Blu KBD-59R User manual

INSTRUCTION MANUAL
KBP PREP TABLE

INSTRUCTION MANUAL
KBP PREP TABLES
SELF CONTAINED AND REMOTE MODELS
BLU TECHNOLOGY PREP TABLES
Kairak BLU refrigeration prep tables are designed to provide consistent, uniform cooling to each individual
pan and prevent food spoilage. This new system provides inclined walls for trouble-free reach to food pans
while keeping the chiller plates as close to the food pans for efcient heat transfer. Our NSF7 approved
BLU pan chilling system ensures condiments for salads, pizzas, and sandwiches always stay fresh without
the need for fans, blower coils or other refrigeration enhancing components.
Standard features on the KBP models include stainless steel construction (galvanized back) LED temperature
display, hinged night cover, 6-inch casters, white polyethylene cutting board and wire shelves.
The KBP models are available as self-contained or remote installations. Available options include stainless
steel back panel, 2 drawer and 3 drawer modules, tray slides, 6 inch legs, 4 inch casters, multiple depth
pan opening, door or drawer locks and optional door hinging.
REMOTE REFRIGERATION & BLU
Kairak is committed to producing environmentally friendly and sustainable product offerings without
sacricing quality or reliability, Kairak’s Remote Refrigeration System assures customers maximum energy
savings and a substantially smaller environmental footprint.
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PREP TABLE
KAIRAK. 4401 Blue Mound Rd., Fort Worth, TX 76106 | Phone: [phone], Web: www.kairak.com
© KAIRAK, a division of ITW Food Equipment Group LLC. All Rights Reserved.
“For proper operation of remote equipment, Kairak recommends all remote glycol racks to provide a constant supply of 20ºF glycol without any interruption in
prescribed flow or capacity. The glycol supply temperature should operate with a +2ºF differential. Every three (3) hours, the glycol temperature must elevate to
+35ºF for thirty (30) minutes to shed frost from the chiller plate surface. After the thirty minute duration, the glycol temperature should resume 20ºF+2ºF operation.
Flow rates for all Kairak equipment are noted in their respective specification documents. Temperature and flow rate values may need to be adjusted depending on
site conditions. Contact factory before making any adjustments.”

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PREP TABLE
TABLE OF CONTENTS
1. THE SERIAL TAG
2. RECEIPT INSPECTION
3. INSTALLATION
A-Unpacking
B-Locating the equipment
C-Installing Parts Shipped Loose: Cutting Board
D-Installing Parts Shipped Loose: Compressor Filter
4. STARTUP INSTRUCTIONS
A-Refrigeration Lines
5. ELECTRICAL CONNECTIONS
6. PRESTART CHECKS
A-Control/Temperature Settings
B-Removing Food Product at Night
C-Leaving Food Product at Night
7. OPERATION
A-Pan Chiller
B-Lower Storage Cabinet
C-Shutdown for Extended Periods
8. MAINTENANCE PROCEDURES
A-Cleaning Lower Storage Cabinet
B-Cleaning Pan Chiller
C-Cleaning Condensing Unit
D-Cleaning Air Filter
E-Cleaning Evaporator Coils
9. TROUBLESHOOTING GUIDE
10. TIPS
11. PRODUCT REGISTRATION INFO
12. WARRANTIES
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PREP TABLE
The serial tag is a permanently afxed label on which is recorded vital electrical and refrigeration data about
your Kairak product, such as the model and serial number. The tag is located inside the storage cabinet
on all standard KBP model refrigerated units. Prior to installation, test the electrical service to assure that
it agrees with the specications of the equipment marked on the serial tag.
READING THE SERIAL TAG
1. THE SERIAL TAG

