Kolpak PCL149MOP Installation Manual
Installation, Use & Care Manual
This manual is updated as new information and models are released.
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Specified #1 Among Walk-ins
Part Number 11324 2/08
Walk-ins
Safety Notices
! Warning
!
Caution
Important
!
Caution
Important
! Warning
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:
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.
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 proc eeding, and
work carefully.
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:
Read These Before Proceeding:
Proper installation, care and maintenance are
essential for maximum performance and troublefree operation of your Manitow oc 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.
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
NOTE: SAVE THESE INSTRUCTIONS.
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.
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about th e pr oce dur e yo u
are performing.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
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
Section 2
Installation Instructions
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-fabricated Floor Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Wall Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Ceiling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Finishing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electrical Connections for Door(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Post Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Table of Contents
Storage Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Storage Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Posi-Loc Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Types of Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Floor Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installing Floor Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Multiple Compartment Walk-ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Wall Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Door Frame Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Completing Wall Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installing Ceiling Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Ceiling/Wall Joint Alignment on Large Structures . . . . . . . . . . . . . . . . . . . . 2-9
Door Threshold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Thermometer Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Panel Penetrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Part Number 11324 2/08 i
Section 3
Operation
Section 4
Maintenance
Table of Contents (continued)
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
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
ii Part Number 11324 2/08
Section 1
!
Warning
!
Warning
!
Caution
!
Caution
General Information
Model Numbers
This manual covers the following models:
Model Numbers
R Series
General Safety Notices
Read these safety notices before beginning any
installation work on these Kolpak Walk-ins.
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.
To avoid injury while assembling a Kolpak walk-in,
you must wear protective gear, including eye
shields, a hard hat and steel-toed boots.
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.
Until the walls are made stable by constructing the
corners, support extended wall lengths by bracing
them from both the inside and the outside.
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.
Modular Construction Made Fast and Easy
Kolpak walk-in coolers and freezers, or multicompartment 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 OUTSIDE
If the panels must be stored outside, stor e them on edge
with the grooved side (female rail) facing down. Kilndried 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.
Part Number 11324 2/08 1-1
General Information Section 1
THIS PAGE INTENTIONALLY LEFT BLANK
1-2
Part Number 11324 2/08
Section 2
Installation Instructions
Installation Overview
1. Unpack and inspect the shipment.
2. Prepare the installation area.
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.
3. If required, assemble pre-fabricated floor.
Continued on next page …
Part Number 11324 2/08 2-1
Installation Instructions Section 2
NOTE: Keep adjacent top and side surfaces flush. This
will make locking the Posi-Locs easier.
6. Reach the sec on d co rn er.
8. Install the door frame panel.
9. Complete the finishing work.
7. Construct the opposite walls in parallel. Begin
installing the ceiling.
2-2
Part Number 11324 2/08
Section 2 Installation Instructions
Important
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.
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 counterclockwise.
Operating the Posi-Loc Device
Part Number 11324 2/08 2-3
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