Kooltronic KA4C3RP33R, KA4C4RP33R, K2A4C4RP33R, KA4C5RP33R, K2A3C5RP33R Operator's 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
ADVANTAGE
RP33 SERIES
900-039-32
2
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. Warranty 15
I. Introduction
Kooltronic Air Conditioners are designed to provide a cool, dehumidified en vironment for your
electronic components. There are models to fit vir tually all sizes and shapes of electronic
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.
GA00350A - Rev. A - 9/07 - EC 07/314
3
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 han-
dling, 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 cer tain that it is placed in its correct mounting position.
All Air Conditioners containing an M, P, or V as part of the model number are designed to operate
in a vertical position only. All Air Conditioners containing an H 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 (preferab ly 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 par t 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.
4
IV. Product Identification and Labels
Each Kooltronic Air Conditioner includes an identification label. This label provides:
Model Number
Serial Number
Electrical power characteristics
Maximum and minimum ambient operating temperatures
Cooling capacity
Type and amount of refrigerant required for recharging
Design Pressure
Underwriters Laboratories Inc. Listed or Recognized Marks and NEMA ratings
We recommend you copy this information from your unit.
When ordering par ts, specify
the Model Number and Serial
Number.
Before operating, be sure that
the power source matches these
requirements.
Use of incorrect type or amount
of refrigerant will adversely affect
performance and may damage the
unit.
Make 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.
o
FMAX 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
5
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 her metically-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 and evaporated in the condensate
evaporator tray and released to the ambient air by the condenser blower.If latent heat exceeds 25% of the total
cooling capacity excess condensate is released to the ambient through the drain tube.
The heat removed through the e v apor ator 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.
Kooltronic Air Conditioners are designed to operate continuously in order to eliminate compressor cycling, which
shortens compressor life and causes line transients.The unit is equipped with a Low Temperature Thermostat to
prevent the evaporator coil from freezing. A high head pressure switch is standard on this unit and prevents the
evaporator coil from freezing under low ambient temperature.The crankcase compressor heater allows the unit
to start with an ambient temperature of 0ºF. In applications having frequent voluntary or involuntary power
interruptions, a Short Cycle Protector is recommended to allow adequate time for the internal pressures of the
Air Conditioner to equalize before restarting.
V. Principles of Operation
COOL AIR TO
ENCLOSURE
M/TAB
HEATED AIR FROM
ENCLOSURE
ACCUMULATOR
COMPRESSOR
REFRIGERANT
FILTER DRYER
CONDENSATE AIR
EVAPORATOR TRAY
CONDENSER HEAT
EXCHANGER
CONDENSER AIR
OUTLET
(Heated Ambient Air Out)
CONDENSER AIR
INLET
(Ambient Air In)
EVAPORATOR
HEAT EXCHANGER
6
VI. Pre-Installation T esting
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 is 75°F.
4. Heat up sensor bulb in evaporator compar tment to 90°F using heat pipe or light bulb.
5. Turn electrical power on.
6. Verify that the evaporator blower or fan is running.
7. The compressor should start. On units equipped with a shor t cycle protector, the compressor will have a
delayed start of 6 minutes from the time power is applied to the unit.
8. Verify that the condenser blower or fan is running. Note, the start of the condenser fan or blower will be
delayed until the system pressures rise.
9. Operate the air conditioner for appro ximately ten min utes .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.
10. Turn off the electrical power source, and disconnect the air conditioner from the power source.
11. If any cover plug is removed to adjust the unit, make certain to put 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:
1. Loosen two screws on the bottom of the unit.
2. See Figure 1 for proper M/TAB orientation.Place the M/TAB flush against the outside of the enclosure
to locate cutouts and mounting holes.
3. NOTE: The top cutout for the warm air return does not have to match the full 7.75" opening on the
M/TAB.You can locate your cutout anywhere within this opening. Locate your cutout close to the bottom
and not less than 3" high. Make sure the cutouts don't interfere with components inside your cabinet.
4. Mount the M/TAB to the outside of the cabinet using all the mounting hardware supplied by Kooltronic
(
1
/
4
-20 screws/nuts/washers). NOTE: Make sure the screws are inserted with heads on M/TAB side.
Tighten nuts securely.
5. Route the power cord through the top cut out in your cabinet. Mount the unit to the M/TAB by sliding the
slots located on the front panel on the hooks of the M/TAB.
6. Tighten two screws on the bottom of the unit and seal the unit against the enclosure.
7. Attach overflow drain hose supplied to the drain exit in bottom of the unit.
NOTE:The installer has the option of mounting the Air Conditioner to the M/TAB using torx
temper screws instead of hex screws.The (2) torx temper are supplied by Kooltronic in the
hardware bag.
CAUTION
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 performance specifications.
7
MOUNTING PLAN
FIGURE 1
Dimensions (inches) are for reference only and are subject to change.
ENCLOSURE
AIR OUT
ENCLOSURE
AIR IN
CONDENSER
AIR OUT
CONDENSER
AIR IN
1.94
[49.3]
[244.5]
(8) .281 [7.1]
DIA. HOLES
1.78
[45.1]
[313.8]
[254.0]
[260.4]
1.15
[29.3]
1.78
[45.1]
[228.6]
12.35
10.00
10.25
9.62
TYP.
