Kolpak MAC 7 Operators Manual
MAC Series
Operation Manual
Manitowoc Foodservice Walk-In Division
2915 Tennessee Avenue North
Parsons, TN 38363
Phone: 800-225-9916
www.manitowocfoodservice.com
www.manitowocfoodservice.com 800-225-9916 1
P/N 550003765 REV. 5
August, 2014
ECO KPR114586
www.manitowocfoodservice.com 800-225-9916 - 2 -
Table of Contents
Cool Start Guide ……………………………………………………………… 4 - 5
Safety Information ……………………………………………………………. 6
Condensing Unit Specifications …..………………………………….…….. 7
Evaporator Unit Specifications …………………………………………. ….. 8
Receiving Inspection ……………………………………………………. ….. 9
Locating and Mounting Condensing Units ………………………………… 9 – 10
Locating and Mounting Evaporator Coils …………………………………. 11
Condensing Unit and Evaporator Coil Wiring……………………………… 12
Piping …………………………………………………………………………. 12 - 14
Leak Test ……………………………………………………………………… 15
Evacuation ……………………………………………………………………. 16
Refrigerant Charging ………………………………………………………… 17
Compressor Mounts………………………………………………………….. 17
ArcticFox Interface Installation………………..…………………………….. 18 - 19
Operational Start-Up ….……………………………………………………… 20
Compressor Superheat ……………………………………………………… 21
Evaporator Superheat ………………………………………………………. 22
ArcticFox Features…………………………………………………………… 23
ArcticFox Wiring……………………………………………………………… 24
ArcticFox Initialization……………………………………………………….. 25
ArcticFox Button Functions…………………………………………………. 25
ArcticFox Programming……………………………………………………… 26 – 30
ArcticFox Alarm Codes………………………………………………………. 31
Sustaining Mode………………………………………………………………. 31
Data Logging…………………………………………………………………... 32
On Demand Defrost…………………………………………………………… 32
System Defaults………………………………………………………………. 32 – 36
Parts List………………………………………………………………………. 37 - 38
Maintenance ………………………………………………………………….. 39
Warranty Information ………………………………………………………… 40
System Start-Up Data Sheet ………………………………………………… 41
Appendices……. ……………………………………………………………… 42 – 51
A – Sensor Failure Codes……………………………………………. 42 – 43
B – Cooler or Freezer Set Up………………………………………… 44
C – Defrost Set Up…………………………………………………….. 45
D – Condensing Unit Wiring Diagram………………………………… 46 - 47
E – Air Defrost System Wiring Diagram…………………………….. 48
F – Electric Defrost System Wiring Diagram……………………….. 49
G – Standard Exterior Door Section Wiring…………………………. 50
H – Standard Partition Door Section Wiring ……………………….. 51
www.manitowocfoodservice.com 800-225-9916 - 3 -
ArcticFox Cool Start Guide:
Alternative Display for
Single Unit
Manual Light Indicator
Soft Buttons (SB1, SB2)
Selects the item highlighted
on the display
Up and Down Arrows
Used to highlight items or
enter values
Menu Button
Light Button
Enter ()
Cancel (X)
Note: Dual control mode shown
General operation of the UI:
SB1 and SB2 perform or select the item that is highlighted above it. In the case
of the picture above pressing SB1 will activate the “Cooler” menu.
The Up and Down arrows are used to select items from a list or adjust the value
of a setting.
The <X> key has the following functionality:
o Cancels entry of current setting
o Silences the Alarm for 5 minutes
o Stops the status scrolling on the top of the display (The enter key also
stops the scrolling). Pressing either the <X> or the <> key will resume
scrolling (there may be a 1-2 second delay for the scrolling to start again.
With the scrolling stopped the Up or Down arrows change the parameter shown.
The light key turns on both the Cooler and Freezer’s lights (if walk-in is so
equipped).
The <Menu> key allows access (with password) to the system parameters and
other service features.
The <> key “enters” or “accepts” a choice while changing settings.
