Kooltronic Hazardous Location HL 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
900-039-84 (2/20)
(CDR: 20204)
HAZARDOUS LOCATION SERIES
K3A4C18HL58LV
480 VOLT 3-PHASE
U.S. Pat. No. 9,157,670 B2
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. Warnings 5
VI. Principles of Operation 6 - 9
VII. Pre-Installation Testing 10
VIII. Customer Enclosure Requirements 10 - 11
IX. Specific Model Data 12 - 15
Mounting
Drawings and Dimensions
Technical Data
Major Component Replacements
Standard Features
X. Maintenance 16 - 17
XI. Trouble Shooting 17 - 18
XII. Warranty 19
NOTE: Wiring Schematics are available on the specific model page of the Kooltronic website.
I. Introduction
Kooltronic Hazardous Location Air Conditioners (HL Series) are designed to provide a cool, dehumidified
environment for your electronic components. 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. Mounting instructions and technical data are presented on pages
12 through 15.
2

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 Hazardous Location Air Conditioner until you read and thoroughly
understand this Manual. See section VII PRE-INSTALLATION TESTING.
2) Before operating the Kooltronic Hazardous Location 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.
3
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 Nameplate
Each Kooltronic Air Conditioner includes an identification nameplate. This nameplate provides:
qModel Number
wSerial Number
eCooling capacity
rHeating capacity (Optional)
tElectrical power characteristics
yType and amount of refrigerant required for recharging
uDesign Pressure
iMaximum and minimum ambient operating temperatures
oManufacturing Order Number
aFilter Part Number
sUnderwriters 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.
tBefore operating, be sure that the power source matches these requirements.
yUse of incorrect type or amount of refrigerant will adversely affect performance and may damage the unit.
i Make sure that these parameters are met. Failure to do so may result in permanent damage to the unit.
SERVICE AIR FILTER REGULARLY
UL RECOGNIZED AND CSA CERTIFIED FOR USE WITH CLASS I, DIVISION 1, GROUPS
A, B, C AND D HAZARDOUS LOCATIONS, TYPE X PURGE AND CLASS I, DIVISION 2, GROUP
A, B, C AND D, TYPE Z PURGE ENCLOSURES WHEN INSTALLED ON AN APPROVED
PRESSURIZED ENCLOSURE AND CONNECTED TO PURGE/PRESSURIZATION
CONTROL SYSTEM PER NFPA496
AIR LEAKAGE @ 0.5 I.W.G. PRESSURE CFM - 0.36
INTERNAL PRESSURIZED VOLUME CU. FT. - 7.7
ALL MOTORS ARE THERMALLY PROTECTED
UNAUTHORIZED SERVICE OR MODIFICATION VIOLATES WARRANTY
NEMA/EEMAC/UL50 BY UNDERWRITERS LABORATORIES, INC. TYPE 1
SPECIAL PURPOSE AIR CONDITIONER EQUIPMENT COMPARTMENT ONLY
TYPE 3R, 12 & 4/4X INTERFACE TO THE ELECTRICAL ENCLOSURE ONLY
NEMA/EEMAC/UL50 BY UNDERWRITERS LABORATORIES, INC.
SPECIAL PURPOSE AIR CONDITIONER
OUTDOOR USE ALLOW 5 MINUTES BEFORE RESTARTING AFTER SHUTDOWN
Air Conditioner
KOOLTRONIC, INC. PENNINGTON, NJ
MANUFACTURED BY:
Heating BTU/H:
Cooling BTU/H:
Max:
Ambient Temperature: Min:
P.S.I.G.
P.S.I.G.
Design Pressure, Low Side:
Design Pressure, High Side:
Oz. Factory ChargeRefrigerant:
Max. Fuse Size / HACR Type Circuit Breaker:
Min. Circuit Ampacity:
Watts:Amps:VoltsElectric Heater:
R.L.A.:L.R.A.:VoltsCompressor:
Amps:Hp:VoltsCondenser Fan Motor:
Amps:Hp:VoltsEvaporator Fan Motor:
Hertz:Phase:Volts
Mfg. Order No.:
Rated Voltage:
Serial No.Model No.
Filter P/N:
LISTED 84H7
SPECIAL PURPOSE
AIR CONDITIONER
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5
V. Warnings
WARNING - PRESSURIZED ENCLOSURE
Kooltronic Air Conditioner K3A4C18HL58LV must be properly installed on a pressurized enclosure
and connected to the pressurized enclosure Purge/Pressurized Control System before operating.
WARNING - PRESSURIZED ENCLOSURE
This Air Conditioner must not be opened unless the area atmosphere is known to be below the
ignitable concentration of combustible materials or unless all devices within have been
de-energized.
WARNING - HIGH TEMPERATURE INTERNAL PARTS
This Air Conditioner must not be opened unless the area atmosphere is known to be below the
ignitable concentration of combustible materials or unless all devices within have been
de-energized for at least thirty (30) minutes.
WARNING FOR CLASS I ENCLOSURE
After the Air Conditioner has been opened, power must not be restored until the Air Conditioner
has been purged for the length of time required for the enclosure upon which the Air Conditioner
is installed.

