Kolpak Walk-ins PCL249LOP Operating instructions

Type
Operating instructions

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Installation, Use & Care Manual
This manual is updated as new information and models are released.
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Specified #1 Among Walk-ins
Walk-ins
Part Number 11324 2/08
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Safety Notices
As you work on Manitowoc equipment, be sure to pay
close attention to the safety notices in this manual.
Disregarding the notices may lead to serious injury and/
or damage to the equipment.
Throughout this manual, you will see the following types
of safety notices:
Procedural Notices
As you work on Manitowoc equipment, be sure to read
the procedural notices in this manual. These notices
supply helpful information which may assist you as you
work.
Throughout this manual, you will see the following types
of procedural notices:
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you
are performing.
Read These Before Proceeding:
NOTE: SAVE THESE INSTRUCTIONS.
! Warning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
!
Caution
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure to
read the Caution statement before proceeding, and
work carefully.
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
!
Caution
Proper installation, care and maintenance are
essential for maximum performance and trouble-
free operation of your Manitowoc equipment. Read
and understand this manual. It contains valuable
care and maintenance information. If you encounter
problems not covered by this manual, do not
proceed, contact Manitowoc Foodservice Group.
We will be happy to provide assistance.
Important
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
! Warning
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
Part Number 11324 2/08 i
Table of Contents
Section 1
General Information
Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Modular Construction Made Fast and Easy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Panel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Storage Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Storage Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section 2
Installation Instructions
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Posi-Loc Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Types of Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Pre-fabricated Floor Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Floor Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installing Floor Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Multiple Compartment Walk-ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Wall Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Wall Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Door Frame Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Completing Wall Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Ceiling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installing Ceiling Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Ceiling/Wall Joint Alignment on Large Structures . . . . . . . . . . . . . . . . . . . . 2-9
Finishing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Door Threshold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Thermometer Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Panel Penetrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electrical Connections for Door(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Post Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Table of Contents (continued)
ii Part Number 11324 2/08
Section 3
Operation
Component Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operational Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Posi-Seal Door Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Dial Thermometer Testing and Recalibration . . . . . . . . . . . . . . . . . . . . . . . 3-2
Digital Thermometer Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Section 4
Maintenance
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Interior/Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Door Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Heater Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Plug Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Door Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Part Number 11324 2/08 1-1
Section 1
General Information
Model Numbers
This manual covers the following models:
General Safety Notices
Read these safety notices before beginning any
installation work on these Kolpak Walk-ins.
Modular Construction Made Fast and Easy
Kolpak walk-in coolers and freezers, or multi-
compartment walk-ins can be assembled in any size
from Kolpak modular panels.
To ensure proper set-up and many years of trouble-free
use, read and follow the instructions in this manual
carefully before and during installation.
This manual covers the basics of installation for a
standard walk-in. Refer to the enclosed blueprint and
special features sheets for information and instructions
pertaining to your specific walk-in.
Panel Storage
STORAGE INSIDE
If the walk-in panels must be stored on a job site before
installation, store them inside if possible.
If the panels are received on skids, they may be stored
as shipped, provided the skids are on a level surface
and kept free of moisture. If the panels are received
without crating, store them on edge with the grooved
side (female rail) facing down. In either case, store the
panels in an area where they are not likely to be
damaged.
Panel Storage
STORAGE OUTSIDE
If the panels must be stored outside, store them on edge
with the grooved side (female rail) facing down. Kiln-
dried wood spacers provide a ventilation gap to prevent
moisture stains from forming on the panels’ metal skins.
Cover the panels with black plastic to keep out sunlight
and moisture. Be sure the plastic does not touch the
ground, to allow air circulation.
Model Numbers
R Series
!
Warning
The Kolpak walk-in panels are heavy and require at
least two people to move them safely.
When lifting, bend your legs to avoid back injury.
Do not move large panels without the aid of a
mechanical lifting device.
!
Warning
To avoid injury while assembling a Kolpak walk-in,
you must wear protective gear, including eye
shields, a hard hat and steel-toed boots.
!
Caution
Until the walls are made stable by constructing the
corners, support extended wall lengths by bracing
them from both the inside and the outside.
!
Caution
This Installation Manual should be used only as a
general reference. During the installation process,
follow your blueprint and any special feature sheets
for information specific to your walk-in.
General Information Section 1
1-2
Part Number 11324 2/08
THIS PAGE INTENTIONALLY LEFT BLANK
Part Number 11324 2/08 2-1
Section 2
Installation Instructions
Installation Overview
1. Unpack and inspect the shipment.
2. Prepare the installation area.
3. If required, assemble pre-fabricated floor.
4. Complete the first corner.
NOTE: When constructing the walls, begin and end at a
corner. The final wall panel must mate with two other
wall panels at the same time. This can only happen at a
corner.
