Norlake CPB0501C-A Installation Manual

RefRigeRation

SyStemS

inStallation

manual

07/14 Rev. H 040086

table of ContentS

Tools Required 3
General Information 4-5

Unpacking & Inspection for Ceiling Mount 4
Unpacking & Inspection for Remote 5
Wall Mount Refrigeration Systems 6-7
Installation Instructions 6
Freezer Models 100 & 150 or Cooler Model 075 7

General Installation Instructions for Ceiling Mount 8-9
Remote Refrigeration Systems 10-13

With Electric Vaporizer 10
With Optional Electric Condensate Vaporizer 11
Instructions for Pre-Charged Lines 12-13
Instructions for Wire Harness 14
Outdoor Systems 15-16
Membrane Roong Material 15-16
Operation 17-20
Standard Temperature (Cooler) Systems 17
Low Temperature (Freezer) Systems 18-20

Maintenance 20-21
Maintenance Analysis 22

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toolS RequiRed

toolS RequiRed foR unCRating and inStallation of the RefRigeRation SyStem

• Safety GlaSSeS

• Metal SnipS

• pry Bar

• HaMMer

• adjuStaBle Open end WrencH (2)

• drill driver

• pencil

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RefRigeRation SyStemS-geneRal infoRmation

Ceiling mounted RefRigeRation SyStem

geneRal infoRmation

This Refrigeration System was produced utilizing the latest in manufacturing technology, the highest quality
materials available, along with innovations that make it a distinctive product in its field. Despite rigid controls in
the production of the product, there is no substitute for thoroughly reading and UNDERSTANDING the instructions
that follow. The result will be an orderly and efficient installation. Please take the time to follow the steps explicitly!

unpaCking & inSpeCtion--Ceiling mount SyStem

Check the Delivery Receipt for the number of pieces that made up the shipment and make sure that the number
of pallets, boxes or crates agrees with that number. Each piece should be clearly marked with the same five-digit
order number that appears on the Delivery Receipt as the shipper's number.

Examine the general condition of the shipment and, as soon as unpacking is completed, carefully inspect all parts
for possible shipping damage. If damaged parts are discovered, contact the supplier immediately.

Delivery Receipt

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RefRigeRation SyStemS-geneRal infoRmation

unpaCking & inSpeCtion--Remote RefRigeRation SyStemS

Check the Delivery Receipt for the number of pieces that made up the shipment and make sure that the number
of pallets, boxes or crates agrees with that number. Each piece should be clearly marked with the same five-digit
order number that appears on the Delivery Receipt as the shipper's number.

Examine the general condition of the shipment and, as soon as unpacking is completed, carefully inspect all parts
for possible shipping damage. If damaged parts are discovered, contact the supplier immediately.

It is recommended the condensing unit be elevated from the deck a minimium of 12"-18" to ensure the condenser
fan is not drawing or pulling heat reflected off the building roof or pavement in a grade level installation in which
the summer heat may exceed 120°F.

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Wall mounted RefRigeRation SyStemS

inStallation inStRuCtionS

Note: If the system to be wall mounted is a freezer model 100 or 150 or cooler model 075, please see the next
section with special instructions on mounting these units.

Carefully raise the entire refrigeration system and insert the projecting sleeve of the evaporator section into the
opening of the walk-in wall. While supporting the system, lock it into position by turning the locks exactly as you
did when locking the walk-in sections together. Make sure that the locks are positively engaged and insert the plug
buttons into the lock access holes when finished. Refer to Figure 1.

Note: Some motor compressors are openly spring mounted to absorb vibration. Be sure that these bolts are
loosened to permit the compressor to float freely on the springs. A reminder label is applied to systems where this
procedure applies.

Some systems require a permanent connection to an electrical service and a connection at the junction box located
within the condensing unit housing. Refer to the serial tag for all pertinent electrical data. These systems must be

connected to a power supply disconnect switch and wired according to local and national electric codes.

Figure 1.

Wall Mounted Refrigeration System

No plumbing drain is required, under normal conditions, for indoor installations. A built-in hot gas vaporizer
dissipates the condensate moisture automatically. In outdoor installations, the condensate should be plumbed to
the nearest drain. Check local building codes. Outside drain lines must also be wrapped with a suitable heater wire
if they are ever subjected to below freezing temperatures. Outdoor installations also require the attachment of the
rain hood that will divert rainfall from the upper surface of the evaporator housing. See Figure 1 for an illustration.

Be sure to allow for sufficient airflow around the condenser. A minimum clearance of six inches is required for
installation and a minimum of two feet is required for service consideration. Ambient temperature around the
system should be less than 90°F and 50% RH. If multiple units are located in the same area, be sure they do not
exhaust hot air flows into one another. In addition to allowing for proper airflow, consideration should be given to
the final mounting location of the refrigeration system relative to the customer location to avoid any possible risk
of noise impacting the customer experience.

Please see the section “Instructions for Pre-Charged Lines” if the installation of this system involves the use of
pre-charged lines to connect the evaporator and condenser sections.