6
VI. Principles of Operation
Kooltronic HL Series Air Conditioners are designed for Class I, Division 1 and Division 2 applications. They are used only
when installed on pressurized customer enclosures and connected to a pressurized enclosure Purge/Pressurized
Control System.
When Kooltronic HL Series Air Conditioners are installed on Class I customer enclosures, before operating they must
be purged simultaneously with the pressurized customer enclosure according to the purge protocol for that pressurized
enclosure.
The Purge/Pressurized Control System has to be selected by first taking into account the Kooltronic HL Series Air
Conditioner volume and air leakage (these parameters are specified in the Technical Data on page 15), in addition to the
volume and air leakage of the pressurized customer enclosure. The Kooltronic HL Series Air Conditioner and the
pressurized customer enclosure must be connected to the Purge/Pressurized Control System by gas (air) lines in
parallel.
The Kooltronic HL Series Air Conditioner must be powered from the pressurized customer enclosure power supply, and
the customer enclosure must be controlled by the Purge/Pressurized Control System.
All electrical and electronic components in the Kooltronic HL Series Air Conditioner are located in the pressurized
evaporator enclosure.
Mechanical components, including the condenser blower housing and wheel, are made of aluminum, and are installed
in the condenser compartment, exposed to ambient air. The condenser blower motor shaft extends from the evaporator
compartment to the condenser compartment, and is sealed by a set of PTFE V-rings.
If condensate occurs in the Kooltronic HL Series Air Conditioner it will be removed through a drain line. In order to prevent
pressurized gas (air) loss, the condensate drain system utilizes a floating type gate valve.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
012345
CFM
i.w.g
K3A4C18HL58LV AIR LEAKAGE

Principles of Operation (con’t)
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.
This unit is equipped with a Low Temperature Thermostat to prevent the evaporator coil from freezing. In conditions of low
ambient temperature and low enclosure load, the thermostat regulates the return air temperature from 75°F to 86°F.
Temperature on the thermostat display is 5°F higher than the return temperature from the enclosure. The low
temperature thermostat set point is 75°F. The set point can be adjusted. Consult with Kooltronic if the set point
needs to be adjusted below 80°F.
The optional heater 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 heater limiter features a manual reset. This unit is
equipped with a Temperature Alarm, which has normally-closed and normally open contacts, and a set point of 115°F. This unit
is equipped with a high pressure switch. When abnormal conditions are detected, the switch shuts off the compressor. 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.
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.
PROGRAMMABLE
THERMOSTAT
CONDENSER
AIR OUT
CONDENSER
AIR IN
RETURN
AIR IN
SUPPLY
AIR OUT
7
HL58LV
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.
FRONT PANEL COMMANDS

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 80°.
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).
8
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.:
9
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

VII. Pre-Installation Testing
Before mounting the air conditioner to the enclosure, test for proper operation to verify the shipping integrity of
the system. Pre-installation testing must be done in a non-hazardous location.
CAUTION
1. The unit must sit in an upright position at a minimum room temperature of 65°F to allow the system to
warm-up. This is particularly important during winter months.
2. Refer to the nameplate for proper electrical voltage and current requirements. Connect the power cord
to a properly grounded and fused electrical supply, leaving electrical power to the unit turned off.
3. Turn the electrical power on by turning the switch on the front panel to ON.
4. Observe the temperature on the digital display. The thermostat must be set a minimum of 5°F below this
temperature for the compressor to operate (the factory setting is 75°F). To adjust the thermostat, push
the SET button for two (2) seconds, then use the arrows to set the temperature. To store the new set
point value push the SET key again, or wait ten (10) seconds.
5. Verify that the evaporator blower or fan is running.
6. After one (1) minute the condenser blower and compressor should start.
7. Verify that the condenser blower is running.
8. 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°F and 80°F.
9. Reset the thermostat to the factory setting (75°F).
10. Turn off the electrical power and disconnect the air conditioner from the power source.
NOTE: Before shipment all Kooltronic Air Conditioners are subjected to a performance test.
CAUTION
VIII. Customer Enclosure Requirements
1. The internal air conditioner pressurized volume is 7.7 cu. ft. as shown on the air conditioner nameplate.
This volume must be added to the customer enclosure volume for proper selection of the
Purge/Pressurized Control System.
Air conditioner air leakage is 0.36 CFM at pressure 0.5 i.w.g. For other pressures see the table in
“Principles of Operation on page 6. This air leakage should also be taken into account for proper
selection of the Purge/Pressurized Control System.
2. The air conditioner must be connected to the main enclosure’s (panel’s) power, which must be de-energized
upon loss of pressure by the enclosure Purge/Pressurized Control System.
10
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.
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 15.