Portable Heat Pumps
Operation Manual
P P
P P
H
PORTABLE HEAT PUMPS
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KwiKool KPHP Series
Operation Manual
Table of Contents
Section I / Unit Components - Page: 3
Section II / Assembly and Installation - Page: 4-6
Section III / Operational Safeguards - Page: 6
Section IV / System Operation - Page: 6-9
Section V / Built In Safeguards - Page: 9-10
Section VI / Application Requirements - Page: 10-11
Section VII / Maintenance - Page: 11
Section VIII / Utilizing Your KwiKool System - Page: 11
Section IX / Fault Codes - Page 11
Section X / KPHP Troubleshooting Guide - Page: 12-15
Before installing and using your KwiKool Portable
Cooling/Heating System, read this manual carefully for
instructions and proper usage and all safeguards.
This manual should be retained for future reference.
I / Unit Components
Legend
1. Cold Air Return
2. Control Pad
3. Cold Air Supply
4. Condenser Air Inlet
5. Condenser Air Outlet
6. Cord Storage
7. Condensate Nipple
8. Condensate Alarm Jack
9. Access Door
10. Vent Control
Page 3
II / Assembly and Installation
Air Chutes (If equipped or as an optional accessory) - Install supply air flanges to the
A.
front of your KwiKool unit above the control panel. (See instructions in the air chute kit
for specific procedures).
Air Chutes - Conditioned air supply,
if equipped or as an optional accessory.
Condensate Tank - KwiKool systems come standard with an external 5-gallon
B.
condensate tank. The external condensate tank is equipped with a float switch that
shuts your KwiKool down and alerts operators with an alarm and display CF
(“Condensate Full”) when the condensate tank is full. This prevents accidental water
overflow on the floor. The alarm will clear automatically upon emptying the 5 gallon tank
and reconnecting it. If connecting to a permanent drain, do NOT connect or use the
equipped tank. To use the external condensate tank, remove the factory installed
condensate float switch bypass plug on your KwiKool unit and install the male connector
jack supplied on the condensate tank. Next connect the factory supplied ¼” ID condensate tubing to the ¼” OD barbed condensate water outlet on the back of your KwiKool
and connect the discharge end of the tube to the ¼” barbed connector on the condensate tank. The condensate float jack must be inserted into the female condensate jack
to operate your KwiKool. CF displays if the jack is not connected or the bypass plug is
not inserted properly.
Condensate Water Outlet 1/4” OD barbed fitting
Condensate Float Switch Jack Connects to the condensate tank or is bypassed by
the factory installed male bypass switch plug pictured
Condensate Tank - 5-gal Condensate
Tank with float assembly for automatic
cutoff.
Cord Compartment
Power cord with plug -
available on 1.1-ton thru 2.5-ton models
Page 4
C.
Ceiling Kit (Optional Accessory) - The ceiling kit is comprised of flanges with foam
tape, fasteners, two (2) eight foot lengths of flexible duct, duct clamps, and one
24”X24” replacement ceiling tile for KPHP1811 and KPHP2211.
Follow these installation steps:
Align the holes of the flange to the holes located on the top of the unit. Attach to the
1.
top of the KwiKool unit using the factory supplied fasteners.
2.
Attach each duct to the flanges on the replacement ceiling panel(s); secure the duct
to each flange using the supplied clamps.
Install the replacement ceiling panel(s) in the ceiling grid with the duct attached,
3.
connect the open end of the duct to the flanges on your KwiKool and secure with
supplied clamps. Be sure the area where you are ducting can absorb the discharge
air and is open enough to keep the system from returning its own discharge air. Your
KwiKool must have fresh make up air going to the condenser to operate.
**For Ceiling Kit Users** - The standard two duct ceiling kit (CK12) is recom-
4.
mended to be used with KPHP models for optimum performance. KwiKool’s KPHP
systems may be used for primary, supplemental or standby cooling or heating. Using
KwiKool’s exclusive ceiling kit ensures that you are able to utilize 100% of the units
rated capacity and without creating a negative pressure in your conditioned space.
KwiKool’s exclusive IO integral condenser system isolates both the condenser
discharge air and the condenser make up air from the conditioned space.