5. Extend the wall.
Continued on next page
Installation Instructions Section 2
2-2
Part Number 11324 2/08
NOTE: Keep adjacent top and side surfaces flush. This
will make locking the Posi-Locs easier.
6. Reach the second corner.
7. Construct the opposite walls in parallel. Begin
installing the ceiling.
8. Install the door frame panel.
9. Complete the finishing work.
Section 2 Installation Instructions
Part Number 11324 2/08 2-3
POSI-LOC LOCKING DEVICE
As the walk-in is assembled, adjacent panels (wall,
ceiling and floor) are locked together by means of the
Posi-Loc device. These devices are built into the edges
of the panels.
After setting two panels adjacent to each other, insert the
5/16" hex wrench (packed in the hardware box) through
the access hole on the interior side of the panel skin and
into the hex opening in the Posi-Loc. Turn the hex
wrench clockwise approximately 7/8 of a complete turn.
The Posi-Loc is completely locked down.
Operating the Posi-Loc Device
Important
Be sure the Posi-Loc is in the unlocked position
before attempting to lock two panels together. To
completely unlock the Posi-Loc, insert the hex
wrench into the Posi-Loc and turn it counter-
clockwise.
Installation Instructions Section 2
2-4
Part Number 11324 2/08
TYPES OF FLOORS
Installation instructions are provided for three basic
types of walk-in floors:
Pre-fabricated sections on an existing floor
Pre-fabricated floor sections in a recessed pad
Built-in insulation screed floor
Instructions for installing screed-type and other types of
flooring are available through the factory, or with the
Special Installation Instruction Sheets which may be
enclosed with your installation materials.
Pre-fabricated Floor Section Installation
Stationary floor loads of up to 700 pounds per square
foot can be stored on Kolpak standard pre-fabricated
floor sections.
If mobile equipment is used (dollies, carts, etc.), the floor
must be reinforced with a diamond tread aluminum
plate.
If forklift trucks are used, special construction techniques
must be followed.
If the walk-in is to be installed next to an existing wall,
allow a minimum of 2" of clearance of airflow.
!
Caution
Staining or discoloration of panels caused by quarry
tile or “concrete wearing” floor is not covered by the
warranty.
The sheet metal panel facings may be susceptible
to staining due to excessive moisture created by
hydration of concrete-type materials. Therefore
proper ventilation of each room is required.
Special precautions must be taken when using
muriatic acid. The hydrochloric acid fumes can have
an effect on both aluminum and stainless steel.
Section 2 Installation Instructions
Part Number 11324 2/08 2-5
FLOOR LEVELING
In cases where the floor is level and no shimming is
required, lay a 6 mil polyethylene sheet or 50 pound
asphalt paper (not supplied) between the floor sections
and the existing floor.
In cases where the floor is not level, determine the high
point of the installation area and level from this point.
Kolpak recommends using a transit level (rather than a
spirit type).
One method of leveling uses shims (redwood or western
red cedar) and wooden supports as shown below.
Always shim between the building floor and the wooden
supports.
Leveling with Shims and Wooden Supports
The leveling method shown below uses shims spaced
24 inches on center under the floor panels.
Leveling with Spaced Shims
If a heavy product load will be stored in the walk-in,
support the entire underside of the floor with dry sand
poured level with the shims. Also, add a sealer strip
around the perimeter of the walk-in.
Leveling for a Heavy Product Load
!
Caution
A level walk-in floor is essential.
Take care to ensure a level floor. Wall and ceiling
panels will not align properly, causing installation
and operation problems.
Installation Instructions Section 2
2-6
Part Number 11324 2/08
INSTALLING FLOOR SECTIONS
Refer to the blueprint in the installation packet. The
blueprint shows the panel identification for installation of
the walk-in.
1. Begin with an edge section corresponding to the
blueprint and place it in position in the installation
area.
2. Check the floor section to be sure it is level.
Checking the Levelness of the Floor Section
3. Move the next panel into position and check to be
sure it is level.
4. Engage the Posi-Locs between the two floor panels.
(See “Posi-Loc Locking Device” on page 2-3.)
5. Repeat this procedure until the floor is fully installed.
MULTIPLE COMPARTMENT WALK-INS
Special “tee” floor panels are supplied with a multiple-
compartment walk-in. Be sure that these panels are
installed in the correct positions according to the
blueprint. Be careful to note that the tongue and groove
edges are the same as shown on the blueprint when
installing “tee” panels.
Typical “Tee” Floor Panel
Important
Be sure the floor panel(s) with the door cut-out (if
applicable) are installed in the correct position(s)
according to the blueprint. This will ensure that the
door can be installed properly later.
