BEPNESA COCA COLA

G003315 380 GPM

MECHANICAL DATA

OEM literature Index

MANUFACTURER COMPONENT
TRAIC WE-500 SERIES ELECTRIC ACTUATOR
ASAHI QUARTER MASTER SERIES 94 ACTUATOR
SVF E SERIES ELECTRIC ACTUATOR
KOOLTRONIC KXHE122A OPERATOR'S MANUAL
FILTREK EF LOW FLOW MODELS IOM
ITT FILTER CARTRIDGE
 Division of A-T Controls Inc. INSTALLATION & MAINTENANCE MANUAL
11363 Deerfield Road
Cincinnati, Ohio 45242 WE-500 Series Electric Actuator
(513) 247-5465 Fax (513) 247-5462 On / Off Control

Installation Instructions
Introduction
The WE-500 Series electric actuator is a rotary 3. Mount Triac actuator to valve with Triac
valve actuator with outputs of 500 in-lbs. It has provided mounting hardware to ensure
been designed for NEMA 4, 4X and can come proper alignment. (Note: Some valves
with an optional 4-20mA card for modulating have manual stops; remove if appropiate
service. or set actuator to operate within those
Storage travel stops.
1. Keep conduit entries plugged. 4. Care should be taken to align valve stem
2. Store in a dry enviroment. properly and Triac actuator output shaft.
(Note: Misalignment will cause premature
3. Periodically cycle the actuator if possible. failure of assembly)
Maintenance 5. Connect power to terminal strip according
WE-500 Series actuators contain a to schematic diagram. The actuator
permanently lubricated precision cut, heat should be wired and grounded in
treated gear train for long, reliable cycle life. accordance with local and National
There is no need to change gear train Electrical Codes.
grease. 6. Before replacing cover, actuate valve and
Permanent split capacitor gearmotors have check to see if it opens and closes to
been equipped with thermal protectors. To preferred positions. If valve does not
guard the motor against overheating, the perform correctly, adjust cams to set
thermal protector opens the circuit to the actuator travel properly.
motor and maintains this state until the 7. Drive actuator to desired open position.
temperature of the motor drops to a The cams are adjusted by simply losening
satisfactory level. the set screw and rotating cam to desired
Installation position. When open position is set,
1. This section of the instruction sheet tighten the set screw to maintain position.
applies to the on-off units. For 8. To adjust closed position, repeat step 7
instructions on modulating units, please with actuator in desired closed position.
see IOM5004 (TMC2) 9. Operate the unit several times and
2. Manually open and close valve to ensure recheck position.
freeness of operation. Make sure valve
and Triac actuator rotate in the same
direction and are in the same position Note: Make sure the limit switches
(i.e. valve closed, actuator closed). If not stop the actuator, not the mechanical
sure, electrically operate the actuator to stops.
determine its operating range. The Triac
electric actuators are factory set for 90
degree operation.

012805-a /documents/iom/iom8010.p65
 Division of A-T Controls Inc. INSTALLATION & MAINTENANCE MANUAL
11363 Deerfield Road
Cincinnati, Ohio 45242 WE-500 Series Electric Actuator
(513) 247-5465 Fax (513) 247-5462 On / Off Control

Manual Override Operation

Problem:
1. Manual override can be operated only • The actuator performs erratically.
when motor is de-energized Solution:
Handwheel will turn as actuator operates. • Check the ambient temperature rating.
2. No mechanical stops are available to The permanet split capacitor units are
stop the actuator at the full open and equipped with thermal cut-outs.
closed position during manual operation. Excessive temperatures and cycle
5. Reconnect the electric to actuator for frequencies may heat the motor up and
automatic operation. the thermal cut-out turns off the motor.
6. The manual override handwheel will turn Wiring Diagrams
during operation.
• Caution: Electric operation of each
actuator must be through an individual
single pole control switch, in order to
isolate the unused motor winding.
• Wiring diagrams show internal wiring
Trouble Shooting Guide connections and customer connections
• For additional voltages & control options
Problem: please consult factory.
• There is power to the unit, but it does not
repond.
Solution:
• Check the nameplate to see that the
correct voltage has been applied.
• Check the wiring to see that it is per the
wiring schematic.
• Check the limit switches to see if they are
in the normal operating position.

Problem:
• Power is getting to the motor, but it merely
hums.
Solution:
• Check to see that the proper voltage is
applied.
• Make sure all the connections are tight.
• Check to see that CW and CCW power
connections are not powered at the same
time.
• Make sure the limit switches stop the
actuator, not the mechanical stops.

012805-a /documents/iom/iom8010.p65
 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Quarter Master
Series 94 Actuator

Installation, Operation
and
Maintenance Manual

Assembly Series 94 Manual Rev R April 1, 2006 Page 1 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Table of Contents
Series 94 Electric Actuator Introduction ......................................... 3
Description ...................................................................................................... 3
Electrical Requirement .................................................................................... 3
Installation ..................................................................................................... 4
Electrical.......................................................................................................... 4
Type 21 Ball Valve .......................................................................................... 4
Type 23 Ball Valve (3-way).............................................................................. 5
Type 57 / 57L Butterfly Valves......................................................................... 5
Actuator Mounting Dimensions........................................................................ 6
Operation ....................................................................................................... 7
Manual Override Operation ............................................................................. 7
Setting Limit Switches ..................................................................................... 7
Options............................................................................................................ 8
Single Limit Switch....................................................................................... 8
Double Limit Switch ..................................................................................... 8
Heater and Thermostat................................................................................ 9
Mechanical Brake ........................................................................................ 9
Feedback Potentiometer.............................................................................. 9
Series 94 Options Codes for Serial # Tags................................................ 10
Troubleshooting ........................................................................................ 10
Maintenance .............................................................................................. 12
Spare Parts ................................................................................................... 12

Assembly Series 94 Manual Rev R April 1, 2006 Page 2 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Series 94 Electric Actuator Introduction

Description
The Series 94 electric actuators feature a reversing,capacitor run motor, with a
permanently lubricated gear train. These actuators are equipped with integral
thermal overload protection (AC models) with automatic reset, independently
adjustable limit switches, declutchable manual override, position indicator, Zytel
FR50 housing with stainless steel trim, ISO bolt circle, and 2 (two) ½” NPT
conduit entries.

