KPO Indoor / Outdoor Portable Cooling Manual

Technical Manual

Section One

Application Requirements

Air Temperature Requirements Cool Mode
The condenser make up air vents which are located on both sides of the KPO units, have environmental requirements of 0°F to 110°F. If the unit is operating in an environment with a temperature greater than 110 °F the high pressure switch may trip. This would potentially stop the compressor or you may notice diminished performance. 

High Pressure Switch
The High Pressure Switch is a manual reset switch located in the front service compartment on both the KPO5 and KPO12.  The KPO25 is equipped with two reset switches, located in the return air compartment. You can reset the the pressure by locating the compressor discharge line and pressing the button on the switch.  When the switch has tripped, you will hear a distinct click. It is standard that KwiKool’s KPO models will not operate at temperatures below 60°F. Temperatures below 60°F will cause the evaporator coil to freeze.

Capacity & Temperature Settings
KPO size is based on how the heat load corresponds to capacity while maintaining a temperature 72°F. In order to reach temperatures below 72°F, the unit must have additional capacity. For this reason we recommend the operator avoid setting the temperature set point below 72°F. If you find that you have excess cooling capacity beyond your heat load, realize you are in risk of freezing the evaporator coil.

Positioning
Firstly, be sure the surface is able to support the weight of your KwiKool. Position your KwiKool on a level surface to ensure proper condensate water flow. Position the system as close to the heat generating equipment as possible. Make sure the return air duct is in the space with the highest heat load. Blocking the return air duct will cause low performance and potentially could freeze the evaporator coil.

Notes For Heat Mode
When activating your KwiKool KPO systems heat function, the compressor is NOT used. Therefore, there is no need to manage condensate water or condenser air discharge.

To ensure heat function works accurately, supply and return air must be in the same space being heated. The system is designed to heat and then recirculate air back to the system. When properly sized, this process raises overall temperature to the set point.

Fire rated or high temperature duct is NOT required. The heat rating for KPO systems is as follows; KPO25 is 48 KVA, KPO12 is 24 KVA and KPO5 is 12 KVA.

Section Two

Operational Safeguards

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.

d.)  To insure your KwiKool© system is stable, the floor on which the system is to be place should be level, free of vibration and strong enough to support the weight of your KwiKool© model. Lock casters to prevent unit movement.

e.)  Do not move the system while it is operating. Before moving the system, first turn to OFF then unplug the system from the power source. Then unlock casters.

f.)  Do not tilt or overturn your unit, since this could damage the compressor.

g.)  Do not place objects on top of your unit.

h.)  Do not insert your hand or any other object into the cold 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.

Section Three

Assembly

Attachments and Casters

Casters
Casters will need to be manually installed on both the KPO-5 and KPO-12 systems. Utilizing the built in fork pocket carefully lift the unit keeping it level. Using the bolts provided, connect the casters to the base on all four corners. Use all of the bolts and nuts included, and tighten well.

Flanges
Install flanges with fasteners that are included with the collars. Start 2 fasteners in the top 2 female inserts that are around each inlet or outlet on your KPO and then hang the collar on the 2 fasteners that are started in the insert, push the collar flush with the cabinet and then install and tighten the remaining fasteners, be sure the fasteners are tightened well, loose flanges will leak air and diminish performance.

Positioning Is Key
KPO is designed to be placed outside the conditioned space and ducted in. DO NOT place the KPO in the space that you are cooling. Before moving your KPO into place, preview the installation site. You will want to identify a few things before you settle on a spot and power up. 

Identify
1) The direction the cold air supply and return should face.

2) The direction you would like the hot air exhaust to face.

3) Where the condenser make up air will be coming from.

4) Where your power supply is located.

5) Where the condensate water be pumped out.

To ensure the condenser operates properly, plan for a minimum of five feet of open air space around the make-up air inlets.

Connect The Ducts

Air Supply Flex Duct
The KPO series requires duct to direct the cooling or heating into the conditioned space. This is done with 12” duct on KPO5 & KPO12 and 20” duct on KPO25. As you face the unit opposite to the control end, the air supply is on your right side on KPO12 and KPO5 models and on KPO25 systems the air supplies are located one 20” flange on each side of the system. Clamp supply ducting onto the flange(s), and route the duct to your desired location. The supply air works best directed to the inlets of your equipment or directly on the area to be conditioned.