www.manitowocfoodservice.com 800-225-9916 - 4 -
Function Steps
Set Time and Date
Set Temperatures
Set Temperature Alarms
Set Door Alarm Time
Silence Alarms
Clearing Alarms
Set User Password
Set Service Password
1. Press the <Menu> button and enter password (AAAA is default)
2. Enter password, then press <>
3. Press <Down> to scroll to "Set Date & Time", then press <>
4. Press <Up> or <Down> to select the hour, then press <>
5. Press SB2 (under NEXT) to move on to the minute screen.
6. Follow steps until time & date are set, then press < X > to return to main display
1. Press <SB1> or <SB2> and enter password (AAAA is default)
2. Press <Up> or <Down> to change the desired temperature
3. Press <> to enter selection
4. Press <X> to return to main display
1. Press <SB1> or <SB2> and enter password (AAAA is default)
2. Press <SB2> to navigate to "SET COOLER HIGH ALARM"
3. Press <Up> or <Down> to obtain the desired setting
4. Press <SB2> to navigate to "SET COOLER LOW ALARM"
5. Press <Up> or <Down> to obtain the desired setting
6. Press <> to enter selection
7. Press <X> to return to main display
1. Press <SB1> or <SB2> and enter password (AAAA is default)
2. Press <SB2> to navigate to "SET COOLER DOOR ALARM TIME"
3. Press <Up> or <Down> to obtain the desired setting
4. Press <> to enter selection
5. Press <X> to return to main display
Pressing <X> will silence the alarm for 5 minutes
Pressing <X> and <> simultaneously for 3 seconds will permanently silence alarm
1. Press <SB1> or <SB2> and enter password (AAAA is default)
2. Press <SB1> to navigate to "CLEAR COOLER ALARMS"
3. Press <Up> or <Down> to obtain the desired setting
4. Press <> to enter selection
5. Press <X> to return to main display
1. Press the <Menu> button
2. Enter password, then press <>
3. Press <Down> to scroll to "Set User Password", then press <>
4. Enter old password (default is AAAA) and press <>
5. Enter new password and press <>
6. Re-enter new password to confirm and press <>
7. Press <x> twice to return to main display.
1. Press the <Menu> button
2. Enter password, then press <>
3. Press <Down> to scroll to "Service Menu", then press <>
4. Press <Down> to scroll to "Set Service Password", then press <>
5. Enter old password (default is ZZZZ) and press <>
6. Enter new password and press <>
7. Re-enter new password to confirm and press <>
8. Press <x> three times to return to main display.
www.manitowocfoodservice.com 800-225-9916 - 5 -
Note: If the walk-in is a freezer, substitute freezer in place of cooler nomenclature.
General Safety Information:
Read this manual carefully before beginning the installation and operation of the
refrigeration system. Special attention is required to all sections identified with the
following warning and caution notices:
WARNING
Text in a Warning box alerts you to a potential personal injury situation. Read each
Warning statement before proceeding and work carefully.
CAUTION
Text in a Caution box alerts you to a situation in which you could damage the
refrigeration system. Read each Caution statement before proceeding and work
carefully.
Disregarding these special notices may result in personal injury and/or damage to the
refrigeration system.
Safety Notices:
Installation and maintenance/servicing are to be performed only by trained and
qualified personnel familiar with commercial refrigeration systems.
Ensure that all field wiring conforms to the equipment requirements and all
applicable local and national codes.
Disconnect all power sources before installing the controller wiring.
Disconnect all power sources before servicing the refrigeration equipment.
Sheet metal and coil surfaces have sharp edges. Use appropriate protective
gloves to prevent injury.
Use appropriate eye protection during installation and servicing.
www.manitowocfoodservice.com 800-225-9916 - 6 -
Condensing Unit Specifications
Model Location Compressor Voltage HP MCA MOP
FREEZER ZF13K4E-TF5 208-230/3/60 4.5
MAC 7
COOLER CF04K6E-TF5 208-230/3/60 1.5
FREEZER ZF15K4E-TF5 208-230/3/60 5.5
MAC 8
COOLER CF04K6E-TF5 208-230/3/60 1.5
31.3 40 660 lbs
38.8 50 660 lbs
Approx.
Weight
MCA – Minimum Circuit Ampacity.
MOP – Maximum Overcurrent Protection.
www.manitowocfoodservice.com 800-225-9916 - 7 -
Evaporator Unit Specifications
No.
of
Fans
A B
Suction
OD
Liquid
OD
Motor
Amps
Heater
Amps
Model Location
FREEZER EL36-140-2MAC 14,000 3 63.50 55.00 7/8" 3/8" 1.35 13.00 115 lbs
MAC
7
COOLER AM28-134-2MAC 13,400 2 45.50 37.00 7/8" 3/8" 0.90 n/a 77 lbs
FREEZER EL46-185-2MAC 18,500 4 81.50 36.50 1-1/8" 3/8" 1.80 13.00 155 lbs
MAC
8
COOLER AM28-134-2MAC 13,400 2 45.50 37.00 7/8" 3/8" 0.90 n/a 77 lbs
Evaporator
Model
BTUH
Approx.