Standard models are offered in 115 VAC, feature an enclosure of Nema-4X, and
provide up to 300 in/lbs of output torque.

Various options are available such as operating voltages, additional limit

switches, heater and thermostat, feedback potentiometers, etc.
Please see page 8 regarding these options.

Electrical Requirement
CAUTION: Proper voltage must be supplied to actuator or damage will result.

CAUTION: If 115vac & 220vac models are PLC driven, output contacts of PLC
should be rated at a minimum of 1.5 times required input voltage of actuator

NOTE: To conform to various electrical codes, a green grounding screw has

been installed (on the baseplate) inside of actuator.

Terminal strip is suitable for up to #14 AWG wire, and should be wired as per the
attached diagrams or the wiring diagram affixed inside of actuator cover.

115 Vac 230 Vac 12 Vdc 24 Vdc 12 Vac 24 Vac Cycle

Time per Weight
Torque Amp Duty Amp Duty Amp Duty Amp Duty Amp Duty Amp Duty 90 (lbs)
Model Degrees
(in/lbs) Draw Cycle Draw Cycle Draw Cycle Draw Cycle Draw Cycle Draw Cycle
(Seconds)
A94 150 0.5 100% 0.4 100% 2.0 75% 4.0 75% 2.0 75% 4.0 75% 5 3.5
B94 300 0.8 75% 0.6 75% 2.0 75% 4.0 75% 2.0 75% 4.0 75% 5 3.5
Note: Amp rating is considered locked rotor
Duty cycles are for ambient temperature (73º F)

Assembly Series 94 Manual Rev R April 1, 2006 Page 3 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Installation
Electrical
Reference Drawing #279QM

1. To gain access to terminal strip (Part #8 & 9) it is necessary to remove

manual override handle (Part #34) by loosening slotted setscrew (Part #35).
Remove 8 cover screws and cover.

2. Make electrical connections to terminal strip as shown on wiring schematic

located inside the cover (per various electrical codes there is a green screw
on the actuator base plate for grounding purposes). Terminals are suitable for
up to #14 AWG wire. All units are completely calibrated prior to shipment,
and no internal adjustments should be required.

3. Install 1/2" NPT conduit fitting(s) to actuator base.

Note: Proper conduit fitting must be used to maintain NEMA 4X enclosure rating

NOTE: We recommend sealing conduit openings on units installed outdoors or

exposed to large temperature swings (15ºF or more).
We also recommend the heater and thermostat option in these applications.

4. Replace actuator (gasket if removed) cover, and install 8 cap screws supplied
and tighten securely. For outdoor or wet locations it is recommended prior to
replacing the cover that the top shaft seal be cleaned and coated with silicone
grease. Also clean shaft and lightly coat seal area of shaft with silicone
grease. Unit is now ready for operation.

Type 21 Ball Valve

Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position
Type 21 Ball Valves (See Drawing #0106BV sizes ½” – 2”)
Install mounting bracket #3 to actuator #2 using bolts #8 and washers #9. Insert
coupling #4 on stem of valve #1 and then bolt valve #1 to mounting bracket #3
using bolts #5, nuts #7, and washers #6.
Note: All bolts should be snug and not excessively over tightened.

Type 21 Ball Valves (See Drawing #0112BV sizes 2-1/2” - 3")

Install mounting bracket #3 to actuator #2 using bolts #8 and washers #9. Insert
coupling #4 on stem of valve #1 and then bolt valve #1 to mounting bracket #3
using bolts #5, nuts #7, and washers #6.

Note: All bolts should be snug and not excessively over tightened.

Assembly Series 94 Manual Rev R April 1, 2006 Page 4 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Type 23 Ball Valve (3-way)

Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position

Type 23 Ball Valves (3-way): (See Drawing #0129BV, sizes ½” - 3”)

Install mounting bracket #3 to actuator #2 using bolts #8 and washers
#9. Insert coupling #4 on stem of valve #1 and then bolt valve #1 to
mounting bracket #3 using bolts #5, nuts #7, and washers #6.

Type 57 / 57L Butterfly Valves

CAUTION: If valve is in line, system must be shut down and have no line
pressure before removing throttle plate and retaining washer.

Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position

Butterfly Valves (See Drawing # 0203BF57 sizes 1-1/2” - 4”)

No specially machined stem or valve body drilling required. Remove handle
(remove handle cap and hex head bolt) to expose throttle plate screws. Remove
throttle plate and retaining washer to expose existing bolt pattern.
Mount bracket #3 to actuator #2 with bolts #8 and washers #9 and tighten evenly.
Insert coupling #4 into actuator #2.Install valve #1 onto mounting bracket #3 and
align stem of valve to engage with coupling. (Line scribed on top of stem
indicates disc orientation). Install bolts #5, washers #6 and nuts #7 and tighten
evenly.