Section 2 Installation Instructions
Part Number 11324 2/08 2-7
Wall Installation
WALL PANELS
To install the wall panels:
1. Start installing wall panels with a corner panel.
Follow the blueprint to select the correct panel.
2. Place the corner panel in position, but do not
Posi-Loc it to the floor yet.
NOTE: All panels are marked “TOP” for correct
orientation.
3. Following the blueprint, select and install the next
adjacent wall panel.
4. Engage the Posi-Locs to their fully locked position.
(See “Posi-Loc Locking Device” on page 2-3.)
5. Make sure the tops of the corner and wall panels are
flush.
NOTE: If walls panels have a stair step effect, take wall
panels down and level floor panels or concrete pad.
6. Repeat Steps 3 – 5 to continue adding wall panels
in both directions from the corner panel. Do not
Posi-Loc the wall panels to the floor yet.
7. When you reach a corner, follow the blueprint to
select and install the correct corner panel.
8. Repeat Steps 3 – 7 until all of the wall panels are
installed. Do not Posi-Loc the wall panels to the
floor yet.
NOTE: Plan to end at a corner. The final wall panel must
mate with two other wall panels at the same time. This
can only happen at a corner.
Installation Instructions Section 2
2-8
Part Number 11324 2/08
DOOR FRAME PANEL
During installation of the wall panels, you will eventually
reach the door frame panel. To install:
1. Follow the blueprint to place the door frame panel
correctly.
2. Posi-Loc the door frame panel to the adjacent wall
panel.
3. Check for plumb using a spirit level on the face of
the door frame panel.
Checking for Plumb
4. Adjust the position of the door frame panel (if
necessary) before installing the next wall panel.
COMPLETING WALL PANEL INSTALLATION
After all of the wall panels are installed:
1. Check all panels for flush fit across the tops of the
vertical seams.
2. Posi-Loc the wall panels to the floor panels or
screeds.
!
Caution
Do not remove the door from the jamb.
The door frame panel has blocking between the
door and the frame to protect them from twisting
during shipping. Do not remove the blocking until
the door frame panel is locked to both adjacent wall
panels. Do not discard the threshold plate mounted
to the blocking.
Section 2 Installation Instructions
Part Number 11324 2/08 2-9
Ceiling Installation
INSTALLING CEILING PANELS
To install the ceiling panels:
1. Start installing ceiling panels with an end or outside
panel. Follow the blueprint to select the correct
panel.
2. Place the end ceiling panel in position on top of the
wall panels.
3. Following the blueprint, select and install the next
adjacent ceiling panel.
4. Adjust the panel position to align the end caps.
5. Posi-Loc the two ceiling panels together. (See “Posi-
Loc Locking Device” on page 2-3.) Do not Posi-Loc
the ceiling panels to the wall panels yet.
6. Make sure that all joints and seams are flush.
7. Repeat Steps 3 – 6 to continue adding ceiling
panels. Do not Posi-Loc the ceiling panels to the
wall panels yet.
8. After all of the ceiling panels are installed and locked
together, check all wall to ceiling joints for flush fit
and proper alignment.
9. Posi-Loc the ceiling panels to the wall panels.
CEILING/WALL JOINT ALIGNMENT ON LARGE
STRUCTURES
When installing the ceiling on a large structure, it may
appear that there is a problem aligning the final row of
ceiling panels with the wall panels. The ceiling may
appear to be longer than the walls.
This condition is not due to a manufacturing defect. It is
a result of the manufacturing tolerances in the panels
and uneven pull-up at the panel joints. Since, in large
structures, there are many more wall panels than ceiling
panels, this condition shows up as the final row of ceiling
panels is installed.
There is a simple way to correct this condition. If the
distance from the end of each ceiling panel to the
nearest wall joint (called “stagger”) is maintained along
the entire length of the structure, all of the panels will fit
and Posi-Loc properly.
Measuring the Stagger
Single Compartment Structures
1. During the wall installation process, install just
enough wall panels to allow installation of the first
ceiling panel.
2. Install the first ceiling panel. Align it with the corner
and lock down the corner Posi-Loc.
3. Measure the stagger from the end of the ceiling
panel to the nearest wall joint.
Important
On multi-compartment walk-ins, start with a “tee”
ceiling panel instead of an end or outside ceiling
panel.
Important
Be sure any ceiling panels with cut-outs for the
refrigeration systems are installed in the correct
position(s) according to the blueprint.
!
Caution
If the wall panel tops were not leveled (made flush)
at the seams earlier, the ceiling panels will not install
correctly. The wall and ceiling panels will not align
properly, causing gaps. This will lead to operational
problems.
Correct any level problems at this time.
Installation Instructions Section 2
2-10
Part Number 11324 2/08
4. Compare the measured stagger to the stagger
dimension on the blueprint.