Weight
www.manitowocfoodservice.com 800-225-9916 - 8 -
Receiving Inspection
Check the shipment carefully and compare to the bill of lading. Account for all items
listed and inspect each container for damage. Carefully inspect for any concealed
damage. Report any shortages or damages to the carrier, note on the bill of lading, and
file a freight claim.
Damaged material cannot be returned to the manufacturer without prior approval. A
Return Material Authorization (RMA) must be obtained. Contact a sales representative
at 800-826-7036.
Locating and Mounting Condensing Unit
General Guidelines:
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.
Use the condensing unit skid and base when moving the unit. Do not remove
unit from skid until the unit is moved to the mounting location.
Mount the condensing unit base to pads or structural rails using properly sized
bolts through the unit base.
WARNING
Do not lift the condensing unit by the refrigerant tubing or components. These features
will not support the condensing unit weight. Injury and unit damage may occur!
CAUTION
Do not leave the condensing unit mounted to the wooden skid. This prevents all of the
unit supports from contacting the mounting surface. Excessive vibration and premature
equipment failure can occur.
www.manitowocfoodservice.com 800-225-9916 - 9 -
Clearance Requirements:
Locate where there is a sufficient and unrestricted supply of clean ambient air.
Locate where there is adequate space for the removal of the heated discharged
air from the condensing unit area.
Do not position multiple units so that discharge air from one unit is blowing into
the condenser inlet air of the other unit.
All sides of the unit should be positioned a minimum distance equal to the total
width of the condensing unit away from any other unit, wall, or obstruction.
Example of Multiple Units with Horizontal Airflow
AIR
FLOW
AIR
FLOW
MINIMUM
DISTANCE
24”
INTAKE AIR
MINIMUM DISTANCE 24”
(VIEWED FROM ABOVE)
24”
BUILDING WALL
24”
INTAKE AIR
MINIMUM DISTANCE 24”
CAUTION
Failure to observe clearance and air flow requirements will result in poor system
performance and premature equipment failure!
www.manitowocfoodservice.com 800-225-9916 - 10 -
Locating and Mounting Evaporator Coil
General Guidelines:
Do not place the evaporator above or close to door openings. This will help
prevent potential icing problems.
Allow a minimum clearance equal to or greater than the coil height on all sides of
the coil for proper air flow and service access. This does not apply to fan side.
Use the evaporator coil for a template to locate and drill the mounting holes (1/2”
diameter).
Place a 1” and a 1-5/8” washer on each nylon bolt and insert through the drilled
mounting holes.
Lift the evaporator coil until the nylon bolts extend through the mounting
brackets.
Install washers and secure with nuts. Tighten until the coil is firm against the
ceiling. The evaporator coil must be level.
Additional information is available in the installation manual supplied with the
evaporator.
CAUTION
Failure to observe clearance and air flow requirements will result in poor system
performance and premature equipment failure!
Evaporator Coil Mounting Diagram
Nylon Bolt 1” O.D. washer
1-5/8” O.D. washer
1” O.D. washer
Nut
Note: Fasteners are
supplied in the
mounting kit.
Evaporator
Mounting
Bracket
www.manitowocfoodservice.com 800-225-9916 - 11 -
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. Wire type should be of
copper conductor only and properly sized to handle the electrical load. The unit and coil
must be properly grounded. Condensing unit wiring diagrams are attached inside the
electrical box cover. Evaporator coil wiring diagrams are located inside the evaporator
end panel. Copies of the wiring diagrams are also available in the back of this manual.
WARNING
All wiring must comply with local and national codes. Wiring must be performed only by
a refrigeration technician or certified electrician. Failure to follow these guidelines may
result in injury!
CAUTION
Check all wiring connections, including factory terminals, before operation. Connections
can become loose during shipment and installation.
Piping
General Requirements:
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. Long radius elbows should be used. Short radius elbows have
points of excessive stress concentration and are subject to breaking at these points, do
www.manitowocfoodservice.com 800-225-9916 - 12 -
not use short radius elbows. Suction lines must be insulated with a minimum 1” thick
armaflex to reduce heat pick-up.
Cleanliness:
Condensing units and evaporator coils are cleaned and dehydrated at the factory. The
condensing unit must remain closed and pressurized until the piping is complete and
final connections are ready to be made.
CAUTION
The maximum air exposure for dehydrated condensing units is 15 minutes. Systems
exposed longer than 15 minutes must have the compressor oil and drier filter replaced.
Leaving a system exposed to the atmosphere for more than 15 minutes can result in
premature system failure.
Note: PC model condensing units are supplied with a refrigerant charge. PR model
condensing units are supplied with a dry holding charge.