CAUTION: If mounted unit is installed other than straight up, the actuator should
be supported independently to prevent side loading and loosening up of
fasteners.

Assembly Series 94 Manual Rev R April 1, 2006 Page 5 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Actuator Mounting Dimensions

Assembly Series 94 Manual Rev R April 1, 2006 Page 6 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Operation
Manual Override Operation
Reference Drawing #279QM

Push down on handle (Part #34) and rotate within labeled limits.
To re-engage simply rotate actuator handle in opposite direction until it moves up
and re-engages.

CAUTION: The manual override should only be used when there is no power
applied to actuator. When power is restored the actuator will automatically
resume normal operation.

Setting Limit Switches

Reference Drawing #279QM

Disconnect power!

Open Travel Limit Switch (SW-2 Part #14):

Using declutchable manual override, move the valve into a full open position.
Then loosen set screws on top cam (Part #21) and rotate cam (CCW) into limit
switch arm until a click is heard, this designates the switch circuit has opened
and defines a full open position. Tighten 2 set screws (Part #22) on cam.

Close Travel Limit Switch (SW-1 Part #14):

Using declutchable manual override, move the valve to a full closed position,
loosen set screws on bottom cam (Part #21) and rotate cam (CW) into limit
switch arm until a click is heard, this designates the switch circuit has opened
and defines a full closed position. Tighten 2 set screws (Part #22) on cam.

Manually position valve to midstroke. Reapply power to actuator and drive to

open or closed position. Actuator motor will run. The shaft will not turn until drive
pins (Part #7) reseat in drive gear. This could take up to 25 seconds.

Assembly Series 94 Manual Rev R April 1, 2006 Page 7 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Options

Models A94 & B94

Single Limit Switch

Install additional limit switch directly on top of standard limit switches using
screws provided.

Wiring for SW-3 is as follows:

Pink = Common to Terminal #6

Purple = NC to Terminal #7
Blue = NO to Terminal #8
Cam must be set so that this switch is tripped just ahead of Closed limit switch.
Wire tie loose wiring and check operation before installing cover.

Double Limit Switch

Installation and wiring is the same as for the single limit switch, with the addition
of wiring for SW-4 as follows:

Brown = Common to Terminal #9

Green = NC to Terminal #10
Orange = NO to Terminal #11
Cam must be set so that this switch is tripped just ahead of Open limit switch.
Wire tie loose wiring and check operation before installing cover.

Assembly Series 94 Manual Rev R April 1, 2006 Page 8 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Heater and Thermostat

Install Heater into threaded hole located on actuator base plate.

Wiring is as follows:
Heater lead = Terminal #12
Thermostat lead = Terminal #13
Wire tie loose wiring and check operation before installing cover.

Mechanical Brake
Loosen two (2) motor screws diagonally from each other and install bracket with
tabs facing upward. Tighten screws

Install hexagonal adapter over armature shaft and tighten set screws.
NOTE: The adapter should be resting on the step of the armature shaft.

Install brake assembly onto hexagonal adapter making sure that the brake
assembly is sitting flush on the bracket. Tighten with supplied screws.

Remove motor leads “A” & “B” from capacitor and install “piggy back connectors
to capacitor, the re-install motor leads to their original locations.

Connect brake leads to piggy back connectors on capacitor (orientation does not
matter)

Wire tie loose wiring and check operation before installing cover.

Feedback Potentiometer
Install drive gear face up over output shaft.

Install potentiometer and bracket on to base plate with potentiometer gear facing
output shaft.

Wiring for potentiometer as follows:

#1 on potentiometer (white w/black stripe) #16 on terminal strip.
#2 on potentiometer (grey) #15 on terminal strip.
#3 on potentiometer (brown w/white stripe) #14 on terminal strip.

Using multimeter set at 2k ohms, calibrate potentiometer with leads from meter
connected to terminals #15 and #16. With actuator in closed position multimeter
should read between 95 and 100 ohms.

Rotate actuator 90 degrees (open position).

Connect leads from multimeter to terminal #14 and #15; multimeter should read
95 to 100 ohms.If necessary adjust open limit switch cam so that multimeter will
read 95-100 ohms.

Assembly Series 94 Manual Rev R April 1, 2006 Page 9 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Series 94 Options Codes for Serial # Tags

M1 1 extra limit switch

M2 2 extra limit switches
HT Heater & thermostat
P Feedback potentiometer
DP Dual feedback potentiometers
C1 4-20 mA Positioner
M Mechanical brake
CO Center off
CLC Cycle length control
2WC 2-wire control
FS Failsafe Battery Pak
C3 4-20mA Output Transducer
A4 4-12mA Input Signal Positioner
B12 Split Range Positioner

Example 1: A94HTPWJ

Heater & thermostat and feedback potentiometer installed.

Example 2: AM94M1WJ

Mechanical brake and 1 extra limit switch installed.

Troubleshooting
Q: What if there is no output, but the motor runs?
A: Manual override possibly engaged.
When the manual override is engaged, the motor will run, but no output will be
observed until the manual override re-engages with the output shaft.
A: Valve stem broken. When the valve stem is broken, there will not be a change
in fluid movement, making it seem as if the actuator has no output.

Q: What if valve does not cycle?

