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Table of Contents
Summary of Contents for Kolpak PR
- Page 1 Protecting Your Future Refrigeration System Original Instructions Installation, Operation and Maintenance Manual This manual is updated as new information and models are released. Visit our website for the latest manual. Part Number: 550001058-12 08/19...
- Page 2 Safety Notices DANGER Indicates a hazardous situation that, if not avoided, will Read this manual thoroughly before operating, installing or result in death or serious injury. This applies to the most performing maintenance on the equipment. Failure to follow extreme situations. instructions in this manual can cause property damage, injury or death.
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Page 3: Table Of Contents
Pipe Supports ........................9 Oil Traps ..........................10 Drain Lines ........................10 Pre-Charged Lines ......................11 Leak Testing ..........................12 PR Models ......................... 12 PC Models ......................... 13 PCL Models ........................13 System Evacuation ........................13 PR Models ......................... 13 PC Models ......................... -
Page 4: General Information
6. A Return Material Authorization (RMA) must be obtained. Contact a sales representative at 800-826- 7036. Warranty Information For information regarding warranty guidelines, claim form, product registration, warranty verification, or locating a service provider please visit our website at www.kolpak.com or call 800-225-9916. -
Page 5: Installation
Section 2 Installation Condensing Units Check the selected installation location to ensure that racks, braces, flooring, foundations, etc. are adequate to • support the condensing unit weight. The installation location is clean, dry, and level. • Locate away from corrosive and noise sensitive atmospheres. •... -
Page 6: Evaporator Units
Example of Multiple Units with Horizontal Airflow FLOW FLOW MINIMUM DISTANCE 24” 24” 24” BUILDING WALL INTAKE AIR INTAKE AIR (VIEWED FROM ABOVE) MINIMUM DISTANCE 24” MINIMUM DISTANCE 24” CAUTION Failure to observe clearance and air flow requirements will result in poor system performance and premature equipment failure! Evaporator Units •... - Page 7 Evaporator Coil Mounting Diagram...
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Page 8: Wiring
Section 3 Wiring Wiring • All electrical connections and routing must comply with local and national codes. • Do not modify the factory installed wiring without written factory approval. • The field wiring must enter through the knockouts provided. • Refer to the nameplate on the condensing or evaporator coil to determine the proper electrical power supply. -
Page 9: Piping
Section 4 Piping Piping • All refrigeration piping and components are to be installed in accordance with applicable local and national codes and in conformance with industry refrigeration guidelines to ensure proper operation of the refrigeration system. • Only refrigeration grade copper tubing should be used. •... -
Page 10: Oil Traps
Oil Traps To ensure proper oil return to the compressor, a P-type oil trap should be installed at the base of each suction riser of • four feet or more. • The suction trap must be the same size as the suction line. Additional traps are necessary for long vertical risers. -
Page 11: Pre-Charged Lines
Pre-Charged lines and Quick Connects • Route the suction and liquid line sets between the condensing unit and evaporator coil following the piping guidelines identified in this manual. Remove the dust caps from the quick connect fittings and verify that the o-rings are intact. •... -
Page 12: Leak Testing
• All joints and components, both factory and field installed, should be thoroughly inspected for leaks. • The system installation must be leak free! Leak Testing “PR” model systems • Open both the liquid and suction service valves. • Ensure the solenoid valve is energized and open. -
Page 13: Pc Models
A reliable rotary vacuum pump with an accurate deep vacuum gauge is recommended. • Do not use the system compressor as a vacuum pump and do not operate the compressor while the system is under vacuum. Evacuation of “PR” model systems • Open both the liquid and suction service valves. •... -
Page 14: Pcl Models
Evacuation of “PCL” model systems “ • PCL” systems do not require evacuation. CAUTION Do not use the system compressor to evacuate the system. Do not start the compressor while the system is under vacuum. This may damage to the compressor and cause premature system failure. Refrigerant Charging •... -
Page 15: Operational Start-Up
Section 5 Operational Start-Up Pre-Start Checks The first 2 – 4 hours of operation after initial start-up is a critical time. • Do not just start the system and leave. • Pressure values, compressor and evaporator superheat, and inspecting for excessive vibrations and loose connections •... -
Page 16: Start-Up
