RM in the model

number are designed to operate in a horizontal 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 air

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

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 Labels

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

ÀModel Number

ÁSerial Number

ÂElectrical power characteristics

ÃMaximum and minimum ambient operating temperatures

ÄCooling capacity

ÅType and amount of refrigerant required for recharging

ÆDesign Pressure

ÇUnderwriters Laboratories Inc.Listed or Recognized Marks and NEMA ratings

We recommend you copy this information from your unit.

ÀÁWhen ordering parts, specify

the Model Number and Serial

Number.

Â Before operating, be sure that

the power source matches these

requirements.

ÅUse of incorrect type or amount

of refrigerant will adversely affect

performance and may damage the

unit.

ÃMake sure thatthese parameters

are met. Failure to do so may result

in permanent damage to the unit

MODEL NO. SERIAL NO.

COOLING AMBIENT TEMP.

VOLTS. FREQ. PH. F.L.A. MIN. oF MAX oF

COOLING BTU REFRIGERANT

DESIGN PRESSURE P.S.I.G.

LOW HIGH MAX. FUSE SIZE

SERVICE AIR FILTERS REGULARLY

ALLOW 5 MIN. BEFORE RESTARTING AFTER SHUTDOWN

UNAUTHORIZED SERVICE OR MODIFICATION VIOLATES WARRANTY

ALL MOTORS ARE THERMALLY PROTECTED

THIS PRODUCT IS PROTECTED BY ONE OR MORE OF THE FOLLOWING

PATENTS: 3,019,965 3,120,166 3,211,360 3,559,728 3,807,493 AND

OTHER PATENTS PENDING

MANUFACTURED BY:

KOOLTRONIC, INC. PENNINGTON, NJ VENTURA, CA

Air Conditioner

Â Â Â Â Ã Ã

ÄÅ

ÀÁ

ÆÆ ÂÇ

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. This Air Conditioner utilizes a “Closed-Loop Cooling System” to

ensure optimum performance of the installed components.

Closed-Loop cooling seals the electronics 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

released to the ambient air through the drain tube or the condensate evaporator.

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

condenser coil. Ambient air or water is then passed through the condenser coil, where it absorbs the

heat and is then discharged to the environment.

The cool air discharge temperature is regulated by the capacity control (hot gas bypass) valve. The

unit is equipped with a Low Temperature Thermostat to prevent over-cooling. In applications having

frequent voluntary heat load fluctuations, an optional Compressor Short Cycle Protector is recommended.

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

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 identification label 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 typically 75 to 80°F.

4. Adjust thermostat to its maximum setting.

5. If your unit is equipped with an on-off switch, move it to the on position.

6. Turn electrical power on.

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

8. Adjust the thermostat to its minimum setting.The compressor should start. On units equipped with a

short cycle protector, the compressor will have a delayed start of 6 minutes from the time power is

applied to the unit.

9. Verify that the condenser blower or fan is running.Note, on units equipped with a low ambient kit, the

start of the condenser fan or blower will be delayed until the system pressures rise.

10. 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 discharged air should be less

than 70°F when the room temperature is between 70 and 80°F.

11. On units equipped with heaters, adjust both the cooling and heating thermostats to their maximum

settings. Verify that the compressor and condenser fan or blower has stopped. Verify elevated

discharge air temperature from the evaporator air discharge.

12. If your unit is equipped with an on-off switch, leave it in the on position. Return the cooling

thermostat to its original setting. If unit is equipped with a heater, return the heating thermostat to

its original position.

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

14. 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, Inc. Air Conditioners are subjected to a performance test.

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.

VII. Specific Model Data

Mounting

Kooltronic Air Conditioners have been engineered to be installed easily.To avoid damaging

your Air Conditioner, please read the following information before installation.

•Panel-Mounted Air Conditioners are equipped with two vertical mounting rails.

These rails can be mounted to any available vertical surface on the enclosure.

•Refer to page 8 for the location of all mounting holes and cutouts.

•Make sure the cutouts don't interfere with components inside your cabinet.

•Proper alignment of all air inlets and outlets is essential for optimum performance

of the Air Conditioner.

•All externally-mounted Air Conditioners are fully gasketed to ensure proper sealing.

This seal is necessary to maintain the integrity of the closed loop system.

•Use all existing mounting holes to insure stability and a tight seal.

•High strength mounting screws are recommended.

•Attach the brass drain pan fitting and drain hose supplied to the drain exit on the

bottom or lower side panel of the Air Conditioner. The optional field installed

Condensate Evaporator is mounted underneath the Air Conditioner and the drain

hose is connected to the top fitting of the Condensate Evaporator. The drain hoses,

fittings and Condensate Evaporator must be removed before dismounting the Air

Conditioner, as they will not support the weight of the Air Conditioner unit.

•The external drain hose must not be elevated above the exit port. Improper mounting

will impede the flow of condensate and may cause internal malfunctions.

