Kolpak PCL249LOP Operator’s Manual
Refrigeration Systems
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 11325 03/08
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
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section 2
Installation Instructions
Pre-installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Location of Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Refrigerant Piping Hanger Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installing Model PR Field-charged Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installing Model PCL Pre-charged Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Evaporator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Condenser Unit Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drain Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Panel Penetrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Charging Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Compressor Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mounting Defrost Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Post Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Table of Contents
Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Multiple Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Walls or Obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Multiple Evaporator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Oil Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Walk-in Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Walk-in Freezers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Polyol Ester (POE) Lubricants (Used with HFC Refrigerants) . . . . . . . . . . 2-6
Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Part Number 11325 03/08 i
Section 3
Operation
Section 4
Maintenance
Table of Contents (continued)
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Start-up Proc edure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Defrost Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operational Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Compressor Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Evaporator Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Defrost Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Refrigerant Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section 5
Before Calling for Service
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Equipment/Service Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
System Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Evaporator Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Compressor Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
ii Part Number 11325 03/08
Section 1
Serial Number
KS1005
General Information
Model Numbers
This manual covers the following models:
Pre-charged Lines Field-charged Lines
PCL PR
Serial Number Location
This number is required when requesting information
from your local distributor. The serial number is listed on
the SERIAL NUMBER DECAL affixed to the condensing
unit assembly.
Serial Number Location
Part Number 11325 03/08 1-1
General Information Section 1
THIS PAGE INTENTIONALLY LEFT BLANK
1-2
Part Number 11325 03/08
Section 2
!
Caution
!
Caution
Installation Instructions
Pre-installation Checklist
Follow these guidelines during the installation process:
Check the selected installation location to
ensure that racks, braces, floor, foundations,
etc., are adequate to support the weight of the
unit.
Verify that system piping is in accordance with
good refrigeration practices.
When brazing refrigerant lines, pass an inert
gas through the line at low pressure to prevent
scaling and oxidation of the tubing. Nitrogen is
recommended.
Do not lift the condensing unit assembly by the
refrigerant tubing. Damage may result.
Location of Equipment
CONDENSING UNIT
For optimum air-cooled equipment performance, these
are the most critical clearance requirements:
• a sufficient supply of ambient air to the condenser
• adequate space for removal of the heated
discharged air from the condensing unit area
If either clearance requirement is ignored, higher
system head pressure will result, causing poor
system operation, shorter equipment life and an
increased risk of equipment failure.
Position the condensing unit:
• in a clean, dry, level area
• away from steam or hot air exhaust sources
• away from corrosive atmospheres
• away from noise-sensitive areas
• with adequate support to minimize undesirable
vibration and noise transmission
Part Number 11325 03/08 2-1
Installation Instructions Section 2
!
Caution
MINIMUM
DISTANCE
MINIMUM
DISTANCE
MINIMUM
DISTANCE
AIR FLOW AIR FLOW
BUILDING WALL
(VIEWED FROM ABOVE)
KS1002
AIR FLOW
MINIMUM
DISTANCE
BUILDING
WALL
MOUNTING SURFACE
KS1003
!
Caution
Important
MULTIPLE UNITS
Separate side-by-side units with a minimum distance
equal to the width of the largest unit.
Multiple Units with Horizontal Airflow
WALLS OR OBSTRUCTIONS
To avoid re-circulation of condenser air, an d to allow for
proper airflow and access, all sides of the unit should be
positioned a distance equal to the total width of the
condensing unit away from any wall or obstruction.
Increase this distance where possible to increase airflow
and access to the unit.
Electrical
FIELD WIRING
All electrical connections and routing must conform to
local and national codes. Do not modify the factoryinstalled wiring without written factory approval.
The field wiring must enter through the knockou ts
provided. All field wiring must be properly connected
according to the wiring diagram.
NOTE: The wiring diagram for each unit is located on the
inside of the electrical box within the unit.
Refer to the nameplate rating label on the unit to
determine the correct electrical power supply. Consult
the wiring diagram for proper electrical connections.
Use copper conductors only. The unit must be
grounded.
If a remote defrost timer is used, the timer must be
located outside the refrigerated space.
The power supply to the unit must meet the following
conditions:
• Single-phase must be within + 10% or – 5% of
nameplate ratings.
Space Requirements Near Walls and Obstructions
Do not position multiple units in a way that would
permit discharge air from one unit to enter the air
inlet of another unit. This could cause system
overheating and equipment failure.
• Three-phase voltages must be ± 10% of nameplate
ratings.
• Phase imbalance cannot exceed 2%.
Connections can become loose during shipment.
Check all wiring connections before operation.
MULTIPLE EVAPORATOR SYSTEMS
To assure complete defrost with multiple evaporator
systems, wire the defrost termination controls in series.
2-2
Part Number 11325 03/08
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