A: No power source to actuator. Check for power.
A: Power source disconnected. Check for broken wire, loose connection or no
connection as per appropriate wiring diagram.
A: Low or wrong power source. Check for proper voltage.
A: Mechanical Brake jammed or misaligned. Check alignment of brake
assembly.
This could occur during installation when someone would rest their hand on the
Mechanical Brake to steady themselves.

Assembly Series 94 Manual Rev R April 1, 2006 Page 10 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Q: What if there is water and/or moisture inside of the unit?

A: Conduit fitting installed improperly. Re-install correctly.
A: Cover and/or base seal damaged. Replace damaged seal(s).
A: Base gasket damaged or installed improperly. Check gasket and replace if
necessary.
A: Temperature swings of more than 15 degrees F. Install heater and thermostat
to eliminate condensation.
When these temperature swings occur, the unit will “sweat” on the inside causing
internal corrosion unless the actuator is equipped with a heater and thermostat to
keep a constant temperature inside of the housing.
A: Unit has been submerged. Raise unit above liquid level.
An actuator that is to be submerged MUST meet NEMA 6 for the proper
protection of the actuator and the elimination of a potential hazard. We do not
recommend submerging the Series 94 Actuator as the electrical rating does not
meet NEMA 6.

Q: What if unit is oscillating?

A: Valve torque exceeds output torque of actuator. Check for chemical
compatibility of valve, and flange torque.

Q: What if thermal overload frequently cuts out motor?

A: Frequency of operation exceeds duty cycle rating. Check cycling period.
A: Unit is oscillating. Refer to above.

Q: What if motor hums and no output is observed?

A: Foreign material caught in valve. Remove material and inspect valve for
damaged and/or worn parts. Replace parts as necessary.
A: Unit wired incorrectly (simultaneously powering open and closed). Check
wiring as per appropriate wiring diagram.
A: Capacitor worn. Replace.

Q: What if actuator “over-shoots” limit switches without stopping?

A: Actuator wired in parallel to each other. Please note that each actuator
requires it’s own set of switch contacts.

Assembly Series 94 Manual Rev R April 1, 2006 Page 11 of 12

 ASAHI/AMERICA, INC 35 GREEN STREET MALDEN, MA. 02148 TELEPHONE 800-343-3618

Maintenance
Disconnect power!

NEVER REMOVE ACTUATOR COVER WHILE CIRCUITS ARE LIVE!

CAUTION: It is imperative for reducing the chance of electrical shock, and to

prevent ignition of hazardous atmospheres that you
Disconnect power
before any maintenance or repairs are performed.

Series 94 actuators are virtually maintenance free. We do however, recommend

that periodic checks are made to ensure that all fasteners are tight and properly
torqued to extend the life of the actuator and valve.

Series 94 Actuators are manufactured with factory lubricated grease in the gear
case and gearbox. This lubricant should never have to be replenished.

For outdoor or wet locations keep top and bottom seals coated with a silicone
based grease.

Spare Parts
Reference Drawing #279QM

We recommend that the following be kept on hand as spare parts.

1 --- Limit Switch (Part #14)
1 --- Capacitor (Part #13)

NOTE: When ordering replacement motor parts and/or options specify model #
and voltage.

Attachments:
8 drawings: 296S92, 295S92, 297S92, 0106BV, 0112BV,
0129BV, 0203BF57, 279QM

Assembly Series 94 Manual Rev R April 1, 2006 Page 12 of 12

FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
FOR REFERENCE ONLY
ASAHI/AMERICA
 Keep This Manual
With Heat Exchanger

KXHE120A
KXHE120B
KXHE122A
AIR-TO-AIR
HEAT EXCHANGERS

OPERATOR'S MANUAL

CAUTION KOOLTRONIC, INC.

BEFORE INSTALLING AND 30 Pennington-Hopewell Road
USING THIS AIR CONDITIONER, Pennington, NJ 08534
IT IS IMPORTANT THAT THIS 609 • 466-3400
MANUAL BE READ AND FAX: 609 • 466-1114
UNDERSTOOD THOROUGHLY
www.kooltronic.com

900-041-03
 TABLE OF CONTENTS
Page
I. Introduction 2
II. Incoming Inspection 3
III. Product Handling 3
IV. Product Identification Label 3
V. Principles of Operation 4
VI. Specific Model Data 4-6
Mounting
Drawings and Dimensions
Technical Data
Major Component Replacements
VII. Maintenance 7
VIII. Packing Procedure 7
IX. Warranty 8

I. Introduction
Kooltronic Heat Exchangers are designed to provide a cool environment for your
electronic or electrical components. There are models to fit virtually all sizes and
shapes of electrical or electronic enclosures. 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 Kooltronic Heat Exchangers. Unit specific technical data and mounting
instructions are presented later in the Manual.

2
II. Incoming Inspection
Kooltronic Heat Exchangers 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 any carton handling instructions, falling off conveyors, excessive vibration, crushing, etc.
Therefore, a thorough inspection should be done upon receipt of all shipments. Any carton tears,
dents, scratches, or loose articles should be noted on the Freight Bill. Cartons should be opened
promptly and the units inspected for CONCEALED DAMAGE.
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

■
Do not attempt to operate your Kooltronic Heat Exchanger until you read and thoroughly
understand this Manual.
■
Before operating this unit, all electrical wiring must be checked to assure the proper connections.

CAUTION
Operate this unit only on the proper voltages and frequencies as noted on the nameplate.