**Note: The space where the make up air and discharge air is directed (normally
above a drop ceiling) must be well ventilated and large enough for the discharge air
to be absorbed. Discharge air is prevented from entering the make up air inlet by
way of a factory installed deflector on your Ceiling Kit. Make sure that the deflector
is on the discharge (rear) duct from the unit. However if the condenser discharge
and return space is unventilated, closed off or unable to handle the discharge air, the
make up air will return the discharge air. This will lead to the unit tripping its high
pressure safety switch while in cool mode. If this occurs, you will get an “HP” on
the control panel. To resolve, fix the lack of make up air and reset the high pressure
switch per the instructions in the Troubleshooting Guide section. If in the HEAT
mode and ducted into a confined space you will notice diminished performance,
rapid supply air cycling and/or coil freezing. Additionally, the ceiling kit replacement
panel is not limited to ceiling use and may be placed or fastened to any vertical or
horizontal surface providing the discharge and make up air is able to be directed to
the space where it is mounted. For areas with a closed ceiling or no ceiling use the
double flange ceiling kit method or extended duct method.
Visit www.KwiKool.com for more information and a complete set up guide.
Ceiling Kit - Discharge Outlet (Condenser exhaust)
& Discharge Make Up (Fresh Air Inlet)
Page 5
Power Connection - Verify that the source power, phase and breaker size is
D.
compatible with your KwiKool serial plate information and that the electrical circuit is
dedicated only for the use of your KwiKool Unit. If you aren’t sure about your power,
contact a licensed electrician. KwiKool systems are factory equipped with 8 feet of
power cable sized to meet the power requirement of your system. Extension power
cable is allowed but cannot exceed 25’ and must be rated to operate your KwiKool.
KwiKool units that come supplied with a factory installed plug require the exact receptacle to match the plug and exact circuit size and power. Cutting the power plug on your
KwiKool unit will void its warranty.
III / Operational Safeguards
Read the following safeguards carefully before installing your KwiKool:
A.
Do not operate or install your KwiKool unit in a potentially explosive, combustible, or
corrosive gas atmosphere.
B.
Keep your KwiKool system away from flammable materials and open flame.
C.
To avoid electrical shock keep your KwiKool system away from direct contacts with
water and any liquids and do not touch your system with wet hands.
To insure your KwiKool system is stable, the floor on which the system is to be place
D.
should be level, free of vibration and strong enough to support the weight of your
KwiKool model.
E.
Do not move the system while it is operating. Before moving the system, first turn
system to OFF then unplug the system from the power source. Then unlock casters.
Do not tilt or overturn your unit, since this could damage the compressor.
F.
G.
Do not place objects on top of your unit.
H.
Do not insert your hand or any other object into the air supply chutes.
I.
Do not operate your KwiKool system with its service doors open.
J.
If your KwiKool system makes abnormal noises or vibrations, call KwiKool at
1-800-594-5665.
IV / System Operation
Apply Electrical Power - Once power is engaged by plugging in your system
A.
and/or switching the breaker to the on position, your KwiKool display will come alive
and show the current room temperature. The unit is set to OFF and the fan is set to the
default position. A 2 minute time delay starts, indicated by a flashing F on the display. If
you are not seeing anything on the display, refer to the Troubleshooting Guide section
of this manual.
Page 6
Control Panel - The control panel display shows the current operational status of the
B.
unit.
Display Shows - Current Temperature,
Set Temperature, or Alarm Codes
Display Shows - Unit Mode
Cool / Fan
Cool
FAN
Display Shows - Fan Mode
1.
ON/OFF Button - Pressing this button on your control panel engages or shuts
down your KwiKool system. All settings selected are stored in the microprocessor
board even if the power is lost including the ON/OFF selection. Refer to the
Troubleshooting Guide section of this manual if your KwiKool is alerting an alarm
after selecting ON.
2.
MODE Button - Depressing the MODE button selects your choice of operations.
Cool, for cooling with compressor operation. “Cool” will flash when the compres-
sor is running. “Cool“ will not flash when the room temperature is equal to or lower
than the set temperature or the system is timing out. Heat, for heating with
compressor operation. “Heat” will flash when the compressor is running. “Heat”
will not flash when the room temperature is equal to or higher than the set
temperature or the system is timing out. Heat/Cool mode when conditioning is
required in applications with changing load requirements. The system automatically
selects the mode based on the set point and flashes the current operating function
unless the set point is satisfied or the system is timing out. Fan, for air circulation
without compressor operation.