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PREP TABLE
2. RECEIPT INSPECTION
All Kairak products are factory tested for performance and are free from defects when shipped. The utmost
care has been taken in crating this product to protect against damage in transit.
Carefully inspect your Kairak unit for damage during delivery. If damage is detected, you should save all
crating materials and make note on the carrier’s Bill of Lading describing the damage. A freight claim should
be led immediately. If damage is subsequently noted during or immediately after installation, contact the
respective carrier and le a freight claim. There is a fteen (15) day limit to le freight damage with the carrier.
Under no condition may a damaged unit be returned to Kairak without rst obtaining written permission
(return authorization). You may contact Kairak customer care at [phone].
3. INSTALLATION
3A - UNPACKING
Inspect equipment for shipping damage prior to installation. If shipping damage is found, save the packing
materials and contact the carrier within 5 days of delivery.
Some components are packed and shipped inside the lower storage cabinet to avoid damage during
shipment. Remove these items from the cabinet and remove packing materials. See “Installing Loose Parts”
for instructions. If unit is equipped with shelves, cut and remove the plastic ties holding the shelves in place.
3B - LOCATING THE EQUIPMENT
Prep table models of lengths above 36” can be installed with no clearance at the back and sides of the
units. Units 36” or shorter have a rear mount compressor and require a minimum clearance of 3 inches
at the back and sides of the unit. This allows for sufcient air circulation of the condensing unit. Failure to
provide adequate ventilation may cause severe compressor damage, and will void warranty.

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PREP TABLE
3. INSTALLATION (CONTINUED)
3C - INSTALLING LOOSE PARTS
Place cutting board so that holes in cutting board line up with pins on the counter top. (See Fig. 1)
FIG. 1
CUTTING BOARD
COUNTER

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PREP TABLE
3. INSTALLATION (CONTINUED)
3D - INSTALLING LOOSE PARTS: COMPRESSOR FILTER
Remove louvered panel by lifting up and pulling out entire panel. Slide the lter into the tracks located below
the compressor compartment. Be careful not to catch the lter on sharp edges when installing. Replace
louvered panel by installing top of panel into track and pushing in the bottom so that the locking clips t
inside the opening. (See Fig. 2)
FIG. 2
INSTALLING FILTER REPLACING LOUVERED PANEL

RECEIVING UNIT
1. Uncrate the unit.
2. Check to make sure unit is in tact; no visible freight damage including dents, dings, scratches, missing
parts. If you notice any damage to your unit, please call [phone].
BEFORE TURNING UNIT ON
1. Look in refrigerated base compartment, remove lter.
2. Remove louvered panel over compressor compartment.
3. Insert lter in channels located under the compressor compartment area.
4. On back side of the unit, remove the access panel that covers the compressor compartment. This
is your glycol system. (See Fig. 3) The glycol used is a non-toxic food grade (propylene) glycol.
5. Check ll tank level (small plastic tank). A small amount of glycol may spill from tank during shipment.
Prior to startup, tank should be approximately 1/2 full. Add 35% Propylene Glycol if necessary.
6. Next, inspect the two insulated hoses located in the back of the compressor compartment. For proper
circulation, the hoses must be free of kinks.
7. Reattach access panel.
8. Cut zip-tie securing electrical cord and plug cord into wall socket.
4. STARTUP INSTRUCTIONS
USE ONLY
PROPYLENE GLYCOL
(35% CONCENTRATION)
OPERATING
RANGE
LABEL ON FILL TANK
FIG. 3
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PREP TABLE
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START UP PROCEDURE
1. Ensure doors to refrigerated base are closed and night cover is lowered to cover pan chiller top.
2. On the front side of the unit in the compressor compartment area, ip the main power switch ON.
3. Replace louver panel to cover opening of compressor compartment.
4. Observe the blue LED Temperature Display located just above the louver panel. (See Fig. 4)
5. At start-up, the readout will read H1. This signies that the temperature is above normal operating
range. The reading will alternate every 5 seconds, displaying the refrigerated cabinet temperature
and the glycol liquid temperature.
6. When the liquid temperature cools to 30°F, the unit is ready to go!
4. STARTUP INSTRUCTIONS (CONT.)
FIG. 4
4A - REFRIGERATION LINES
WARNING: GAS REFRIGERATION LINES IN CONDENSING UNIT AREA ARE SHIPPED UNDER PRESSURE