IV. Product Identification Label

Each Kooltronic Heat Exchanger includes an identification label. This label provides:

➀ Model Number
Heat Exchanger ➁ Serial Number
➂ Electrical power characteristics
➃ Maximum ambient operating temperature
MODEL NO. SERIAL NO.
➀ ➁ We recommend you copy this information from
MAX. CABINET
VOLTS. FREQ. PH. AMPS TEMP. oF your unit.
➂ ➂ ➂ ➂ ➃
➀➁ When ordering parts, specify

MAX.
the Model Number and Serial
FUSE SIZE Number.
➂
➂ Before operating, be sure that
the power source matches these
requirements.

UNAUTHORIZED SERVICE OR MODIFICATION VIOLATES WARRANTY ➃ Make sure that these parameters
ALL MOTORS ARE THERMALLY PROTECTED
are met. Failure to do so may result
THIS PRODUCT IS PROTECTED BY ONE OR MORE OF THE FOLLOWING in permanent damage to the unit
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

3
V. Principles of Operation
If ambient air cannot be utilized directly as a cooling medium, another cost-effective
method of cooling is a Water-to-Air system (below). Water is used to remove heat from
the air circulated within the electronics enclosure.
Cooling water is circulated through a tube-and-fin coil. As the heat-laden air circulates
through the coil, the heat is absorbed by the water and carried away, in a continuous
process.

WATER-TO-AIR
Blower

Heated Air
Water
with
Heat Load

Cold
Water

Cooled Air

Heat
Exchanger

Cabinet

A Water-to-Air Heat Exchanger works by transferring heat of internal

air to circulating water, resulting in chilled air which is recirculated
throughout the electronics or electrical cabinet.

Water-to-Air systems are easy to install and usually require minimum maintenance.
The water used must be reasonably clean and cold enough to ensure proper operation
of the cooling system under the most severe anticipated conditions. In some cases, if
sufficiently cold water is available, below-ambient-temperature cooling can be
achieved.

VI. Specific Model Data

Mounting
● Panel Mounted Heat Exchangers KXHE120A and KXHE122A are equipped with two
vertical mounting rails Using these rails, the units may be mounted to any available
vertical surface on the enclosure.
● Refer to page 5 for location of all mounting holes and cutouts.
● Make sure cutouts do not interfere with components inside your cabinet.
● Proper alignment of air inlets and outlets is essential for optimum Heat Exchanger
performance
● All Kooltronic externally mounted Heat Exchangers are fully gasketed to ensure
proper sealing. This seal is necessary to maintain the integrity of the closed-loop
system.
● Use all existing mounting holes to insure stability and a tight seal.

4
Drawings and Dimensions
EXTERNAL MOUNTING (Suffix A)

MOUNTING PLAN
H
1.50 DIA.
POWER 111/2
101/8
CORD HOLE
POWER 13/8
CORD
(8)
➁ .312 DIA.
HOLES

A
➂ ➂ 31/8

A
B C
➀
6 TYP.
FILTER

➃ D
E
➃

G F
111/2

103/4

➀ FILTERED AMBIENT ➁ WARM AMBIENT ➂ WARM AIR RETURN  COOL AIR OUTLET
➃
AIR INLET AIR OUTLETS FROM ENCLOSURE TO ENCLOSURE

INTERNAL MOUNTING (Suffix B)

Flanges are on all four external edges. Airflow pattern is same.
Dimensions (inches) are for both external (A) and internal (B) models, except for top and bottom flanges on (B) models,
for reference only and are subject to change.

DIMENSIONS (inches)
Model A B C D E F G H
KXHE120A 24 191/8 87/8 43/4 3 5/
8 91/2 43/16
KXHE122A 251/2 197/8 8 3/16 61/4 3 3/4 1/
2 7 85/16

TECHNICAL DATA**
Maximum Allowable Performance Approx
Model Element Power Temperature °F Watts/°F Weight
(A & B) Depth Volts Amps Watts Enclosure Ambient Air In Air Out (lbs.)
KXHE120 4" 115 0.8 75 160 115 16 30 20
K2XHE120 4" 230 0.4 75 160 115 16 30 20
KXHE122 8" 115 1.1 90 160 115 19 37 30
K2XHE122 8" 230 0.5 90 160 110 19 37 30
**60 Hz. operation. For 50 Hz. operation, consult Kooltronic.

5
Major Component Replacements
KXHE120A KXHE122A
Fan Motor Assembly 0265-09 0265-07
Heat Exchanger Element 0744-12A 0744-11A
Filter 100-3F 100-3F
Above parts are for 115V units. For 230V, consult factory.

VII. Maintenance
Kooltronic Air-Cooled Heat Exchangers are designed to require only routine cleaning
of air filters and the heat exchanger element to assure unimpeded air flow through the
heat exchanger element. It is not possible to recommend specific filter cleaning
intervals since the level and the nature of air borne particulate matter differs widely
with each installation. It is generally sufficient to remove and wash the reusable
aluminum mesh air filter when the outer surface of these filters appear covered with a
thin layer of dust or lint. Filter recoating adhesive is recommended. Appropriate
disposable filters are available from Kooltronic.
If filter service is neglected or delayed, the heat exchanger will not perform at its design
capacity. The first indication of excessively clogged air filter is usually a gradual
increase of temperature within the equipment cabinet. Continued operation under
these conditions will cause damage, shorten blower motor life and void the warranty.

CAUTION
Disconnect electric power from the Heat Exchanger
before proceeding.

Filter Removal and Service

Kooltronic Heat Exchanger feature an easily removable inlet filter to
facilitate necessary cleaning.