Fan
F
+
OFF
Display Shows - On / Off
-
Display Shows - Fan Speed (except single speed)
3.
F/C - Selects the way that room temperature and set point are displayed on the
control panel. Choices are Fahrenheit or Celsius. F is the factory default. This
indicator will flash when the system is in “time out” to prevent compressor short
cycling.
4.
Fan - Pressing the fan key cycles the supply air fan between auto fan and fan on.
When the system is in auto fan, the supply air fan only operates when the
compressor is running. When the fan is set to on, the fan runs continuously as long
as the unit is in the ON position. The fan speed window will be blank on these
models.
Page 7
NOTE: Operations of KPHP systems will not have control of the supply air fan
when in Heat Mode, the supply air is controlled by a pressure switch to optimize
the systems operation and this switch overrides the microprocessor selection. It is
normal for the supply air fan to delay in starting and to cycle on and off in the Heat
Mode.
Up (+) and Down (-) Arrow Buttons - Raises or lowers the desired set tempera-
5.
ture. When changing the set point, pressing the + or – key, the word SET will
appear on the display and the current set point flashes ON and OFF. The value of
the set point is changed 1 degree each time the + or – is pressed. The adjusted set
point flashes on and off 12 times after the last change and then returns to display
the room temperature.
NOTES:
a.
Lowering or raising the set point will not change the temperature of the supply
air. For best results always adjust the set point to a temperature your KwiKool
can cycle on and off at to avoid operational issues such as freezing or rapid fan
cycling, KwiKool systems are designed to maintain the set point when sized
properly and constant operation without achieving the set point may shorten
the expected operational life of your system.
b.
In Cool Mode the lowest set point temperature available for your KwiKool is
60 degrees F, and the highest setting is 95 degrees F. The control will not
allow adjustments beyond these ranges.
C.
System Operation -
1.
Turn On Your KwiKool System - Pressing the ON/OFF button once on your control
panel will put your unit in the ON position and “ON” will be displayed on the right
side of your display as well as the previously chosen mode.
2.
COOL - If the unit was previously set to the cooling mode (cool) then “cool” will be
displayed. If the compressor is running, the ”cool” on the display will be flashing. If
your unit has been sitting for over 2 minutes, this should happen immediately upon
turning the unit on, unless your set point is lower than the current room temperature. In this case your unit is ready to automatically turn on once the temperature
rises above the set point. If the unit was recently turned off or the unit turned itself
off because it reached the set point, the compressor will not turn on until the
system waits for approximately 2 minutes. This prevents the compressor from
being damaged do to a condition called short cycling. The indicator that the unit is in
the “time out” condition is that the F (or C) in the display will be flashing. When the
compressor starts, the F will stop flashing and the “COOL” will begin flashing.
Note that the condenser fan will not start immediately with the compressor. And
once the condenser fan kicks in and if the ambient temperature entering the make
up air for the condenser return is below 75 degrees F you may notice the fan
cycling on and off, this is normal. If the display flashes 99, this indicates ambient
temperature of 99 degrees F or more. This is normal and will stop flashing when the
ambient temperature falls below 99 degrees F.
HEAT - If the unit was previously set to the Heat Mode then “Heat” will be
3.
displayed. If the compressor is running, “Heat” on the display will be flashing. If
your unit has been sitting for over 2 minutes, this should happen immediately upon
Page 8
turning the unit on, unless your set point is higher than the current room temperature. In this case your unit is ready to automatically turn on once the temperature
drops below the set point. If the unit was recently turned off or the unit turned itself
off because it reached the set point, the compressor will not turn on until the
system waits for approximately 2 minutes. This prevents the compressor from
being damaged do to a condition called short cycling. The indicator that the unit is in
the “time out” condition is that the F (or C) in the display will be flashing. When the
compressor starts, the F will stop flashing and “HEAT” will begin flashing. NOTE:
that the supply air fan will not start immediately with the compressor and once the
supply air fan starts and air is blowing in and if the ambient temperature entering the
make-up air for the return is below 75 degrees F you may notice the supply air fan
cycling on and off, this is normal. The colder the temperature is the longer the off
cycle will be.
4.