Refer to the wiring diagram shipped with the unit located inside the compressor compartment or on the
back of the unit.
CORD CONNECTED UNITS (Self-contained models)
Plug the unit into a properly sized outlet. See serial tag located inside storage cabinet for circuit sizing.
WARNING: THIS MACHINE IS PROVIDED WITH A THREE-PRONGED GROUNDING PLUG. THE OUTLET
TO WHICH THIS PLUG IS CONNECTED MUST BE PROPERLY GROUNDED. IF THE RECEPTACLE IS NOT
THE PROPER GROUNDING TYPE, CONTACT AN ELECTRICIAN.
PERMANENTLY WIRED UNITS (Remote models)
A junction box located on back of the machine near bottom is provided for electrical eld connections.
See wiring diagram shipped with unit on the back of the unit for electrical ratings.
5. ELECTRICAL CONNECTIONS
6A - CONTROL/TEMPERATURE SETTINGS
BLU Prep Tables are designed with four optional (factory pre-set) temperature settings. All temperature
settings can be adjusted only by an Authorized Kairak Service Agent. The LED Display is located above
the compressor compartment, with a blue light indicating which cooling zone is activated.
These set temperatures are based on information provided by “customer” and or “purchasing channel” i.e.
food equipment broker to Kairak. Although Kairak Prep Tables are tested at factory before shipment, there
are variables that can affect cooling performance of unit.
• Ambient Temperature
• Humidity Level
• Air stream patterns
• Over-shelves/Heat lamps
• Product temperature prior to loading into refrigerated pan chiller well
• Surrounding equipment
6. PRESTART CHECKS
PREP TABLE
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PREP TABLE
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6B - REMOVING FOOD PRODUCT AT NIGHT
If system runs only during normal working hours and food needs to be removed from Pan Chiller at night,
simply close the night cover after removing food pans. This will improve energy efciency during overnight
hours. If ALL food is removed from unit (pan chiller and refrigerated base both empty), ip the ON/OFF switch
to shut down entire unit. To turn unit back on, ip switch ON. If you are storing product in the refrigerated
storage base but not in the pan chiller make sure you cover pan chiller section with provided night cover
to prevent refrigeration from escaping.
6C - LEAVING FOOD PRODUCT IN THROUGHOUT THE NIGHT (RECOMMENDED)
This unit is preset at factory and does not require periodic shutdowns for defrost cycle. This upgraded BLU
refrigeration system eliminates the operational burden of removing food pans prior to the defrost period or
for overnight storage. No defrost cycle means that food can be consistently cooled 100% of the time, day
or night. Plastic wrap should be placed over exposed food prior to closing the night cover to help prevent
condensation from getting into the food. The night cover must be closed if food is being left in the pan
chillers overnight.
6. PRESTART CHECKS (CONT.)
BASE LIQUID

7. OPERATION
PREP TABLE
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7A - PAN CHILLER
To insure proper food temperatures are maintained in exposed insert pans, the following conditions are
recommended.
1. All food brought to line must be at 41°F.
2. No direct air blowing on food product from other equipment in the kitchen (max air velocity
50 FPM)
3. Room ambient temperatures of 86° or less around working area of Pan Chiller.
4. All shelving mounted over insert pans (with heated equipment above it) must be insulated. No line of
sight from radiant heat sources to insert pans.
5. Occasional stirring of certain foods may be required in order to maintain consistent temperatures.
6. Some food products chill faster than others i.e., lettuce, dried tomatoes, etc.
7. For remote refrigerators with pan chiller systems, it is imperative that the existing refrigeration
equipment be sized properly and in good working condition.
8. Kairak recommends specied pans for optimum performance.
7B - LOWER STORAGE CABINET
The lower storage cabinet is designed to maintain temperature between 33°F and 40°F. If the base is
overloaded with warm food products, a certain amount of time is required to remove heat from items
before operating temperatures can be maintained. The system is only designed for storage of refrigerated
product. Frequently opening the doors or drawers will increase the temperature in the cabinet and will
require a certain amount of time to recover.
7C - SHUTDOWN FOR EXTENDED PERIODS
If the prep table and lower storage cabinet are not to be used for an extended period of time, disconnect the
electrical power supply and open the doors (or drawers) to the lower storage cabinet. As soon as the divided
bars and the cabinet have warmed to room temperature, wipe out the pan chiller cavity and base interior.