CAUTION
Do not operate the Heat Exchanger for extended periods
of time with the filter removed. The heat exchanger element
may become clogged with dust or lint from the ambient
environment. A clogged heat exchanger element is not
readily detected and will give the same reaction as clogged
filter. A clean filter is the best protection.

6
 1) Move the filter forward, using attached tab, to clear the
near filter retainer. Pull the filter downward and toward you until the
far side of the filter clears the far filter retainer.
2) After removal, the filter 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 warm water rinse as above.
3) The filter may be sprayed with Kooltronic A-16 Filter Recoating
Adhesive to trap fine airborne contaminants, or they can simply
be dried and reinstalled as strainer type filters. Recoating
is recommended for the best results.
4) Reinstall the filter: (a) Holding the tab, slide the filter into the near
retainer, (b) press filter against the unit and (c) slide forward into
far retainer.

VIII. Packing Procedure

■
Keep Heat Exchanger in proper upright position.
■
Pack Heat Exchanger in an appropriate carton (preferably original carton if possible),
with adequate internal protective packaging, making sure carton is marked properly.
■
For local controlled transportation, strap carton where possible, to a secure part of
truck to prevent falling or sliding, minimizing vibration, etc.
■
For common carrier shipment, band unit(s) securely to a pallet. Unpalletized shipment
risks severe damage which voids the warranty.

7
IX. Warranty
KOOLTRONIC products are warranted to be free of KOOLTRONIC assumes no liability beyond the repair or
defects in workmanship, materials and components. The replacement of its own product. This Warranty does not
following warranty periods apply from date of shipment: cover:
■ Air moving devices and components: 20,000 hours ■ Labor or reimbursement of labor for evaluation, removal,
continuous duty installation, repair, or cost of any warranted part, except
■ Hermetic system components: Two years continuous at the KOOLTRONIC factory in Pennington, NJ
duty ■ Use of equipment for other than its designed purpose or
■ Non-operating parts, except filters: 5 years operating conditions
The above warranty applies when the equipment is
■ Operation in harsh, oily, corrosive or other abnormal
operated under the following conditions: environmental conditions, without the proper filtration,
sealing, protective coatings and/or weather protection
■ Ambient temperature not in excess of 125°F (52°C) in
normal atmosphere or as stated on product nameplate
■ Damage to hermetic system resulting from continuous
operation with dirty or clogged air filters or improper or
■ Voltage variation no greater than ± 10% from nameplate negligent maintenance
rating
■ Use of refrigerant other than designated
■ Frequency variation no greater than ± 3Hz from
nameplate rating
■ Customer modification or abuse
■ Maximum cooling load no higher than air conditioner
■ Shipping damage or other accident
nameplate rating Cracked or broken hermetic tubing or brazed joints
■ Waiting five minutes before restarting air conditioner caused by shipping damage or mishandling are not
after intentional or accidental shutoff covered under the Warranty.
■ Compliance to all other installation, maintenance and Claims for shipping damage are the responsibility of
operating instructions, as supplied the Consignee. Timely claims must be filed with the
freight carrier.
KOOLTRONIC cannot assume responsibility for
mis-application of its products or the erroneous
■ Any and all conditions resulting from noncompliance
selection of an inappropriate product by a non- with the preceding operating conditions
authorized KOOLTRONIC representative. Our The purchaser assumes the responsibility of grounding
applications engineers will gladly assist in the the unit and installing it in accordance with local electrical
selection of the proper product, provided all and safety codes, as well as the National Electric Code
required details of the application are furnished. (NEC) and OSHA.

THIS WARRANTY CONSTITUTES THE ENTIRE WARRANTY WITH RESPECT TO THE PRODUCT AND IS IN
LIEU OF ALL OTHERS, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY
AND WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND IN NO EVENT IS KOOLTRONIC
RESPONSIBLE FOR ANY CONSEQUENTIAL DAMAGES OF ANY NATURE WHATSOEVER.

RETURN AUTHORIZATION (RA) PROCEDURE

■ All returns require a Return Authorization number - Contact name, telephone and FAX numbers
whether the return is for warranty or non-warranty
repair, rotation of stock, damage or any other reason.
■ Pack unit in a suitable container for shipment, preferably
Returns without an RA number will be refused. the original packaging if available. All Air Conditioners
and Heat Exchangers must be returned in an upright
■ Customer must call the Kooltronic Customer Service position properly secured to a pallet. Improper
Department, Pennington, New Jersey (609 • 466 • 3400) packaging may void warranty claim. If Air Conditioner
to obtain an RA number. or Heat Exchanger is received laying down or shipped
■ The following information is required when an RA is via UPS or similar service the warranty will be void.
requested: ■ Mark box prominently with Kooltronic’s Return
- Original customer Purchase Order number and date Authorization Number.
- Date product was received by customer ■ Enclose all pertinent documents.
- Number of parts to be returned
- Product description, model and serial number
■ Freight charges on all products returned to Kooltronic
- Reason for return shall be paid by the customer. Collect shipments will
- Action requested be refused.

8
 Fil-Trek Corporation
70 Fleming Drive
Cambridge, ON, N1T 2B1
Voice: (519) 623-7448
Fax: (519) 623-8807
Web Site: www.fil-trek.com

INSTALLATION AND OPERATION MANUAL

FOR EF LOW FLOW MODELS
CONTENTS
A. Shut Down and Cover Removal
B. Media Replacement Components
C. Cover Replacement and Start-Up
D. Warranty
E. Spare Parts List
F. Catalogue Sheet
G. General Arrangement Drawing

NOTE:
Two manuals to be distributed to the customer
• One set to the purchasing department, along with supplementary documentation
specified in the P.O.
• One set to the engineering department, shipped along with the EF LOW FLOW
vessel.