HEAT/COOL - If the unit was previously set to the Heat/Cool mode then “Heat &
Cool” will be displayed. The system functions as described above in the mode
required based on a 2 degree temperature differential. Your KwiKool automatically
selects the mode needed to maintain the set point, and the operating function
flashes on and off while operating and the standby mode stays solid.
FAN - If the unit was previously set to the fan mode then “FAN” will be displayed
5.
and the supply air fan will start to run.
V / Built in Safeguards
KwiKool is proud to provide its customers with high quality features and safety devices
that are not found in most other brands.
Time Delay - Protects your KwiKool from potential damage by delaying the compres-
A.
sor from starting before the pressures in the mechanical system equalize. This always
activates when your KwiKool cycles off, is turned off, power is lost and then restored or
the operational mode is changed. Display flashes C or F if the time delay is activated.
B.
Fan Cycling - Part of your KwiKool limited freeze protection and works by regulating
the air flow to keep the refrigerant pressures at the optimum range.
High-Pressure Switch and Alarm - Protects your KwiKool System from potential
C.
damage to the mechanical system by shutting down, sounding an audible alarm and
displaying a fault code (HP) when the system pressure exceeds safe operating conditions. The high pressure switch is a manual reset switch and must be reset after the
switch is activated and the condition causing the trip is corrected.
D.
Low Pressure Switch and Alarm - Protects your KwiKool from potential damage
to the mechanical system by shutting down the system, sounding an audible alarm and
displaying a fault code (LP) when the low side pressure is too low. This is normally
caused by low refrigerant charge. This switch is an automatic reset.
E.
Automatic Restart - In the event of a power loss your KwiKool System resumes
operation when the power is restored. All operational functions are preserved in the
memory of the Microprocessor Board including the ON/OFF selection.
Condensate Pump & High Level Alarm - All KPHP models are factory equipped
F.
with an internal high lift condensate pump. KwiKool condensate pumps are able to pump
Page 9
the condensation either to the factory supplied condensate bottle, or to a drain or other
location as required by the application. The internal pump is rated at 20 foot of head
pressure. This means it can pump water to a maximum of 20 feet vertically. Each pump
is equipped with an overflow safety cut-off that automatically shuts your KPHP unit
down, sounds an audible alarm and displays a fault code (CP). This prevents accidental
flooding of the conditioned space.
G.
Condensate Tank & High Level Alarm - All KPHP models come standard with an
external condensate tank. The tank is equipped with an overflow safety cut-off. When
the tank is full, the safety will automatically shut down your KPHP systems, sound an
audible alarm and display a fault code (CF) This prevents accidental flooding of the
conditioned space. If you are using the supplied bypass plug and not using the tank this
alarm is nonfunctional.
Service Ports - Located in the filter access compartment in the front of your KwiKool
H.
below the control panel. This gives service personal a connection point for service
gauges to monitor the operating pressures of your KwiKool KPHP refrigeration system.
Sight Glass/Moisture Indicator - Located in the discharge air make up inlet. This
I.
feature allows operators and service personal to view the condition of the refrigerant
returning to the evaporator coil. Used as a diagnostic tool by qualified personal.
VI / Application Requirements
Air Temperature Requirements Cooling - The environmental requirements of
A.
your KwiKool unit at the installation site are 60 to 110 degrees F for the condenser
make up air located on the front inlet on the top of the unit. If the unit is operated in an
environment above 110 F the high pressure switch may trip, stopping the unit’s
compressor. You also may notice diminished performance. The High Pressure Switch
type is a manual reset. The reset switch is located in the Return Air grill filter compartment. Reset the unit by pressing the button labeled HP Reset. Standard air-cooled
KwiKool models are not designed to operate at temperatures below 60 degrees F. in
cooling mode. Low-ambient temperature controls must be special ordered at an
additional cost. Temperatures below 60 degrees F will cause the discharge air exhaust
fan to cycle excessively and may damage the fan cycling switch, which requires
qualified service personal to repair and can void your warranty.
Air Temperature Requirements Heating - The environmental requirements of
B.
your KwiKool unit at the installation site are 40 to 80 degrees F for the supply air
located on the front of the unit. If the unit is operated in an environment above 80 F
the high pressure switch may trip, stopping the unit’s compressor. You also may notice
diminished performance. The High Pressure Switch type is a manual reset. The reset
switch is located in the Return Air grill filter compartment. Reset the unit by pressing
the button labeled HP Reset. Standard air-cooled KwiKool models are not designed to
operate at temperatures below 40 degrees F. in heat mode. Temperatures below 40
degrees F will cause the supply air fan to cycle excessively and may damage the fan
cycling switch, which requires qualified service personal to repair and can void your
warranty.