CAUTION

Major Component Replacements

P28 & P36 P28 & P36 P36

P24 2000-4000 BTU 5000-7000 BTU 8000 BTU

Part Part Number Part Number Part Number Part Number

Compressor 0665-101 0665-101 0665-103 0665-42

Compressor Capacitor N/A N/A N/A 0452-32

Condenser Blower Motor 0261-13 0261-08 0261-08 0261-08

Condenser Blower Motor Capacitor N/A 0452-03 0452-03 0452-06

Condenser Blower Assembly 5417-00-25 5417-00-35 5417-00-35 6015-00-129

Evaporator Blower Motor 0261-13 0261-13 0261-13 0261-08

Evaporator Blower Motor Capacitor N/A N/A N/A 0452-03

Evaporator Blower Assembly 5417-00-25 8009-00-38 5417-00-25 5417-00-35

Filter 8751F 8751F 8751F 12251F

NOTE: Part Numbers shown are for 115v/60Hz/1Ø. For 230v/60Hz/1Ø and all 50Hz consult Kooltronic.

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 on page 9.

289/16

33/4

231/8

289/16

211/2

POWER

CORD

THERMOSTAT

ADJUSTMENT

DRAIN

FILTER

91/2

FILTER

THERMOSTAT

ADJUSTMENT

DRAIN

91/2

POWER

CORD

185/16

(8)

.312 DIA.

HOLES

TYP.

171/2

7/16

131/2

11/2

185/16

(8)

.312 DIA.

HOLES

TYP.

1.50 DIA.

POWER

CORD

HOLE

131/2

TYP.

➀

➁

➂

➃

➀

➁

➂

➃

➂

➃

➂

➃

WARM AIR RETURN

FROM ENCLOSURE

(Enclosure opening should be located as

high as possible within this area, and equal

or exceed size of cool air outlets.)

FILTERED

CONDENSER AIR INLET

(Ambient Air In)

CONDENSER OUTLET

(Warm Ambient Air Out) COOL AIR OUTLET

TO ENCLOSURE

ÀÁ➂Ã

5/16

23/4

5/16

23/4

Drawings and Dimensions

P28 & P36 SERIES

P24 SERIES

Dimensions (inches) are for reference only and are subject to change.

MOUNTING PLAN

DIMENSIONS

(inches)

Model ABCDE

P28 Series 289/16 33/4231/8821

1/2

P36 Series* 3613/16 7/8313/812 293/4

* Consult factory for dimensions of 8,000 BTU/H P36.

* Switchable. Switch is internally-mounted for security.

** Rating shown is for operation at maximum ambient temperature.

"115V, 60 Hz and 230V, 60 Hz models also perform at full capacity when operated

at 100V, 50 Hz or 200V, 50 Hz respectively. No transformer is required.