To ensure safe operation of your Fil-Trek filter housing, all worn or damaged
components shall only be replaced by Fil-Trek replacement parts.

WARNING:

Please read installation, operation manual, and media installation/replacement

instructions prior to operating your EF LOW FLOW Fil-Trek vessel.
Improper use of this model can result in personal injury and property damage.
A1) Shut Down And Cover Removal (swing bolt)
Operator Warning: Do not attempt to open the filter housing
while the inlet/outlet valves are open, or while
the filter housing contains pressure.

1. Inlet and/or pressure inlet valve must always be closed first.

2. Shut off outlet and/or discharge side valve(s).

3. Any pressure, which may be in the filter housing after the inlet and outlet
valves have been closed, should be vented before attempting to open the filter
housing. Care should be taken to keep face and hands protected and clear of
filter vessel while venting the filter housing.

4. Drain the filter housing by opening the side and bottom drain valves. The
dirty drain is located on the side of the EF LOW FLOW Series filter housing
and the clean drain is located on the bottom of the vessel.

CAUTION: Do not, at any time remove or loosen the swing bolts before draining.
Failure to drain the vessel can result in pressurized fluid being trapped in
the vessel. Fluid may spray out when the swing bolts are loosened
causing personal injury or damage to equipment.

5. Open the air vent to relieve the housing pressure.

6. Loosen the cover nuts (eye or hex) in an alternate diagonal pattern.

7. For vessels supplied with a headlift davit, make sure to raise the cover high
enough to clear the cartridge compression springs and guide pin.
A2) Shut Down And Cover Removal (Band clamp)
Operator Warning: Do not attempt to open the filter housing
while the inlet/outlet valves are open, or while
the filter housing contains pressure.

1. Inlet and/or pressure inlet valve must always be closed first.

2. Shut off outlet and/or discharge side valve(s).

3. Any pressure, which may be in the filter housing after the inlet and outlet
valves have been closed, should be vented before attempting to open the filter
housing. Care should be taken to keep face and hands protected and clear of
filter vessel while venting the filter housing.

4. Drain the filter housing by opening the side and bottom drain valves. The
dirty drain is located on the side of the EF Series filter housing and the clean
drain is located on the bottom of the vessel.

CAUTION: Do not, at any time remove or loosen the V-band clamp before
draining. Failure to drain the vessel can result in pressurized fluid being
trapped in the vessel. Fluid may spray out when the V-band closure is
loosened causing personal injury or damage to equipment.

5. Open the air vent to relieve the housing pressure.

6. Remove the V-Band closure bolt.

B) Media Replacement Components

Fil-Trek Corp. utilizes filter cartridges ranging in size from

10", 20", 30" and 40" long. For maximum filtration efficiency, Fil-Trek recommends that
elements should be replaced @ 15-20 PSI D dirty unless otherwise specified.

1. Remove the pressure plate by unthreading the top hex nuts. Once the hex nuts
are removed lift out the pressure plate. If the pressure plate is welded inside
the top cover continue to step 2.

2. Remove the top seat spring assemblies from the cartridges. If you are using
222 SOE cartridges this step is not required and you may continue to step 3.

3. Remove and discard the worn Fil-Trek cartridges.

4. Inspect the support rods and V-posts for any defects. It is only necessary to
remove the support rods and V-posts if they are damaged.

5. Clean and inspect the filter housing interior and all components.

6. Inspect the bottom sump seat cup for any defects.

7. Slide the new Fil-Trek cartridges onto the V-posts. If you are using SOE 222
cartridges you may not require the V-posts.

8. Single open end (SOE) elements with a 222-O'Ring do not require V-posts or
top spring assemblies. Simply press fit the elements into the bottom sump
seat.

THE WARRANTY IS VOID IF ANY OF THE SPARE PARTS ARE NOT SUPPLIED
BY FIL-TREK CORPORATION OR ONE OF ITS DIVISIONS.
C) Cover Replacement and Start-up

1. Clean and inspect the gasket seating surface. Re-lubricate the gasket heavily with
petroleum jelly.

2. Swing bolts and V-Band clamps should be cleaned, inspected and lubricated

3. For swing bolt closure vessels position the cover over the filter body and align the
clevis bracket notches with the swing bolts. If your EF LOW FLOW Series vessel
has a domed top head there will be a guide pin, which will assist with aligning the
cover into place.

4. After the cover is lowered into place, position the swing bolts to the cover and
install the nuts (hex or eye).

5. Tighten the nuts in an alternate criss-cross pattern. Do not apply excessive torque
to the nuts as permanent distortion to the filter may result.

6. Close the drain valves and open the vent valve or plug.

7. Open the inlet valve and allow the vessel to fill slowly.

8. When air is expelled from the vessel and liquid begins to bleed from the vent,
close the vent valve.

9. Open the outlet valve(s).

 D) Warranty

Seller warrants that the items sold hereunder shall be free from defects in material
or workmanship for a period of 12 MONTHS AFTER STARTUP or 18 MONTHS AFTER
THE DATE OF SHIPMENT from Fil-trek Corporation or one of its divisions, whichever
comes first. This warranty comprises the sole and entire warranty pertaining to items
provided hereunder. Seller makes no other warranty, guarantee, or representation of any
kind whatsoever. All other warranties, including but not limited to, merchantability and
fitness for purpose, whether express, implied, or arising by operation of law, trade usage,
or course of dealing, are hereby disclaimed.