C.
Capacity & Temperature Settings - Sizing of our units is based on matching
capacity to a specific heat load while maintaining a 72 degree F temperature. In order
to maintain temperatures at 72 degrees F, the unit must have correctly sized capacity.
Page 10
D.
Positioning of Unit - Do not place your KwiKool unit in direct sunlight. The unit
should be positioned so that the output of the unit can be focused as close to the load
source as possible with the front grill fully exposed. Do not block the front of the unit,
since this will cause a restriction in the airflow, can cause low performance and other
operational issues discussed in the troubleshooting section.
VII / Maintenance
Your KwiKool unit comes from the factory with air filters installed on the evaporator inlet to
prevent dust and debris from entering the system and circulating in the conditioned space,
factory installed filters are a disposable type and must be periodically checked and replaced
based on the air quality of your conditioned space. Failure to maintain the filters will cause
restricted air flow and low overall unit performance. The air filter is located on the front of
your KwiKool unit below the control, release the 2 slotted fasteners on the access door to
open.
VIII / Utilizing your KwiKool System
In contrast to conventional air conditioners, which circulate air conditioning capacity evenly
to an entire floor, KwiKool systems are designed for conditioning an area that needs heating
and/or cooling in a concentrated area. Understanding the capabilities of your KwiKool can
help you avoid problems. For example, if you add heat-generating equipment to the room
after purchasing a KwiKool system, you may be short of the necessary cooling capacity.
Your KwiKool system offers an effective affordable solution for many applications. It can also
provide spot cooling for workers or process cooling within a large space without the use of
condenser ducting, such as a warehouse factory, or production areas. If the system is used
in this manner, the cold air supply must be within 5 feet of the person or equipment being
cooled, since the hot ambient air will mix with the cool air very quickly. Your KwiKool system
is specifically designed to adapt to today’s high tech environments such as telecommunication or computer rooms and is equipped with the necessary controls to maintain those
special environments. Call your nearest KwiKool Distributor or 1-800-594-5665 for help or
for questions about other applications.
IX / Fault Codes
Your KwiKool Iceberg System incorporates a self-diagnostic system that sounds an audible
alarm, stops your system and displays a fault code to indicate the nature of the problem on
the display panel. See the troubleshooting guide later in this manual for further information.
CF = Condensate Tank Full
CP = Condensate Pump Fault
HP = High Pressure Switch Tripped
LP = Low Pressure Switch tripped or tripping
A1 = Phase Monitor Senses power problem (if equipped)
FP = Freeze Protection
Page 11
X / KPHP Troubleshooting Guide
Fault Possible Cause Possible Solution
Unit displays CF, Audio
alarm fails to clear on start
up or while operating
Unit Displays CP and Audio
alarm is sounding during
start up or while operating.
Unit Displays HP, Audio
alarm is sounding during
start up or while operating.
External Condensate Tank is
full. Condensate bypass jack
or condensate float switch
jack is not installed or not
positioned correctly. Water
level switch is engaged
Microprocessor board has
detected high water level in
the condensate pump.
Microprocessor board has
detected high pressure. The
High Pressure switch is
tripped.
Empty External Tank (if
using). Make sure thank is
upright and level. Unplug
bypass plug or tank plug and
reinstall to assure good
connections. System
automatically resets when
fault condition is corrected.
Inspect condensate pump for
over flow and proper
operation, check condensate
line for a clog or crimping.
Resets automatically upon
fault correction, or call
1-800-KwiKool if the problem
persist.
High pressure is normally
caused by reduced
condenser air flow. In Cool
Mode check for restriction in
ducting. Check condenser
motors and/or blowers for
proper operation. In Heat
Mode be sure the service
door is closed, check the air
filter for blockage and be
sure that the return air flow
is unrestricted and the
supply air fan is operating.
High pressure is a manual
reset type. To reset, open
filter door. The button is
located above the filter.
Press button to reset (you
should feel a click).