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Freezer Models 100 and 150 or Cooler Model 075

1. After uncrating, before attempting to attach the refrigeration system to the walk-in, a substantial temporary

support should be built. The support should be approximately 28 inches high and placed directly below the wall
opening of the walk-in.

Note: Due to the weight of these systems it is highly recommended that proper lifting equipment, such as a fork
truck, be utilized during installation.

2. Lift the refrigeration system onto the temporary support. Determine whether the coil section sleeve is positioned
properly so that it can be inserted into the opening without being bent or damaged. Shim the system appropriately
so that this can be accomplished.

3. Carefully slide the entire system so that the coil section sleeve enters the opening without disturbing the
temporary support below the refrigeration system. Continue until the gasket around the coil section contacts and
seals around the entire perimeter of the coil section. Shim the system and adjust it accordingly so that the gasket
seal will be uniform on all four sides.

4. Using the section-latching wrench provided for the erection of the walk-in, insert the wrench into the latch access
holes of the coil section. Turn each of the locks clockwise until the latches engage the strikes in the walk-in. Turn
the lock until a full stop is encountered. DO NOT REMOVE THE TEMPORARY SUPPORT!

5. Remove the louver assembly and drill four 9/16” diameter holes through the two upright angles of the condensing
unit section. Drill completely through the walk-in wall and insert the 1/2" threaded nylon rods. Secure with the flat
washers and nuts provided. Refer to Figure 2.

6. With the leveling screws threaded completely into the leg support, insert the leg support into the leg retainers
at the outer corners of the condensing unit section. Unscrew the leg leveling screws until they contact the floor or
other supporting surface. Note: If the supporting surface is extremely uneven, suitable shimming material must be
provided under one or both of the leg supports.

7. Attach the diagonal leg support braces using the
threaded fasteners provided. Make the final adjustments
to the leg leveling screws so that they serve as supporting
devices to the outer edge of the refrigeration system.

8. Insert plug buttons into each of the latch access holes.

9. Remove the temporary support assembly that was

provided in Step 1.

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This section has the general instructions for installing the ceiling
mounted Refrigeration System. Before proceeding, also see the
following section on mounting "Remote Systems with Electric
Vaporizer", if applicable.

Note: Proper "temporary" interior support must be added during the
installation of the refrigeration.

Note: Due to the weight of these systems, it is highly recommended
that proper lifting equipment, such as a fork lift or scissor lift, be utilized
during installation. Also, be sure to allow for sufficient airflow around
the condenser. Model numbers ending with the letter "A" require
a minimum clearance of two feet for proper unit operation. Model
numbers ending with the letter "B" require a minimum of five inches
behind the unit and open to
the front for proper operation.
If multiple units are located
in the same area, be sure
they do not exhaust hot air
into one another. In addition
to allowing for proper airflow,
consideration should be
given to the final mounting
location of the refrigeration
system relative to the
customer location to avoid
any possible risk of noise
impacting the customer
experience.

Position the insulated
evaporator section of the
Refrigeration System over
the hole in the walk-in ceiling
section.

Align the tabs on the side of the insulated evaporator section with
the predrilled holes in the ceiling section. Before proceeding to the
next step, the evaporator cover should be removed. Look inside
the evaporator section and be sure the air divider in the ceiling section lines up with the black gasket divider in
the evaporator section. Some adjustment may be required by simply bending the ceiling section divider slightly
forward or backward. This will prevent any short cycling of discharge and return air.

Fasten the insulated evaporator section down to the ceiling using the provided drive screws, which can be
found attached to the side of the refrigeration system. CAUTION! This must be done to prevent the entire
refrigeration system from moving during operation.

Note: On smaller refrigeration systems, you may elect to install the system on the ceiling section while the section

is still on the floor. CAUTION! Make sure to fasten down the system to the ceiling panel. The ceiling section and
the refrigeration system may then be erected together in the normal sequence of assembly as shown in the Kold
Locker™ Walk-in Installation Instructions. This method is not practical and should not be used with larger systems
of 100 series or above, such as a 100, 150 or 151 model.

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Note: The process above is the same when locating/installing the insulated evaporator section of a Remote
Refrigeration System.

After the system is in place, make sure that the bolts fastening
the condensing unit section to the evaporator section are
loose enough so that the two sections can adjust to the ceiling
surfaces. Note: On large systems, 100 series and above, the
units are placed on a rack assembly and do not have these
bolts connecting the two sections together. No adjustment is
necessary.

Note: Some motor compressors are openly spring mounted to
absorb vibration. Be sure that these bolts are loosened to permit
the compressor to float freely on the springs. A reminder label

is applied to systems where this procedure applies.

Some systems require a permanent connection to an electrical service and a connection at the junction box located
within the condensing unit housing. Refer to the serial tag for all pertinent electrical data. These systems must
be connected to a power supply disconnect switch and wired according to local and national electric codes. No
plumbing drain is required, under normal conditions, since the condensate moisture is dissipated automatically by
a built-in hot gas vaporizer.