Notwithstanding the foregoing, there are no warranties whatsoever on items built

or acquired wholly or partially, to buyer’s designs or specifications.

Limitation of Remedy: Seller’s liability arising from or in any way connected

with the items sold or this contract shall be limited exclusively to repair or replacement of
the items sole or refund of the purchase price by buyer, at seller’s sole option. In no
event shall seller be liable for any incidental, consequential, or special damages of any
kind or nature whatsoever, including but not limited to lost profits arising from or in any
way connected with this agreement or items sold hereunder, whether alleged to arise from
breach of contract, express or implied warranty, or in tort, including without limitation,
negligence, failure to warn or strict liability.

THIS WARRANTY IS VOID IF ANY OF THE SPARE PARTS ARE NOT SUPPLIED
BY FIL-TREK CORPORATION OR ONE OF ITS DIVISIONS.
 E) Spare Parts List

SERIAL NUMBER
MODEL NUMBER
QTY
CUSTOMER
YEAR BUILT

Part No. Description Qty required per unit Qty to order

5315-4039-1 5/8” Swingbolt

5315-4039-2 Eyenut
5315-4039-3 Washer
5315-4039-4 Clevis pin
5315-4039-5 Cotter pin
4144-1397-B Gasket O-ring
5320-5165 Sump seat bottom
5320-5040 V-post
40” Filter Cartridge
5320-5200 Top spring assembly

FOR SPARE PARTS ORDERING PLEASE CONTACT:

Fil-Trek Corporation
70 Fleming Drive
Cambridge, ON
N1T 2B1
Telephone (519) 623-7448
Fax (519) 623-8807
YARN WOUND FILTER CARTRIDGES
TFT's depth wound cartridge, with its tapered
passages, assures the best filtration available.
All TFT filter cartridges are wound in a precise manner
to provide true depth filtration through hundreds of
tapered passageways. Depth wound cartridges offer
gradual pressure increase, compared to the sudden
increase with surface-type filters. Progressive dirt
removal from surface to core provides high dirt
holding capacity. Core covers are available to prevent
fiber migration.
One of the main advantages of the wound filter
cartridge is its exceptionally high structural strength
that can withstand severe operating and handling
conditions. TFT cartridges are available in a wide
variety of materials compatible with most liquids and
gases, and in micron ratings from 0.5 to 300 nominal.

APPLICATIONS BY INDUSTRY
Food and Beverage: Soft drink process water, filtered bottled water, edible oil processing,
corn/fructose syrup polishing, beer polishing, wine clarifying, spice oils
Chemicals: polishing colloidal silica fluids, water polishing fluids, industrial chemical
polishing, monomer filtration for PVC, cooling water, organic solvents
Electronics: printed circuit process water, plating solutions, precious metal recovery,
photo resist, solvents, acids, DI water, R.O. prefiltration
Photographic: photo processors, photo emulsions, wash water, rinse water, chemicals
Hospitals: water, X-ray processing, dialysis prefiltration
Magnetic Coatings: audio, video, computer tape, computer hard disks, solvents
Oil Production: secondary oil recovery, well completion, waterflood
Cosmetics: oils, perfumes, creams, gels
Pharmaceuticals: solvents, process water, cooling water, R.O. prefiltration
Paint and ink: process water, emulsions, pigments, dyestuffs
Consumer Products: household and municipal water, prefilter for desalination
Plating: process water, plating solutions

To Order, Call :

1-561-684-6300
 ORDERING CODES
5 P 10 P F
Micron Ratings: Options:
0.5, 1, 2, 3, 5, 10, 15, 20, 25, FDA Approved Fiber - F
30, 40, 50, 75, 100, 150, 200, 300 Core Cover - C
Extended Core - X
Filter Media: End Treatment - E
4 1/2" Outer Diameter - BB
Polypropylene - P
Polypropylene (Fibrillated) - PF
Bleached Cotton - C Core:
Natural Cotton - CU Polypropylene - P
Rayon - R Tin - T
Nylon - N 304 Stainless Steel - A
Acrylic - A 316 Stainless Steel - S
Jute - J (non-standard) Nylon - N
Teflon - PTF (non-standard) Phenolic - H
Polypropylene (Heavy Wall) - PH
Lengths:
3 7/8" - 50" in 1/16" increments
Examples: Length 10" = Order Code 10
Length 29 1/4" = Order Code 294 Standard Outside Diameter: 2 1/2"
Length 19 1/2" = Order Code 198 Standard Inside Diameter: 1.08"
Length 9 3/4" = Order code 912 others available

PACKAGING
2 1/2" Outer Diameter 4 1/2" Outer Diameter
4" and 5" filters 60/carton 10" filters 8/carton
6" filters 48/carton 20" filters 6/carton
10" filters 30/carton
20" and 30" filters 15/carton
40" and 50" filters 10/carton

Total Filter has the capability to design and manufacture many different filtration products to help you solve your specific
problem. We invite your inquiries to custom design and manufacture a filter cartridge for your specific need.

All data and statements concerning these products may be considered as being indicative of representative properties and characteristics
obtainable. Since industry practices vary, we make no warranty, express or implied, concerning their use, nor do we accept responsibility for
any misapplication of these products, or their use under any conditions.

Bulletin #601 © Copyright 1997 Total Filter Technology, Inc. All Rights Reserved. Printed in U.S.A. 10M•10/97•YWFC