Page 12
Fault Possible Cause Possible Solution
Unit Displays LP, Audio
alarm is sounding during
start up or while operating.
Unit Displays A1, Audio
alarm is sounding during
start up.
Audio alarm fails to clear on
start up or while operating,
unit displays FP.
System is ON and display is
showing ON but unit is not
supplying conditioned air.
Microprocessor board has
detected low pressure. This
alarm might cycle on and
off.
Phase Monitor (if equipped)
has detected incoming
power issue.
Microprocessor has
detected freezing on the
evaporator coil if the system
has a factory installed freeze
sensor. (Special order)
System is in time out (F or
C is flashing), set point is
satisfied below or above
room temperature in
selected mode or control is
adjusted out of operating
parameters or not in the
correct operational MODE.
Check air filter and replace
if dirty. Make sure nothing is
blocking the filter inlet.
Check for icing on coil.
Resets automatically when
fault condition is corrected.
Call 1-800-KwiKool if
condition continues.
Adjust Phase Monitor as
needed to match incoming
power.
Check for freezing on the
evaporator coil and turn the
system off to let it thaw out,
call 1-800-KwiKool if your
system is not equipped with
a freeze sensor. Auto resets
upon correction.
Wait 2 minutes, review
System Operations guide.
System is ON but the
microprocessor board
resets the time delay
(flashing F or C) when the
compressor attempts to
start.
Power is supplied but
control is blank
Microprocessor board
detects voltage drop below
operating parameters.
Low voltage circuit is not
engaged
Confirm the integrity of
your source power, check
for proper wire size and
length of power extension
cable. Be sure the circuit is
dedicated to only the
operation of your KwiKool.
Check source power
breaker and verify incoming
power to connector. Call
1-800-KwiKool for assistance.
Page 13
Fault Possible Cause Possible Solution
System trips breaker on
start up
System starts up and
operates in the chosen
mode but the condenser
discharge air exhaust fan
stops and starts in cool
mode or in heat mode the
supply air fan starts and
stops.
Display shows 32 and unit
will not turn on cooling.
Supply air flow is limited, and
or water is dripping from the
front of the system
Incoming power is incorrect,
breaker is undersized or
faulty, and/or extension
power cable is too long and
or undersized.
Normal operating condition
especially in low temperatures.
No connection of temperature sensor to Microprocessor. Temperature
Sensor malfunction.
Supply or return air is
blocked or restricted, and or
the evaporator coil is
freezing.
Verify the circuit and power
cable is within the systems
specifications, consult with
your electrician or call
1-800-KwiKool for
guidance.
No action required, see
sections IV C. 2 & 3
Note: To avoid excessive
fan cycling, return air must
not be below the specifications of your KwiKool
system.
Call 1-800-KwiKool for
instructions.
Verify that supply and
return air are not blocked
and duct work is installed
to specification, remove or
add duct as needed, check
air filter for blockage.
Condensate is not pumping. Water is below pumping
level, external line
restricted, line installed with
too high of lift.
Evaporator coil is freezing Low or restricted air flow.
Undersized capacity, unit
constantly on, unable to
achieve set point. Low
return air temperature out
of factory specifications.
Evaporator door open,
mechanical system
malfunction.
Reservoir fills, and then
pumps. Check for line
crimping or restrictions and
proper line run height. Refer
to the user guide Section 5:
Built in Safeguards.
Direct supply return air to
area of highest heat load,
check for blocked air flow
from the supply air, replace
air filters, adjust set point to
allow the unit to cycle, add
another KwiKool system or
larger capacity model, close
evaporator compartment
door. Install service gauges
to view pressures.
Call 1-800-KwiKool
Page 14
Fault Possible Cause
Chatter or hum is heard
from the control box while
the system is operating.
Incoming source power is
poor or low voltage component is faulty.
Possible Solution
Check for proper voltage
selection on 208/230 volt
units, remove excess or
undersized power cable, and
check incoming power.
Call 1-800-KwiKool.
99 Flashes on display Ambient room temperature
over 99 degrees F.
Temperature below 60
Flashes on display in Cool
Ambient room temperature
under 60 degrees F.
Mode.
Unit is working properly.
Lowering of room temperature will rectify the flashing.
Limits of unit have been
reached in cool mode.
Operating temperatures are
65 - 105 degrees F.
Page 15
Revision 1017016
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