Air Return Flex Duct
The KPO series come equipped with a high lift condensate pump, the connection is a ¼ inch outer diameter barbed fitting located on the left side as you face the control just below the handle on the 12 ton models. On 25 ton models the connection is located on the left side of the unit as you face the control recessed in the center column, and next to the power cable connection on 5 ton models. It is important to connect the condensate line prior to connecting the electrical power, as the condensate pump is live when the power is engaged. Collected water in the pump’s reservoir could be ejected when powered up.


Ducting Details

Air Supply Flex Duct
The KPO series requires duct to direct the cooling or heating into the conditioned space. This is done with 12” duct on KPO5 & KPO12 and 20” duct on KPO25. As you face the unit opposite to the control end, the air supply is on your right side on KPO12 and KPO5 models and on KPO25 systems the air supplies are located one 20” flange on each side of the system. Clamp supply ducting onto the flange(s), and route the duct to your desired location. The supply air works best directed to the inlets of your equipment or directly on the area to be conditioned.

Air Return Flex Duct
The KPO series come equipped with a high lift condensate pump, the connection is a ¼ inch outer diameter barbed fitting located on the left side as you face the control just below the handle on the 12 ton models. On 25 ton models the connection is located on the left side of the unit as you face the control recessed in the center column, and next to the power cable connection on 5 ton models. It is important to connect the condensate line prior to connecting the electrical power, as the condensate pump is live when the power is engaged. Collected water in the pump’s reservoir could be ejected when powered up.

Direction & Placement
KPO is at its best when the return air duct is focused towards the area of highest load. This placement allows the unit to return the load directly to the evaporator keeping it clear from the conditioned space. This is also done with 12” duct on KPO5 and KPO12 and 20” duct on KPO25. 

Identify The Return
Looking at the Kwikool KPO5 and KPO12, the return is opposite the control end. On KPO5 and KPO 12 you will find the return is on your left side. KPO25 has two 20” flanges in the center. Clamp return ducting onto the flanges, and route the duct to your desired location.


Avoid Freezing The Coil
Avoid freezing your units evaporator coil and keep your units operation at peak performance. Duct collapse can cause big problems. The return air duct is pulling in air and can collapse while operating, avoid this condition by pulling all of the slack out of the duct and anchoring it to a fixed object.


High Static Blowers
KPO models are built with high static blowers. Kwikool has specifically designed KPO models to meet certain standards which require that each inlet and outlet use a minimum of 25 feet of duct. KPO 12 and KPO 25 must use two ducts for a total of 100 feet of duct. KPO5 must have a total of 50 feet of ducting. For example if using a KPO12 you need 100 feet of duct. You can use 4-25’ pcs or 2-50’ pcs on any outlet. If you aren’t sure about your application, call us at 1-800-KWIKOOL.

 

Ducting Pitfalls

Evaporator Motor Failure
If you are planning to blow conditioned air without conditioning a space, you may not need to connect a return air duct.  However Kwikool recommends a minimum amount to operate. If you operate KPO without ducting, you will need to damper the return air by at least 50%. Without dampening the return air you will likely cause condensate water to leak. This in turn will diminish temperature difference and cause evaporator motor failure.

 

Hot Air Discharge In Cool Mode
Direct the hot air discharge away from your conditioned space and away from the condenser air intakes. This is especially important when the KPO is used in a confined space or indoor closed space.

Hot Air Discharge In Heat Mode
It is not necessary to connect hot air discharge duct if you are using the KPO in heat mode or outdoors and ducting cooling into a space. When used indoors or in a confined space in COOL mode, and the hot air exhaust is ducted out, the KPO must have a supply of makeup air for the condenser. The condenser make up air cannot be ducted in to the KPO, and has to come from the surrounding space.

Make sure you have adequate fresh air supply or the unit will shut down to protect the compressor from catastrophic failure.

Condensate Line

Condensate Line
The KPO series come equipped with a high lift condensate pump, the connection is a ¼ inch outer diameter barbed fitting located on the left side as you face the control just below the handle on the 12 ton models. On 25 ton models the connection is located on the left side of the unit as you face the control recessed in the center column, and next to the power cable connection on 5 ton models. It is important to connect the condensate line prior to connecting the electrical power, as the condensate pump is live when the power is engaged. Collected water in the pump’s reservoir could be ejected when powered up.

 

Condensate Water Outlet
The Condensate Water Outlet is located in the back of the unit in the cord compartment.  Look for the 1/4” OD barbed fitting. Push to connect the clear tube to the fitting.

The condensate float switch jack either connects to the condensate tank; or is bypassed by the factory installed male bypass switch, plug. You will find it next to the condensate water outlet.