NOTE: The stagger dimension on the blueprint is always
a multiple of 11-1/2" (11-1/2", 23", 34-1/2").
5. If the measured stagger is not long enough, loosen
the top wall panel Posi-Locs on the adjacent two
panels. Allow the gasket in the seam to push the two
wall panels apart until the measured stagger
matches the stagger dimension on the blueprint.
6. Engage the Posi-Loc on the ceiling panel at the
stagger end to lock it to the wall panel.
7. Posi-Loc the wall panels together again.
8. Engage all remaining Posi-Locs on the ceiling panel
to lock it to the wall panels.
9. Repeat this process throughout the installation until
all of the ceiling panels are installed.
Multi-Compartment Structures
The procedure for multi-compartment structures is the
same as the procedure for single compartment
structures, except that ceiling construction must begin
over the partition wall. Add ceiling panels in both
directions from the first panels, measuring stagger in
each direction as panels are added.
Finishing Work
DOOR THRESHOLD INSTALLATION
Refer to the Special Installation Instruction Sheet
enclosed with your installation materials for information
on your specific installation.
THERMOMETER BULB INSTALLATION
A coiled length of lead wire with a thermometer bulb is
located on the inside of the door frame panel. Uncoil the
wire. Using the plastic clip and screw provided, fasten
the bulb to a wall panel located away from the door
frame panel, at 42" above the floor.
PANEL PENETRATIONS
In some cases, it will be necessary to penetrate the
walk-in to run electrical and refrigeration lines. When
making a penetration, be careful to avoid panel seams
and Posi-Locs.
Area to Avoid When Making Panel Penetrations
To make a penetration into the walk-in:
1. Determine the exact location and size of the hole
needed.
2. Mark the location and the size on the outside and
inside of the walk-in.
3. Use a drill to make the penetration if a drill bit of the
correct size is available. For holes too large to drill,
use metal shears to cut the panel skin.
4. After making the penetration, carefully remove any
insulation from the hole.
Important
Do not locate the thermometer bulb on the door
frame panel. The thermometer will display a false
reading due to the heater wires in the door jamb,
and warm air entering the walk-in when the door is
opened.
!
Caution
Ceiling penetration may only be made on indoor
walk-ins. Do not make ceiling penetrations on
outdoor walk-ins. Water damage from rain in the
walk-in and/or inside the ceiling panel may result.
Section 2 Installation Instructions
Part Number 11324 2/08 2-11
5. Run the line(s) through the hole.
6. Seal the penetration with the sealant provided in the
hardware box.
Electrical Connections for Door(s)
Make the electrical connections for the door area near
the light base on the inside of the door frame panel(s).
Kolpak recommends using a junction box located next to
the light base, as shown in the drawing below.
Connect the power supply to the door frame panel as
shown in the wiring diagram on the next page.
Typical Electrical Connections at the Door Frame Panel
!
Caution
Be sure to seal all panel penetrations completely.
Operational problems and damage to the walk-in
may result.
!
Caution
Do not leave the heater wire power on when the
refrigeration system is not running. Excessive heat
build-up will damage the heater wire and door
gasket.
Damage of this type is not covered by the warranty.
Installation Instructions Section 2
2-12
Part Number 11324 2/08
Wiring Diagram
Section 2 Installation Instructions
Part Number 11324 2/08 2-13
Post Installation Checklist
Complete these checks before operating the walk-in for
the first time. Put a check mark in each box as you
complete each task.
Verify that all Posi-Locs are fully engaged and
that all gasket joints are tight.
Be sure that all plug buttons are installed in the
Posi-Loc access holes.
Important
Metal plug buttons are used on the Posi-Loc access
holes in the floor panels. Plastic plug button are
used on all other Posi-Loc access holes.
Verify that all panel penetrations have been
sealed properly and that all fittings have been
tightened.
Make sure the heater wire around the door
jamb is operating. Feel the metal surface on the
door jamb to see if it is warm.
!
Caution
Do not leave the heater wire power on when the
refrigeration system is not running. Excessive heat
build-up will damage the heater wire and door
gasket. Damage of this type is not covered by the
warranty.
Make sure the self-closing door operates
correctly.
If the door does not operate correctly, check whether
the jamb and door are plumb using a spirit level. If the
door is not level, loosen the Posi-Locs around the door
frame panel, adjust the panel until it is plumb, and
relock the Posi-Locs. If the door is level and still does
not operate correctly, see “Posi-Seal Door Closure” on
page 3-2).
Verify that all of the gaskets around the door
jamb perimeter seal properly.
Make sure that the thermometer bulb has been
secured to the inside wall of the walk-in.
Installation Instructions Section 2
2-14
Part Number 11324 2/08
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Kolpak Walk-ins PCL249LOP Operating instructions

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