Summary of Contents for Kolpak Walk-In
- Page 1 Kolpak Walk-In Installation & Operation Manual Kolpak 2915 Tennessee Avenue North 500000400-10 Parsons, TN 38363 September 2017 Phone: 800-225-9916 www.kolpak.com 800-225-9916...
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Page 2: Table Of Contents
Adjustable Hinges ......................24 Thermometer Testing & Recalibration ................25 Electrical Connections ....................26 Tapered Roof System ....................27 Membrane Roof System ................... 28-31 Maintenance & Housekeeping ..................32 System Start-up Checklist ..................33-36 Warranty Information ..................... 37 www.kolpak.com 800-225-9916... -
Page 3: General Safety Information
General Safety Information Read this manual carefully before beginning the installation and operation of the unit. Scan the QR Code below to view the Basic Walk-In Installation Service Video. Special attention is required to all sections identified with the following warning and... -
Page 4: Receiving Inspection
Make sure to store the panels as noted below if necessary to ensure that they are not damaged prior to being installed. Panel Storage If the walk-in panels must be stored on a job site before installation, store them inside if possible. The PVC protective panel covering should only be removed after final assembly of the walk-in. -
Page 5: Panel Identification
Be sure the plastic does not touch the ground, allowing air circulation. Panel identification Each panel is labeled to aid in identification and proper placement. Panel item numbers are referenced on the product assembly drawing showing proper location for intended installation within the unit. www.kolpak.com 800-225-9916... -
Page 6: Site Preparation
Air circulation around the walk-in of 5 CFM per 100 Sq. Ft. of wall area is recommended. Failure to allow for this clearance and air flow may result in performance issues such as excesive moisture and/or condensation in the unit or adjoining areas. -
Page 7: Cam Action Panel Fasteners
If a problem should occur, such as having to unlock a panel that was not properly positioned, you must turn the handle counterclockwise until it stops, in order to reset the cam position. www.kolpak.com 800-225-9916... -
Page 8: General Installation Guidelines
The tongue side of the panel and cam lock holes is on the left of each seam when viewed from the interior of the walk-in (standing on the inside and looking out). The exact location of the tongue (M) and groove (F) for ceiling and floor panels, if required, will be shown on the assembly drawing. -
Page 9: Screed Identification & Installation
Screed Identification And Installation There are many styles of screeds used in floorless walk-in coolers and freezers. The types of screeds furnished with your unit will be identified on the unit assembly drawing. Breaker strips (thermal breaks) are used to prevent heat transfer between the cooled side and the ambient side of a concrete floor. - Page 10 Mounting angles are supplied in 10’ lengths and field cut to fit the dimensions of the enclosure as necessary. Screed Installation Place the screeds on the floor using the chalk lines as guides. Where factory cut screed is used, screed sizes and layout are identified in the assembly drawings. www.kolpak.com 800-225-9916...
- Page 11 Thermal breaks prevent heat transfer and increase energy efficiency. A 3/8” bead of non-drying butyl sealant is required and should be continuous around the complete perimeter of the walk-in. This sealant application will assist in maintaining the vapor barrier. www.kolpak.com...
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Page 12: Floor Panel Installation
Floor Panel Installation Review the floor panel layout on the assembly drawing. www.kolpak.com 800-225-9916... - Page 13 Mark and level the floor according to site preparation requirements. Lay out floor panels in correct sequence according to assembly drawings, making sure the flooring is level. Lock floor panels together, making sure edges are flush and square. www.kolpak.com 800-225-9916...
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Page 14: Floor Overlay Installation
Continue to follow the layout according to the drawing until all sheets are flush and secured to the subsurface. Caulk all seams and edges of flooring overlay material. Allow 1-3 hours for the adhesive/sealant to dry prior to resuming use of the walk- www.kolpak.com 800-225-9916... -
Page 15: Concrete & Tile Flooring
Adequate ventilation must be provided when the concrete floor or tile setting bed and grout is curing. Leave all doors open for ventilation. If concrete or tile is to be installed after walk-in is erected, protect the wall finish by applying a protective covering. Wall Panels & Door Section Installation Review the wall panel and door sections layout on the assembly drawing. -
Page 16: Ceiling Panel Installation
Check panel alignment. Cam-lock ceiling panels together. After several ceiling panels are in position and locked together, check all wall to ceiling joints for flush fit and proper alignment. Lock ceiling panels to wall panels. www.kolpak.com 800-225-9916... -
Page 17: Split-Over Partition Wall/Ceiling
WARNING The top panels on walk-in units are designed, at a minimum, for an allowable live load of ten pounds per square foot as noted on submittal drawings and installation instructions. Top panels are not designed as work platforms or for dry storage and should not be used as such. -
Page 18: Ceiling Support
These systems must be installed properly in order to provide the necessary support for the ceiling panels, allowing them to maintain their design load rating. Failure to do so may result in an unsatisfactory installation, or an unsafe condition. www.kolpak.com 800-225-9916... -