Section Four

Power Connection

Verify the source power, phase and breaker size is compatible with the unit’s serial plate information, if you are not sure, contact a licensed electrician. The KPO 5 ton comes from the factory with 8 feet of power cable sized to fit the electrical specification of the units’ electrical requirement and has no male receptacle attached.

The KPO 12 & 25 ton comes without power cable and has 4 male cam lock connectors ready to receive the corresponding female cam locks. Female cam locks, or complete power cord line sets can be purchased separately with the proper cable size attached from the factory in various lengths.

Apply Electrical Power
When power is supplied to the unit, the controller will become operational. KPO12 and KPO25 users will have to place the units built in breaker to the on position to engage the controller.

All KPO systems are equipped with a power/ phase monitor, the control will display AL and PH with an audible alarm if the system is turned to ON before 30 seconds have elapsed from the time power is engaged , then clear when the microprocessor in the phase monitor “boots up”, this is a normal condition.

The most common reason the fault PH will not clear on initial startup in three phase systems is incorrect phase. This condition is easily corrected. If the Alarm and PH display fails to clear in 30 seconds, qualified personal may turn the source power off and exchange any of the 3 line voltage wires with the other. Do not swap the GREEN WIRE. Power the unit back up, wait for 30 seconds and then proceed to the next step.

If the fault fails to clear after changing the phase, turn the power off at the source, return the wires back to the original configuration and refer to the troubleshooting section of this manual.

Section Five

Kool Pad Controller

Setting The Controller

When you initially power up the system, you will discover the digital control pad of your KPO system is factory set to start cooling. Also, the manual fan will be engaged and set to start cooling above 72°F. The display will show the current room temperature and will automatically turn on within a 2 degree temperature differential. 

To operate the control press the ON/OFF icon. A short press on this button turns the system on or off and the systems operates in the last parameter that was entered in operating Mode. 

When set to cool, a 2.5 minute time delay will start, signified by °F or °C blinking on and off.  The temperature can be adjusted at any time with the up  or down arrow to achieve the desired temperature.  The system will revert to AUTO FAN in COOL mode. If you set the system to MANUAL FAN, the supply air fan reverts to COOL automatically. When the system is set to HEAT or FAN mode the supply air will remain active. The fan can operate in one of two settings: AUTO for fan operation when needed for cooling or heating, and FAN for continuous fan operation. 

Press ON, if the time delay is finished the word COOL blinks. After the system has built up enough pressure, the hot air exhaust fan will ramp up. It is normal for this fan to have a delayed start. Also, it’s normal for the fan to slowdown and speed up during the operating process. 

Heat Mode
Set the mode to HEAT. Adjust the set point using the or   to the desired temperature. Press ON and heating will begin. You will not have control of the supply fan in this mode. The heat function on KwiKool KPO systems will not require a time delay for compressor operation. In In HEAT mode, there is no need to manage condensate or discharge.

Heat Mode Technical
Access into these operations are described later in this manual, users, administrators and technical staff menus all have different features that allow access into settings and certain functions of the control based on information supplied by your engineers.

Notes For Heat Mode
When activating your KwiKool KPO systems heat function, the compressor is NOT used. Therefore, there is no need to manage condensate water or condenser air discharge.

To ensure heat function works accurately, supply and return air must be in the same space being heated. The system is designed to heat and then recirculate air back to the system. When properly sized, this process raises overall temperature to the set point.

Fire rated or high temperature duct is NOT required. The heat rating for KPO systems is as follows; KPO25 is 48 KVA, KPO12 is 24 KVA and KPO5 is 12 KVA.

Cycling Off
When the system reaches the desired, programmed set point in COOL or HEAT mode it will automatically begin cycling off or you may choose to turn it off. The system will delay before cooling again.

When cycling off by making the set point the evaporator fan stays on in heating .In cooling only if FAN is selected. Heating or cooling will began automatically when the temperature rises above or below the set point, depending on the chosen mode. Turning the system OFF manually will turn the evaporator fan off, impeding the KPO from restarting.  To restart, set the control to ON. The return air temperature will be either above or below the set point. In FAN mode the supply air fan only shuts down when OFF is selected.

Section Six

Specifications

KPO5

KPO5_a
KPO5_b
KPO5_c
KPO5_d

KPO12

kpo12_a
kpo12_b
kpo12_c

KPO25

kpo25_a
kpo25_b
kpo25_c

Section Seven

Maintenance

Air Filters
KwiKool units unbox with 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 can lower overall unit performance.