1.28
[32.4]
9.00
1.08
[27.4]
[101.6]
16.50
[419.1]
[196.8]
4.00
7.75
Drawings and Dimensions
RP33 SERIES
8
Dimensions, inches [mm], are for reference only and are subject to change.
GA00350A - Rev. A
32.29
[820.1]
12.35
[313.7]
12.35
[313.6]
13.20
[335.3]
8.59
32.66
[829.4]
[218.2]
10.45
[265.4]
10.94
[277.9]
2.68
[68.2]
1.00 [25.4]
DIA. HOLE
6.18
[156.9]
1.56
[39.6]
9
Technical Data
RP33 Series
KA4C2RP33R 2000 125/115 0 115/100 60/50 13.6/13.3 98
K2A4C2RP33R 2000 125 0 230/200 60/50 5.8 98
KA4C3RP33R 3000 125/115 0 115/100 60/50 13.6/13.3 98
K2A4C3RP33R 3000 125 0 230/200 60/50 5.8 98
KA4C4RP33R 4000 125/115 0 115/100 60/50 13.6/13.3 98
K2A4C4RP33R 4000 125 0 230/200 60/50 5.8 98
KA4C5RP33R 5000 125/115 0 115/100 60/50 13.6/13.3 98
K2A3C5RP33R 5000 125 0 230/200 60/50 5.8 98
Ambient Ambient
* Approximate
BTU/H Temp. °F Temp. °F Running Weight
Model Rating Max. Min. Volts Hz Amps (lbs.)
✧
✧
* Rating shown is for operation at maximum ambient temperature.
✧
115V, 60 Hz and 230V, 60 Hz models also operate at 100V, 50 Hz or 200V, 50 Hz respectively. No transformer is required.
Major Component Replacements
KA4C_RP33R K2A4C_RP33R
Part Part Number Part Number
Compressor 0665-101 0665-107
Compressor Capacitor N/A N/A
Condenser Blower Motor 0261-08 0261-54
Condenser Blower Motor Capacitor 0452-03 0452-03
Condenser Blower Assembly 200033-00-19 200047-00-57
Evaporator Blower Motor 0261-08 0261-54
Evaporator Blower Motor Capacitor 0452-03 0452-03
Evaporator Blower Assembly 5417-00-35 6008-00-10
Filter 7006F 7006F
NOTE: Part Numbers shown are for 60Hz/1Ø.For 50Hz consult Kooltronic.
Standard Features
Built-in Condensate Evaporator
CFC-Free
EMI/RFI Suppressor
Low Temperature Control Thermostat
M/TAB Mounting System
NEMA3R Rating
Head Pressure Control Switch
Crankcase Compressor Heater
Units in BOLD are current standard products. Other units are prior product offerings and shown for reference only.
Wiring Schematic
10
WD-430 Rev. B
RP33 SERIES
WE BK
EVAPORATOR
BLR MTR
GN
OPTIONAL
SHORT
CYCLE
PROTECTOR
OPTIONAL
HEATER
2
3
HEATER
CONDENSER
SHORT
CYCLE
TIMER
BLR MTR
1
SR
RELAY
CAP
TRANSFORMER
WITH TEMP.
DISPLAY
THERMAL
CUTOUT
CAP
C
COMPRESSOR
0665-101
SUPPRESSOR
CRANKCASE HEATER
T-STAT
PRESSURE
SWITCH N.O.
O/L
BU
T-STAT
Y
SET 70˚F
R
TO CUSTOMER
ALARM SYSTEM
COOLING EFFECT DETECTOR
{
TERMINAL
BLOCK
OPTIONAL
11
VIII. Maintenance
Kooltronic Water-Cooled Air Conditioners require no maintenance. Air-Cooled air conditioners are designed
to require only the routine cleaning of air filters to assure unimpeded air flow through the condenser heat
exchanger. It is not possible to recommend specific filter cleaning intervals since the level and the nature of
airborne par ticulate matter differs widely with each installation. It is generally sufficient to remove and wash
the reusable aluminum mesh air filters when the outer surfaces of these filters appear co vered with a thin la y er
of dust or lint. Filter recoating adhesive is recommended. Appropr iate disposable filters are available from
Kooltronic.
If filter service is neglected or delayed, the air conditioner will not perform at its design capacity. The first
indication of excessively clogged air filters is usually a gradual increase of temperature within the equipment
cabinet. If operation is continued under these conditions, the compressor will be shut off by the thermal
overload device. The compressor will restart when its external temperature drops below the protector
threshold setting and the compressor will continue to cycle on and off. Continued operation under these
conditions will cause damage, shor ten compressor life and void the warranty.
A. Filter Removal and Service
Kooltronic Air Conditioners feature an easily removable inlet filter to facilitate necessary cleaning.
CAUTION
1) Lift the filter, using the attached tab, to clear the lower filter retainer. Pull filter toward you and downward
until the top of the filter clears the upper filter retainer.