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Remote RefRigeRation SyStemS

Remote SyStemS With eleCtRiC VapoRizeR

Set the Refrigeration System evaporator section over the
hole in the ceiling section. Align the tabs on the side of
the insulated evaporator section with the predrilled holes
in the ceiling section. Before proceeding to the next
step, the evaporator cover should be removed. Look inside
the evaporator section and be sure the air divider in the
ceiling section lines up with the black gasket divider in the
evaporator section. Some adjustment may be required by
simply bending the ceiling section divider slightly forward or
backward. This will prevent any short cycling of discharge
and return air.

Fasten the evaporator section down to the ceiling using the
provided drive screws, which can be found taped to the side
of the insulated evaporator section.

CAUTION! This must be done to prevent the entire
refrigeration system from moving during operation.

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Remote RefRigeRation SyStemS

optional featuRe - eleCtRiC CondenSate VapoRizeR

Note the location of the condensate drain line coming
from the evaporator. Locate the electric vaporizer so
the condensate will run into it. If the vaporizer cannot
be located at the drain line, use the supplied plastic
tubing, copper elbow, and hose clamp(s) as required to
extend the drain line. Cut the plastic tubing to length as
required.

Provide power to the electric vaporizer per local and
national electric codes.

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Remote RefRigeRation SyStemS

inStRuCtionS foR pRe-ChaRged lineS - Remote SyStemS

By employing self-sealing refrigeration couplings, the condensing unit section, evaporator section, and the
connecting tubing are separately pre-charged with refrigerant and leak tested at the factory before shipment.
Follow steps 1-8 below to install the connecting tubing at both the condensing unit and the evaporator section.

1. Carefully uncoil the suction line. This is the line covered with a continuous
length of sponge rubber insulation.

2. Carefully uncoil the liquid line. The liquid line is the smaller diameter, bare
copper tube.

3. Before making any connections, determine the routing of both lines and
carefully hand bend them to suit the situation. Keep any bend radius rather
large to prevent kinking the tubing. It is a general practice to route the suction
and liquid line parallel and close together in the installation.

4. Remove the dust caps and plugs from the couplings and inspect them to
see if the synthetic seals are intact.

5. Using a clean cloth, wipe the coupling seals and threaded surfaces to
prevent the inclusion of any dirt or foreign material in the system.

6. LUBRICATE the synthetic seal in the male half of the couplings with
refrigeration oil and thread the two coupling halves together BY HAND to
ensure proper mating of the threads. Note: Make certain that the insulated
suction line is connected to the coupling half marked "Suction Line" and that
the bare tube liquid line is connected to the coupling half marked "Liquid Line".

Note: Always use two wrenches on the coupling body hex nut and on the union
to prevent twisting of the tube while tightening the connections as described in
the next step.

7. Using the proper size wrench on the union nut, tighten until the coupling
bodies bottom, or until a definite resistance is felt. Tighten an additional 1/6 to
1/4 turn. This final turn is necessary to ensure the knife edge metal seal bites
into the brass seat of the coupling halves, forming a leak proof joint.

Connecting to the Condensing Unit Side

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Remote RefRigeRation SyStemS

8. Once the suction line is connected, the sponge insulation must be
pulled up to cover the quick connects. Tie or tape off the insulation to
prevent air infiltration and reduce water/ice formation on the suction
line.

All valves are open and the system is ready for operation. Remember,
the refrigeration couplings on this system are self sealing and, if the
need ever arises, the couplings may be disconnected without any loss
of refrigerant.

IMPORTANT: Since this system is equipped with pre-charged
refrigerant lines, it is the installing contractor’s responsibility to ensure
that the quick connect refrigerant couplings are properly mated and
are leak free. It is also their responsibility upon start-up to check the
system for proper operation and make any necessary temperature
control or thermal expansion valve adjustments.

Note: A drain line is required to be run by the contractor for this type
of installation.

CAUTION: Line set must not exceed 3 feet longer than required length
to complete connection or improper oil return may result in compressor
failure. Contact the Service Department with model and serial number
for further assistance.This information is also included on a tag
attached to the line set.

Some systems require a permanent connection to an electrical
service and a connection at the junction box located within the
condensing unit housing. Refer to the serial tag for all pertinent
electrical data. These systems must be connected to a power
supply disconnect switch and wired according to local and
national electric codes.

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Connecting to the Evaporator Section Side

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reMOte refriGeratiOn SySteMS WitH Wire HarneSS

1. All systems with a wire harness will have a “K” at or near the end of the model number.
Example: RCPB100DC-A-50K.

2. These systems will come with the wire harness already wired to the condensing unit section of the refrigeration
system.

3. These wire harnesses will have approved seal tight conduit and connectors.

4. Before power is connected to the condensing unit section it should first be wired to the evaporator section with
the wire harness provided.

5. Remove the control box cover on the evaporator section.

6. Make the proper connections inside the control box on the evaporator section as shown in the wiring diagram
provided with the system.

7. Replace the cover on the control box when wiring is completed.

8. Now power can be brought to the condensing unit section of the refrigeration system.

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