The air filter(s) are located in the supply air return; remove the return air panel by turning the slotted lock fastener to the horizontal position and lift up to remove the panel. Remove and replace the filters. 

Condenser Drive Belts
KPO12 and KPO25 systems only, your KwiKool moves air over the condenser coil to remove heat from the conditioned space by way of a motor that drives a blower wheel. This wheel turns by way of a pulley and belt system. Inspect/adjust these belts every 60 days of operation, replace as needed.

Failure to maintain the drive belts will cause low performance, high pressure trip or in extreme cases damage to the blower/motor in the event of a belt breaking. Located in the condenser access compartment on the control end of your KPO, release the 2 slotted fasteners to give you access to the condenser belts and motor. Note: Adjust the tension on the belts by adjusting the motor base. DO NOT ADJUST THE DRIVE PULLEY.

Service Ports
For both the KPO 5 Ton and KPO 12 Ton, while you are facing the control panel, service access door will be on the left.

For the KPO 25 Ton, you will find the service ports conveniently located in the return air compartment. This enables technicians with easy access to service gauges in order to monitor the operating pressures.

Sight Glass
Sight glass allows operators and qualified service technicians to easily see the condition of the refrigerant returning to the evaporator coil. A handy diagnostic tool, sight glass is conveniently located inside the condenser access compartment on the KPO’s control side.

Using Your Kwikool System

In contrast to conventional air conditioners, which circulate air conditioning capacity evenly to a space. KwiKool systems are generally used for cooling an area with a high concentration of heat load, many times from electrical or computer equipment.  Understanding the capabilities of your KwiKool can help you avoid problems. 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.  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.

Section Eight

Built In Safeguards

Power Safe Phase Monitor

The power/phase monitor is standard on all KwiKool KPO systems. The power monitor automatically shuts everything down and alerts operator in the event of low or high voltage, incorrect voltage, phasing or motor fault. PF will display as will a red fault light in the case of a shut down. When the issue is corrected, the system will reset automatically. The monitor is located in the electrical control Panel and displays the reason for activation. Clear the fault history by pressing and holding FAULT for three seconds. See the troubleshooting guide for adjustment details if your KwiKool phase monitor is alarming and displaying faults.

VFD-Variable Frequency Drive

Used on KPO systems to optimize the operation of the condenser fan by slowing down and speeding up the rotations of the blower. This helps to maintain the best pressure needed to operate in the current environment.  Your VFD is located in the return air compartment and displays the current operating frequency or any error message needed for fault diagnosis. The condenser motor VFD will not operate the condenser fan in heat or fan mode, as it is not needed for these modes.

Section Nine

Setting User Parameters

Parameters For Technicians

Setting For Your Technical Staff
Hold MODE until it beeps and flashes a lock icon, then FAN until it beeps. Release FAN then touch it again, it will beep and then display P04. To scroll use FAN and MODE. Use the UP and DOWN arrows to select 0 to unlock and 1 to lock. Select ON/OFF to exit, or after 1 minute the display defaults to the operating screen

PO4 – Lock Fan Button
Select 0 or 1  (O-Unlock, 1-Lock) 

PO5 – Lock Mode Button
Select 0 or 1  (O-Unlock, 1-Lock) 

PO6 – Lock On/Off Button
Select 0 or 1  (O-Unlock, 1-Lock) 

PO7 – Lock Plus/Minus Button
Select 0 or 1  (O-Unlock, 1-Lock) 

Parameters For Users

Setting User Settings
Start by going to SETTINGS. Use FAN and MODE to scroll. Select ON/OFF to exit or after 1 minute the display will defaults to the operating screen.

P30 – Beeper Enable
Select 0 or 1  (0 – Disable, 1 – Enable) 

P40 – Filter Counter
Hours 10 – 999  (Read Only)

P41 – Filter Counter Reset
Select 1 to Reset  (Defaults to 0) 

P42 – Filter Alarm Delay
Days, Select 0 or 180  (0 – Disable)

P100 – Enable Dimming
Select 0 or 1  (0 – Disable, 1 – Enable) 

P101 – Dimming Time
Min, Select 0 – 10  (Defaults to 5) 

P102 – Dimming Brightness
(%) 1, 5, 10 – 90 (Defaults to 10) 

P105 – Active State Brightness
(%) 50 – 100 (Defaults to 100)

Alarm Codes

A1 – Customer Installed Input – Optional

A2 – Customer Installed Input – Optional

CP – Condensate Fault Pump – Standard

LP – Low Freon Level Detected – Standard

HP – High Pressure Detected – Standard

FD – VFD Fault – Standard

PH – Incoming Power Fault – Standard

FL – Run Time For Filter Has Elapsed

FS – Freezing Is Detected – Optional

DC – Deicer In Cool – Optional

Section Ten

Troubleshooting

FAULT – Control displays PH and audible alarm fail to clear on startup, phase monitor displays lock out “Front Fault” red light

CAUSE – Phase monitor detects phasing issue or improper power incoming.