GKA4C1P_ _L 1000 120/50 115/100 60/50 14.2 90 90 110

GKA4C1P_ _L56 1000 120/50 115 50/60* 14.2 90 90 110

GK2A4C1P_ _L 1000 125/50 230/200 60/50 6.2 90 90 110

GK2A4C1P_ _L5 1000 125/50 230 50 6.2 90 90 110

GKA4C2P_ _L 2000 120/50 115/100 60/50 14.2 90 90 110

GG KA4C2P_ _L 2000 125/50 115/100 60/50 12.0 90 90 110

GKA4C2P_ _L56 2000 120/50 115 50/60* 14.2 90 90 110

GG KA4C2P_ _L56 2000 120/50 115 50/60* 12.5/12.0 90 90 110

GK2A4C2P_ _L 2000 125/50 230/200 60/50 6.2 90 90 110

GG K2A4C2P_ _L 2000 125/50 230/200 60/50 5.9/5.8 90 90 110

GK2A4C2P_ _L5 2000 125/50 230 50 6.2 90 90 110

GG K2A4C2P_ _L5 2000 125/50 230 50 6.0 90 90 110

GKA4C3P_ _L 3000 120/50 115/100 60/50 14.2 90 90 110

GG KA4C3P_ _L 3000 125/50 115/100 60/50 12.0 90 90 110

GKA4C3P_ _L56 3000 120/50 115 50/60* 14.2 90 90 110

GG KA4C3P_ _L56 3000 120/50 115 50/60* 12.5/12.0 90 90 110

GK2A4C3P_ _L 3000 125/50 230/200 60/50 6.2 90 90 110

GG K2A4C3P_ _L 3000 125/50 230/200 60/50 5.9/5.8 90 90 110

GK2A4C3P_ _L5 3000 125/50 230 50 6.2 90 90 110

GG K2A4C3P_ _L5 3000 125/50 230 50 6.0 90 90 110

GKA4C4P_ _L 4000 120/50 115/100 60/50 14.2 90 90 110

GG KA4C4P_ _L 4000 125/50 115/100 60/50 12.0 90 90 110

GKA4C4P_ _L56 4000 120/50 115 50/60* 14.2 90 90 110

GG KA4C4P_ _L56 4000 120/50 115 50/60* 12.5/12.0 90 90 110

GK2A4C4P_ _L 4000 125/50 230/200 60/50 6.2 90 90 110

GG K2A4C4P_ _L 4000 125/50 230/200 60/50 5.9/5.8 90 90 110

GK2A4C4P_ _L5 4000 125/50 230 50 6.2 90 90 110

GG K2A4C4P_ _L5 4000 125/50 230 50 6.0 90 90 110

GKA4C5P_ _L 5000 120/50 115/100 60/50 14.2 90 90 110

GG KA4C5P_ _R 5000 125/50 115/100 60/50 17.6/19.8 90 90 110

GKA4C5P_ _L56 5000 120/50 115 50/60* 14.2 90 90 110

GG KA4C5P_ _R56 5000 125/50 115 50/60* 17.6 90 90 110

GG K2A4C5P_ _L 5000 125/50 230/200 60/50 9.5/9.9 90 90 110

GG K2A4C5P_ _L5 5000 115/50 230 50 8.0 90 90 110

GG KA4C6P_ _R 6000 125/50 115/100 60/50 17.6/19.8 90 90 110

GG KA4C6P_ _R56 6000 125/50 115 50/60* 17.6 90 90 110

GG K2A4C6P_ _L 6000 125/50 230/200 60/50 9.5/9.9 90 90 110

GG K2A4C6P_ _L5 6000 115/50 230 50 8.0 90 90 110

GG KA4C7P_ _R 7000 125/50 115/100 60/50 17.6/19.8 90 90 110

GG KA4C7P_ _R56 7000 125/50 115 50/60* 17.6 90 90 110

GG K2A4C7P_ _L 7000 125/50 230/200 60/50 9.5/9.9 90 90 110

GG K2A4C7P_ _L5 7000 115/50 230 50 8.0 90 90 110

GKA3C8P_ _R 8000 120/50 115/100 60/50 18.0/17.5 90 90 110

GKA3C8P_ _R56 8000 115/50 115 50/60* 16.5/18.0 90 90 110

GK2A3C8P_ _L 8000 115/50 230/200 60/50 9.5 90 90 110

GK2A3C8P_ _L5 8000 120/50 230 50 7.9 90 90 110

Approx.

Series ** Ambient ** Weight

Height BTU/H Temp. °F Running (lbs.)

24 28 36 Model Rating Max./Min. Volts Hz Amps 24 28 36

Technical Data

Units in BOLD are current standard products. Other units are prior product offerings and shown for reference only.

Wiring Schematics

COIL

RELAY

WE BK

SUPPRESSOR

SHORT

CYCLE

TIMER

THERMOSTAT

COMPRESSOR

TO CUSTOMER'S

ALARM SYSTEM

TERMINAL BLOCK ON UNIT

BLR MTR

EVAPORATOR

BLR MTR

CONDENSER

RCO/L

RELAY

SHORT

CYCLE

PROTECTOR

OPTIONAL

CRANKCASE HEATER

CAP

CONDENSER

BLWR MTR

WE BK

PRESSURE

SWITCH

(OPTIONAL)

PRESSURE

SWITCH

(OPTIONAL)

0FF

SWITCH

ADDITIONAL OPTIONS

1) AIRFLOW SWITCH

2) COOLING EFFECT DETECTOR

NOTES:

1) ADDITIONAL OPTIONS ARE WIREDTO AN

INDIVIDUAL 3 POSITIONTERMINAL BLOCK

SHOWN ABOVE.

2) 50Hz: CONTACT KOOLTRONIC

3) EXCESS PRESSURE DETECTOR

FOR KA4C1-4P24 ONLY

SCR

COMPRESSOR

SUPPRESSOR

O/L

OPTIONAL

CAP.

EVAP

BLOWER

MOTOR

826

CRANKCASE HEATER

MOTOR

BLOWER

COND

TIMER

CYCLE

SHORT

PRESSURE

SWITCH

OPTIONAL

RELAY

MCAP

RED

ALARM SYSTEM

TO CUSTOMER

BLOCK

TERMINAL

EXCESS PRESURE DETECTOR

INCREASE

OPENS ON PRESS.

RED TO BLUE

INCREASE

CLOSES ON PRESS.

RED TO YELLOW

COMMON

RED

BLUE

YELLOW

BLUE

RED

COMMON

RED TO YELLOW

CLOSES ON TEMP.

INCREASE

RED TO BLUE

OPENS ON TEMP.

INCREASE

COOLING EFFECT DETECTOR

TERMINAL

BLOCK

TO CUSTOMER

ALARM SYSTEM

{

LOW AIR FLOW DETECTOR

{

TERMINAL

BLOCK

RD-N.C.

BK-N.0.

WE-COM

TO CUSTOMER

ALARM SYSTEM

0RELAY

HEATING

T-STAT CUTOUT

THERMAL

HEATER

T-STAT

ON/OFF

SWITCH

(FOR UL LISTED

UNITS ONLY)

{

WD-176 REV. C

WD-208 REV. D

P24 SERIES

P28 & P36 SERIES, 2000-4000 BTU/H

P28 & P36 SERIES, 5000-7000 BTU/H

(Consult factory for 8000 BTU/H P36)

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