Table of Contents
Troubleshooting
Related Manuals for Welbilt KOLPAK
Summary of Contents for Welbilt KOLPAK
- 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: 550001058-14 8/21...
- 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.
-
Page 3: Table Of Contents
Table of Contents Section 1 General Information Receiving Inspection ........................4 Warranty Information ......................... 4 Section 2 Installation Condensing Units ........................5 Evaporator Units ......................... 6 Section 3 Wiring Wiring ............................8 Section 4 Piping Piping ............................9 Cleanliness .......................... 9 Pipe Supports ........................ -
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” INTAKE AIR INTAKE AIR MINIMUM DISTANCE 24” MINIMUM DISTANCE 24” BUILDING WALL (VIEWED FROM ABOVE) 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...
-
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
CAUTION Quick connects are for one time use only. Once disconnected, the coupling cannot be re-used. Refrigerant leaks will occur if the couplings are re-used resulting in poor system performance. • Excess line set length should never be allowed to coil in the vertical position. Excess line length should be laid flat on its side. -
Page 13: Pc Models
Leak Testing “PC” model systems • Leave the service valves closed, the condensing unit is charged with refrigerant. • Ensure the solenoid valve is energized and open. • Add 50 psi refrigerant, then pressurize with dry nitrogen to the low side test pressure identified on the unit rating label. -
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 are some of checks that must be performed prior to leaving the system. -
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. To determine the evaporator superheat: •... -
Page 18: Johnson Control Thermostat
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. Johnson Control A421 Electronic Temperature Control •... -
Page 19: Parameter Codes And Modes Of Operation
Relay status LED • The green LED on the front panel illuminates when the SPDT output relay is energized and the LC and LNO contacts are closed. Parameter codes and modes of operation • Relay Off temperature (OFF) Select the temperature at which the output relay de-energizes, the LC to LNO relay contacts open (cutout), and the green LED goes off. - Page 20 Note: When the ASd value is greater than 0, the delay interval initiates every time that the A421 Control is powers on and every time that an off-cycle begins. When the ASd interval is activated, the temperature sensed at the A99 sensor and the parameter code ASd flash alternately on the LCD.
- Page 21 • Defrost Cycle Time (dFt) Select the time in minutes that the defrost cycle overrides On and keeps the relay Off. The dFt value can be between 1 minutes and 99 minutes. When the defrost cycle is On, the control is NOT running and the LCD displays the following screens: dEF (defrost mode), minutes remaining, and the temperature at the sensor.
- Page 22 Standard parameter setup codes, descriptions, range of values, and default values Parameter code Parameter description Range of usable values Factory default value (menu) Temperature Units ºF or ºC ºF (Advanced only) Relay Off Temperature -40ºF to 212ºF (-40ºC to 25ºF (Basic, Advanced, and 100ºC) Restricted)
-
Page 23: Basic Menu
Navigating the Basic and Advanced menus • The A421 Control buttons and display operate the same way in Basic and Advanced menus. You can observe the following behavior in any parameter code screen: The parameter code flashes on and off. To navigate through all of the parameter code screens, press Down or Up. -
Page 24: Advanced Menu
Viewing and changing values in the Basic menu • To access the Basic menu and view and change the Basic parameter values, complete the following steps: 1. On the Main screen, press MENU. The LCD displays OFF, which is the first parameter code screen displayed in the Basic menu. - Page 25 Viewing and changing values in the Advanced menu • To access the Advanced menu and view and change the parameter values, complete the following steps: 1. On the Main screen, press and hold Down or Up simultaneously for 5 seconds. Un displays on the LCD, which is the first parameter code screen displayed in the Advanced menu.
-
Page 26: Setting Up A Regular Or Timed Defrost Off-Cycle
Setting up a regular or timed Defrost Off-Cycle • The controller enforces the following behavior: • At power up, the initial Defrost Interval (dI) does not have a Defrost Cycle (dFt). Subsequent defrost intervals (dI) begin with the selected dFt value. •... - Page 27 Control behavior when starting or stopping an automatically enabled Defrost Off-Cycle • The controller enforces the following behavior: • At power up, the initial Defrost Interval (dI) does not initiate a Defrost Cycle Time (dFt). A defrost cycle occurs at the beginning of each subsequent defrost interval. •...
- Page 28 • When the A421 Control is set up in the restricted adjustment mode, the controller enforces the following behavior: 1. The selected HtS and LtS values define the restricted temperature adjustment range. 2. The On and OFF values define the control band differential, and the control band between On and OFF remains fixed and not adjustable.
-
Page 29: Troubleshooting
Note: To completely restrict and lockout all user adjustment on the control, set the HtS value equal to the On or OFF value and the LtS value equal to the OFF or On value. Then the (On to OFF) control band is equal to the restricted adjustment range, LtS to HtS, and the OFF value cannot be adjusted in the restricted mode. - Page 30 Troubleshooting procedure Check for proper voltage to the A421 Control. • 1. To remove the cover, loosen the two captive cover screws. 2. Use an AC voltmeter to check the voltage between the COM and 120 V or 240 V terminals on line-voltage models and the two 24 V terminals on low-voltage models.
-
Page 31: Electric Defrost Timer
Note: If the anti-short cycle delay is set to a value other than 0 minutes, when the control is powered On, on the relay does not energize until the time delay elapses. 8. If the output relay does not perform as expected, replace the A421 Control. 9. - Page 32 • When the coil warms to approximately 55°F, the defrost termination thermostat closes and energizes the switching solenoid in the timer. At this time, switch 1 to 3 in the timer opens, terminating the defrost heaters. Simultaneously, switch 2 to 4 closes in the time clock, energizing the temperature control circuit. •...
-
Page 33: 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 34: 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 35: 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 36 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 conditions open...
-
Page 37: 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 38 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 39 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:...
- Page 40 All of our products are backed by KitchenCare® – our aftermarket, repair, and parts service. CLEVELAND DELFIELD® FRYMASTER® KOLPAK® MANITOWOC® MERRYCHEF® CONVOTHERM FITKITCHEN™ GARLAND LINCOLN MERCO® MULTIPLEX® ©2017 Welbilt Inc. except where explicitly stated otherwise. All rights reserved. Continuing product improvement may necessitate change of specifications without notice. Part Number: 550001058-14 8/21...
Need help?
Do you have a question about the KOLPAK and is the answer not in the manual?
Questions and answers