SOLUTION – Exchange any line voltage wire with the other, verify incoming power.

FAULT – Control displays PH and audible alarm fail to clear on startup, phase monitor displays, lock out “Front Fault” low volt red light

CAUSE – Phase monitor detects Voltage lower than factory setting.

SOLUTION – Exchange any line voltage wire with the other, verify incoming power.

FAULT – Control displays PH and audible alarm fail to clear on startup, phase monitor displays, lock out “Front Fault” high volt red light

CAUSE – Phase monitor detects voltage higher than factory setting.

SOLUTION – Verify incoming power, Slowly lower voltage on monitor to match incoming power.

FAULT – System sounds audible alarm, control displays CP, LP or HP.

CAUSE – A condition exists with the mechanical system involving pressure or condensate flow.

SOLUTION – See advanced troubleshooting, or call 1-800-KwiKool

FAULT – System starts up but is not operating in the selected mode

CAUSE – System is in time out; control is set above or below room temperature or control is adjusted out of operating parameters.

SOLUTION – Wait 3 minutes, review operations guide. Set up control

FAULT – Systems with phase monitor starts up but go into PH and audible alarm when the compressor starts.

CAUSE – Phase monitor detects voltage drop

SOLUTION –  Observe the phase monitor on start for fault lights and adjust accordingly, verify incoming power. If no fault light is present see advanced troubleshooting.

FAULT – Display reads LP

CAUSE – Mechanical system has detected low pressure.

SOLUTION – Install service gauges to view pressure readings below 20 psi. Check for icing on the evaporator coil or low return air temperature. Resets automatically upon correction.

FAULT – KPO control displays PH phase monitor displays lock out back fault

CAUSE – A fault has been detected from the load side of a component circut

SOLUTION – Inspect components for faulty or loose connections

FAULT – Chatter or hum is heard from the control box while unit is operating.

CAUSE – Chatter or hum is heard from the control box while unit is operating.

SOLUTION – This is not adjustable thru the phase monitor, check for proper voltage selection on 208/230 volt units, and correct incoming power. Isolate low voltage controls to find faulty component.

FAULT – Evaporator coil is freezing in cool mode.

CAUSE – Low or restricted air flow. Undersized capacity, unit constantly on, unable to achieve set point. Low return air temperature out of factory specifications. Service door open or off, mechanical system malfunction.

SOLUTION – Review duct engineering , direct return air to area of highest heat load, replace air filters , adjust set point to allow unit to cycle, add KwiKool system, close service compartment door, Install service gauges to view pressures.

FAULT – Control Displays A1 If equipped

CAUSE – Appears when Input from A1is engaged.

SOLUTION – Fault is detected from A1 input, confirm usage and call 1-800-KWIKOOL if input code is not used but appearing.

FAULT – Control Displays A2 If equipped

CAUSE – Appears when Input from A2 is engaged.

SOLUTION – Fault is detected from A2 input, confirm usage and call 1-800-KWIKOOL if input code is not used but appearing.

FAULT – Control Displays FD If equipped

CAUSE – Appears when Input from FD is engaged. This occurs when the Condenser VFD has a fault.

SOLUTION – Check VFD and all condenser fan and motor components including belts and pulleys

FAULT – Control displays FIL If operation is engaged on control

CAUSE – Appears when the time set for filter change has elapsed.

SOLUTION – Check condition of air filters, replace as needed. Reset time for filter change. Found in technical settings

FAULT – Control displays FS If equipped

CAUSE – Appears if the evaporator coil is below 28 degrees F.

SOLUTION – System must be cycled off to thaw coil, switch to fan mode for 10 minutes and cycle back on.

FAULT – Hot air exhaust fan (condenser fan) stops and the High Pressure Switch trips while the compressor is operating.

CAUSE – Condenser drive has detected a fault with the incoming electrical power or is not receiving an operating signal.

SOLUTION – Check condenser motor drive (VFD) for trip, reset if needed. Note displayed fault code on the drive and call 1-800 KwiKool if problem persist.