Do not remove system tubing covers until work is ready to be performed. Ensure that
all refrigeration tubing is clean and dry prior to installation. Use only tubing cutters when
trimming tubing to the proper length. Do not use saws to cut tubing.
CAUTION
The use of saws to cut tubing can contaminate the system with copper chips causing
premature system failure.
Brazing joints require a dry inert gas, typically nitrogen, be passed through the lines at a
low pressure to prevent scaling and oxidation. Use only silver solder brazing alloys.
Minimize the amount of flux to prevent internal contamination. Flux only the male
portion of the joint. Thoroughly clean fluxed joints after brazing.
CAUTION
Dry inert gas must be passed through the system while brazing to prevent scaling and
oxidation. Scaling and oxides can clog refrigeration components resulting in system
failure.
Pipe Supports:
All tubing should be supported in a least two locations (near the end of each tubing run).
Long runs will require additional support. As a guide, support 3/8” to 7/8” pipe every five
feet, 1-1/8” to 1-3/8” every seven feet, and 1-5/8” to 2-1/8” every ten feet. Do not leave
a corner unsupported when changing directions. Place supports within 2 feet of each
direction change. Piping that is attached to a vibrating object (such as a compressor or
www.manitowocfoodservice.com 800-225-9916 - 13 -
compressor base) must be supported in a manner that will not restrict the movement of
the vibrating object. Rigid mounting will fatigue the tubing causing refrigerant leaks.
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. Add a
trap for each length of pipe (approximately 20 feet) to insure proper oil return. Suction
lines must slope ¼” per 10 feet toward the compressor. Install a suction line trap at the
evaporator outlet if the suction line rises to a point higher than the connection on the
evaporator.
CAUTION
Failure to properly install oil traps can prevent sufficient oil return to the compressor
resulting in premature compressor failure.
Drain Lines:
Evaporator coil drain lines should be pitched a minimum of ½” per foot to allow proper
drainage and exit the walk-in as quickly as possible. Insulate and seal the drain line
where it passes through the wall. Copper drain line is required. If the refrigerated
space is 33°F or lower, drain line insulation and heat tape are required. Drain lines
must be insulated with minimum ½” thick armaflex. The drain line heat tape must be
wrapped around the copper drain line. Do not locate bends, elbows, or drain traps
within the refrigerated space. Do not reduce the drain line size. Locate a drain line Ptrap outside of the refrigerated space. Any traps exposed to low ambient temperatures
should be wrapped with a drain line heater (provide 20 watts of heat per foot of drain
line at 0°F, 30 watts per foot at -20°F.
www.manitowocfoodservice.com 800-225-9916 - 14 -
Pitch drain line
½” per foot
Seal and
Insulate
Typical Drain Installation
P-Trap
Leak Testing
After all connections are complete the refrigeration system must be tested for leaks.
Failure to perform a leak test can result in unsatisfactory system performance,
additional servicing and service costs, and possible system failure. Leak test should be
performed using an electronic leak detector. 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.
Add 50 psi refrigerant, then pressurize with dry nitrogen to the low side test
pressure identified on the unit rating label.
Allow thirty minutes for refrigerant to reach all parts of the system.
Check all joints and components with an electronic leak detector.
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.
www.manitowocfoodservice.com 800-225-9916 - 15 -
Add 50 psi refrigerant, then pressurize with dry nitrogen to the low side test
pressure identified on the unit rating label.
Allow thirty minutes for refrigerant to reach all parts of the system.
Check all joints and components with an electronic leak detector.
If a leak is detected, relieve the pressure and/or reclaim the refrigerant and repair the
leak. If additional brazing is required, pass a dry inert gas (nitrogen) through the system
to prevent contamination. Retest the system as outlined above until no leaks are
detected.
CAUTION
If a braze joint is detected leaking, dry inert gas must be passed through the system
while repairing the joint to prevent scaling and oxidation. Scaling and oxides can clog
refrigeration components resulting in system failure.
CAUTION
Always use the system specified refrigerant when pressuring to perform a leak test.
System Evacuation
Evacuation of the refrigeration system is necessary to remove all air and moisture from
the system. 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.
Ensure the solenoid valve is energized and open.
Connect vacuum pump to the liquid and suction service valves.
Evacuate the system to 250 microns and maintain for a minimum of 4 hours.
Perform a vacuum decay test for a minimum of ten minutes to ensure the system
is leak free and dry.
Evacuation of “PC” model systems:
Leave the service valves closed, the condensing unit has been evacuated and is
charged with refrigerant.
Ensure the solenoid valve is energized and open.
www.manitowocfoodservice.com 800-225-9916 - 16 -
Loading...