Kolpak Walk-ins PCL249LOP2 Operating instructions

Brand: Kolpak Walk-ins

Model: PCL249LOP2

Type: Operating instructions

This manual is also suitable for

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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