Start-Up CAUTION Do not start the system while in a vacuum. Do not leave the system unattended until normal operating conditions are achieved. • Operate the system for a minimum of two hours and perform checks of the following: Check the compressor discharge and suction pressures to ensure they are in the normal operating range. Check the liquid line sight glass for proper refrigerant charge (based off of 105ºF condenser coil). -
Page 17: Evaporator Superheat
Evaporator Superheat • Check the evaporator superheat once the walk-in has reached the desired temperature. Generally, systems with a design temperature drop of 10°F should have an evaporator superheat value of 6°-10°F on freezers and 8°-12°F on coolers for maximum efficiency. •... -
Page 18: Arcticfox Thermostat With Lda
CAUTION Minimum compressor superheat of 20°F may override these recommendations on systems with short line runs. CAUTION The condensing unit must have the discharge pressure above the equivalent 105°F condensing pressure (reference refrigerant charging on page 16). CAUTION Correct location and full contact of the expansion valve bulb is extremely important for proper system performance. ArcticFox Thermostat With LDA •... -
Page 19: Setpoints
P/N 550005663 - is used on all Air Defrost model evaporators and features a built in Air Defrost time clock. The default defrost settings are every 6 hours for 30 minutes. See pages 20-21 for default and custom defrost setting instructions. P/N 550005664 - is used on all Electric defrost model evaporators. -
Page 20: Custom Tod Defrost Setpoints
LAO = Low Alarm Offset tAd =Temperature Alarm Delay Adr = Mod Bus Address Unt = Ynits for temperature display (FAH or CEL) Custom tod (Time of Day) Defrost Setpoints Setpoint Description Minimum Default Maximum Time of Day 12.0 23.5 Start time of day #1 dis (disabled) 23,dis (disabled) Start time of day #2... -
Page 21: Custom Defrost Setup
Custom Defrost Setup... -
Page 22: Electric Defrost Timer
Electric Defrost Timer Electric Defrost Time Clock Instructions: • Instructions for setting the timer is located on the inside cover of the time clock. • The defrost timer clock must be set to the correct time at initial start-up and after any power interruptions. •... -
Page 23: Maintenance
Section 6 Maintenance Preventive Maintenance Tasks Area Task Frequency Evaporator Check for proper defrosting Monthly Clean the coil and drain pan Every 6 months Check for proper drainage Condenser Inspect /clean the coil if the air supply is near polluting sources (such as cooking Monthly appliances) Clean the coil surface... -
Page 24: Troubleshooting
Section 7 Troubleshooting Evaporator Troubleshooting Problem Possible Cause Corrective Action Fan(s) will not operate. Main switch open Close switch Blown fuse(s) Replace fuse(s). Check for short circuits or overload conditions. Defective motor Replace motor. Defective timer or defrost thermostat Replace defective component. Unit in defrost cycle Wait for completion of cycle. -
Page 25: Condensing Unit
Condensing Unit Troubleshooting Problem Possible Cause Corrective Action Compressor will not run. Main switch open Close switch Fuse blown Check electrical circuits and motor winding for shorts or grounds. Investigate for possible overloading. Replace fuse after fault is corrected. Thermal overloads tripped Overloads are automatically reset. - Page 26 Problem Possible Cause Corrective Action Compressor loses oil Lack of refrigerant Locate and repair leak, recover, evacuate and recharge Excessive compression ring blow-by Replace compressor Refrigerant flood back Maintain proper superheat at compressor Improper piping or traps Correct piping Compressor thermal protector switch Operating beyond design Add facilities so that operating open...
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Page 27: System Start-Up Checklist
System Start-up Checklist Date System Installed: Installer and Address: Phone Number: Start-Up Service Agency: Phone Number: Freezer Condensing Unit Inspection Feature Data Accept Reject Action Required Model Number: Serial Number: Electrical Volts: Electrical Phase: Amperage @ L1: Amperage @ L2: Amperage @ L3: Ambient Temp: °F... - Page 28 Cooler Condensing Unit Inspection Feature Data Accept Reject Action Required Model Number: Serial Number: Electrical Volts: Electrical Phase: Amperage @ L1: Amperage @ L2: Amperage @ L3: Ambient Temp: °F Comp. Discharge Pressure: PSIG Comp. Suction Pressure: PSIG Suction Line Temp @ Comp.: °F Discharge Line Temp @ Comp.: °F...
- Page 29 Walk-In Freezer Inspection Feature Data Accept Reject Action Required Serial Number: Interior Lights Installed and Working: All Penetrations Sealed: Doors/Jambs Squared and Operating Properly: All Panel Locks Fully Engaged: All Plug Buttons Installed: Door Heater Working: Door Sweeps Adjusted: Heat Air Vent Working: Door Closers Adjusted and Working: Wainscot and Trim Installed: Alarm Set and Working:...
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- Page 32 KOLPAK 2915 TENNESSEE AVE. NORTH, PARSONS, TN 38363 800-826-7036 WWW.KOLPAK.COM WWW.WELBILT.COM Welbilt provides the world’s top chefs, and premier chain operators or growing independents with industry leading equipment and solutions. Our cutting-edge designs and lean manufacturing tactics are powered by deep knowledge, operator insights, and culinary expertise.