2) After removal, the filters should be flushed under warm running water with the clean side up, driving
contaminants out the dirty side of the filter. If the accumulated dirt is oily, washing in a detergent bath
is recommended, followed by a warm water rinse as above.
3) The filters may be sprayed with Kooltronic A-16 Filter Recoating Adhesive to trap fine airborne
contaminants, or they may simply be dr ied and reinstalled as strainer type filters. Recoating is
recommended for best results.
4) Reinstall the filter: (a) keeping the tab at the bottom, slide filter into the upper retainer, (b) press filter
against the unit and (c) slide down into lower retainer.
Do not operate the air conditioner for extended periods of time with the filter
removed.The condenser coil may become clogged with dust or lint from the air
entering the face. A clogged condenser coil is not readily detected and will give
the same reaction as a clogged filter. A clean filter is the best protection.
B. Blowers
The design life of the blowers used in all Kooltronic Air Conditioners is substantially in excess of 20,000
hours. All Kooltronic condenser and evaporator blowers are equipped with automatic-reset thermal
overload protectors.
CAUTION
If field replacement of a blower motor is necessary, most blower assemblies , including mounting plate , are
readily removable. Each of the blower mounting plates is held to the air conditioner cabinet structure by
screws and nuts. For installation of the replacement blower, electr ical connections may be broken at the
terminal block, or power leads may be cut and appropriately spliced together.
C. Compressor
All Kooltronic compressors are approved by UL and CSA, and require no maintenance.They are hermetically
sealed and charged at the factory, and equipped with automatic-reset thermal overload protectors.
If the compressor or the hot gas bypass valve fails, it is strongly recommended that the air conditioner be
returned to Kooltronic for service.
D. Refrigerant Loss
Kooltronic Air Conditioners are subjected to a series of tests to detect refrigerant leaks, during and after
manufacture.It is possible that shipping or other damage, or microscopic leaks over a long period, may
result in the need for replenishment of refrigerant charge.When it has been verified by a Certified EPA
Technician that a refrigerant shor tage does exist, the leak must be repaired.Then the unit may be
evacuated and recharged in the field by a Cer tified EPA Technician only.
CAUTION
E. Relocation
If your Kooltronic Air Conditioner has to be moved to another location by truck, the following precautions
should be taken:
De-mount Air Conditioner from equipment, controller or enclosure.
Conform to the applicable provisions of PROCEDURE FOR PROPER PACKING AND SHIPMENT OF
KOOLTRONIC AIR CONDITIONERS in this manual under
Section III. "PRODUCT HANDLING".
12
Before opening the air conditioner, disconnect all power.
Refer to the data on the unit name plate which specifies the type of refrigerant
and the amount of charge in ounces.
IX.Trouble-Shooting
Each Kooltronic Air Conditioner is engineered f or perf ormance and built f or reliability.They are
designed to require no routine maintenance other than the cleaning of ambient air filters. If
your air conditioner should require warranty service, please contact Kooltronic. If
you require service out of warranty, we have compiled a trouble-shooting chart to
assist your service personnel. If additional assistance is required contact Kooltronic at
(609) 466-3400
.
Problem Cause Solution
Unit not Cooling No Power Check Power Source and
Electrical Connections
Loss of Refrigerant Locate and repair leak
Evaporator or Condenser Replace Motor, Capacitor or
Blower not operating entire Assembly
Filter clogged Clean or replace Filter
Clogged Evaporator or Clean Coil
Condenser Coil
Low Temperature Control Lower setting until unit starts
(Thermostat) improperly set
Low Temperature Control Replace Thermostat or Relay
(Thermostat) defective when applicable
Failed Compressor Replace Compressor
Ice on Evaporator Coil Insufficient Heat Load or Unit Contact Kooltronic
Oversized for Application
Failed Evaporator Blower Replace Evaporator Blower
Motor or Assembly
Clogged Evaporator Coil Clean Coil
Condensate draining Enclosure not properly sealed Check and seal all openings
continuously
Excessive opening of Enclosure Eliminate the frequency of
door opening
Excessive vibration Defective Motor in Blower Replace Motor
Defective Wheel in Blower Replace Wheel
Compressor Loose Tighten Mounting Bolts
Compressor Inoperative Low line Voltage Check Nameplate Voltage
against supply
Loss of Compressor Oil Replace Compressor
Loss of Refrigerant Locate and repair leak
Failed Compressor Capacitor Replace Capacitor
Thermal Overload Contact Kooltronic
Power interruptions Allow Compressor time to reset
Refrigerant or Oil leaks Crack or pin hole in tubing or Replace tubing or rebraze joint
brazed joint
IX.Trouble-Shooting
Each Kooltronic Air Conditioner is engineered for performance and built for reliability. They are designed to
require no routine maintenance other than the cleaning of ambient air filters. If your air conditioner should
require warranty service, please contact Kooltronic. If you require service out of warranty, we
have compiled a trouble-shooting chart to assist your service personnel. If additional assistance is
required contact Kooltronic at (609) 466-3400
.
13
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