Page 19: Interior/Exterior Ramps
Apply sealant at ramp cavity to concrete and floor intersections. Install ramp and drive fasteners in place. Apply sealant to all ramp edges. Exterior Ramp Installation Install the exterior ramp and fasteners per the details provided on the assembly drawing. www.kolpak.com 800-225-9916... -
Page 20: Plug Buttons & Penetrations
Plug buttons supplied for walls and ceilings are vinyl, plug buttons supplied for floors are either stainless steel or high-strength plastic Penetrations Some areas of walk-in panels contain working parts and should not be penetrated. Do not make a penetration within 2” of cam lock holes or panel seams. -
Page 21: Trim & Wainscoting Material
All sheets must be as flush as possible to one another. Make sure that all sheets make contact with outside finished floor. Caulk all exposed edges of sheeting. Allow 1-3 hours for the adhesive/sealant to dry prior to resuming use of the walk- www.kolpak.com 800-225-9916... -
Page 22: Threshold Installation
Do not extend tile and grout through the unit door opening. Any tile and grout on the interior of a unit must be completely separated from tile and grout on the exterior to prevent condensation issues and excessive heat loss. www.kolpak.com 800-225-9916... -
Page 23: Door Sweep Adjustment
Scan the QR Code below to view the Door Sweep Adjustment Service Video. CAUTION Ensure the exterior tile is level with the threshold throughout the entire door swing, to prevent damage to the door sweeper gasket. www.kolpak.com 800-225-9916... -
Page 24: Adjustable Hinges
Remove all of the shims, and check for door swing clearances and operation If the misalignment has been corrected, replace the hinge leaf covers and screws. If further adjustment is necessary, repeat the above steps using different combinations of shims until the adjustment is completed. www.kolpak.com 800-225-9916... -
Page 25: Thermometer Testing & Recalibration
For higher temperature reading, carefully hold the pointer. Insert the screwdriver in pointer slot and slowly turn counter clockwise a small amount. Adjust to proper setting. Carefully reinstall the face of the thermometer. Scan the QR Code below for the Thermometer Calibration Service Video. www.kolpak.com 800-225-9916... -
Page 26: Electrical Connections
Electrical Connections Consult the installation drawing supplied with the walk-in to determine which application is required. Unless otherwise shown, the door section is furnished with a factory installed vapor proof light fixture on the interior of the section, and a light switch with pilot light indicator flush mounted on the exterior. -
Page 27: Tapered Roof System
WARNING Building codes require a minimum of ¼ inch per foot slope on outside roof systems. If a tapered roof system is not purchased with an exterior walk-in, it is the purchaser’s responsibility to ensure this requirement is met. www.kolpak.com... -
Page 28: Membrane Roof System
6” diameter by 10’ long cardboard tubes. A hardware box containing screws, fastening plates and sealant is also included. Check the roof of the walk-in unit and remove any foreign matter. Seal all protruding rough edges and screw heads, rivets, etc. with tape or sealant. This will prevent any chance of penetrating or wearing a hole in the membrane roof cap. - Page 29 The membrane should overhang the top edge of the wall panel by 5” on all exposed sides of the walk-in unit, and extend at least 8” up on adjacent building walls.
- Page 30 Start at the base of the wall by fastening a plate into the top of the walk-in cooler and into the wall of the adjacent building. Make sure at least 8” of material is up the wall for proper termination. Work away from wall fastening 6” on center. The 1-1/2”...
- Page 31 Use 1-1/2” stainless steel screws spaced 6” on center. Seal top edge of termination bar. www.kolpak.com 800-225-9916...
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Page 32: Maintenance & Housekeeping
When doors are opened for extended periods of time, frost can form on the ceiling and floor due to the excessive condensation of warm moist air inside the walk-in. This can result in the formation of an ice film on wall, ceiling and floor surfaces or around gaskets. -
Page 33: System Start-Up Checklist
Serial Number: Electrical Volts: Electrical Phase: Suction Line Temp @ Evap: °F Evap Superheat: °F Thermostat Set: °F Operating Temp: °F TXV Bulb Properly Mounted: All guards, covers attached: All electrical connections are tight: Defrost Heater Amp Draw: www.kolpak.com 800-225-9916... - Page 34 Model Number: Serial Number: Electrical Volts: Electrical Phase: Suction Line Temp @ Evap: °F Evap Superheat: °F Thermostat Set: °F Operating Temp: °F TXV Bulb Properly Mounted: All guards, covers attached: All electrical connections are tight: www.kolpak.com 800-225-9916...
- Page 35 Door Sweeps Adjusted: Heat Air Vent Working: Door Closers Adjusted and Working: Wainscot and Trim Installed: Alarm Set and Working: Thermometer Bulb Mounted and Calibrated: Walk-In Clean (no excessive caulk, etc.) Walk-in at proper temperature: Walk-In Cooler Inspection Feature Data Accept...
- Page 36 Wainscot and Trim Installed: Alarm Set and Working: Thermometer Bulb Mounted and Calibrated: Walk-In Clean (no excessive caulk, etc.) Walk-in at proper temperature: Notes: Superintendent/Customer Signature: ____________________________ Date: ______________ Service Tech/Installer Signature: ________________________________ Date: ______________ www.kolpak.com 800-225-9916...
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Page 37: Warranty Information
Kolpak warranty only applies to the United States, Canada and Latin America. Warranty claims outside of these regions must be approved by Kolpak prior to start of repair. For warranty information, visit our website or scan the QR Code below.