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PREP TABLE
8. MAINTENANCE PROCEDURES
WARNING: DISCONNECT ELECTRICAL POWER SUPPLY BEFORE CLEANING ANY PARTS ON THE UNIT.
8A - CLEANING LOWER STORAGE CABINET
Use warm, soapy water to clean lower storage cabinet and doors. NEVER use cleaners containing grit,
abrasive materials, bleach or harsh chemicals. Rinse thoroughly and dry with a clean soft cloth. Always
rub in the same direction as the grain pattern on the stainless steel.
To clean the inside of the lower storage cabinet, remove wire shelves. All wire shelves are adjustable and
can be easily removed. Clean shelving in a sink. If shelf clips have been removed, make sure the four clips
per shelf are at same height in pilaster. The shelf clips have a small projection on top which holds the shelf
in position and prevents it from slipping forwards. The clip must be “snapped” in place by squeezing clip
together and inserting into slot in pilaster keyhole. (See Fig. 5)
FIG. 5
If equipped with tray slides, the tray slides can be removed by lifting up on the front of the tray slide
assembly to allow the front tray slide frame to clear the bottom of the door opening, then pull the frame
assembly out. (See Fig. 6)
FIG. 6
TRAY SLIDE FRAME

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PREP TABLE
8. MAINTENANCE PROCEDURES (CONT.)
WARNING: DISCONNECT ELECTRICAL POWER SUPPLY BEFORE CLEANING ANY PARTS ON THE UNIT.
8A - CLEANING LOWER STORAGE CABINET (CONTINUED)
If equipped with drawers, remove the drawers from the drawer frame module. The drawer frame module
can be removed by loosening the black clamping knob on the Cross Rail Locks and Liner Locks. Pull the
Cross Rail Locks toward the center of the drawer frame module and allow the Liner Locks to drop away
from the top of the liner. The entire frame assembly is now free to slide out of cabinet. (See Figs. 7 & 8)
LINER LOCK
BACK
CLAMPING
KNOB
CROSS RAIL
LOCK
(1 ON EACH
SIDE OF
DRAWER)
FIG. 7
DRAWER
MODULE
CROSS
RAIL
LOCK
BACK
CLAMPING
KNOB
FIG. 8

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PREP TABLE
8. MAINTENANCE PROCEDURES (CONT.)
FIG. 9
WARNING: DISCONNECT ELECTRICAL POWER SUPPLY BEFORE CLEANING ANY PARTS ON THE UNIT.
8B - CLEANING PAN CHILLER
Use a soft cloth or sponge to clean the pan chiller. There is one drain located in the pan chiller, provided
for condensate run-off. Drain must be cleared/cleaned regularly for proper operation. Drains should be
cleaned a minimum of once a month.
The drain in the pan chiller compartment is typically located above the louvered compressor compartment.
A removable screen has been provided to prevent the drain from clogging. (See Fig. 9) Clear drain of dirt
and debris so that condensate can ow freely.
If drain is piped to oor sink, pan chiller may be ushed with clean water & mild detergents. Do not leave
standing water in pan chiller.

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PREP TABLE
8. MAINTENANCE PROCEDURES (CONT.)
WARNING: DISCONNECT ELECTRICAL POWER SUPPLY BEFORE CLEANING ANY PARTS ON THE UNIT.
8C - CLEANING CONDENSING UNIT
The condensing unit coil and lter must be cleaned regularly on self-contained models for optimal
performance. The operating environment will affect the required frequency of cleaning. However, both
should be cleaned a minimum of once every three months. Air must be able to freely circulate through
the condenser. Unit performance and operating efciency are signicantly affected by the amount of air
passing through the condenser. Condenser ns that are clogged with dirt and debris greatly reduce airow
and removal of heat. Failure to keep the coil ns and the air lter clean may cause premature
compressor failure, which will not be covered by warranty. (On models that contain lters, operating
unit without lter will void warranty).
Models 42 through 120: The condensing unit is located behind the louvered panel in the compressor
compartment. Remove louvered panel by pulling on the bottom then lifting up and out. Remove rear
access panel located in the back of unit. A phillips head screwdriver is required to remove rear access
panel. Carefully clean dirt and lint from the condenser coil using a vacuum cleaner or soft brush; do not
use a wire brush.
8D - CLEANING AIR FILTER
The lter is located behind the louvered panel, below the condensing unit in the compressor compartment.
Remove lter by carefully sliding out of the tracks. Carefully clean with vacuum or rinse with hot water
exercising care not to bend or damage lter frame. Replace lter by carefully sliding it into the tracks.
Replace louvered panel by installing top of panel into track and pushing in the bottom so that the locking
clips t inside the opening. Replace rear access panel. Reconnect electrical supply.
Replacement lters are available through Kairak Parts and Service Department at 800-833-1106.
8E - CLEANING EVAPORATOR COILS
Evaporator coils should be cleaned every six (6) months for optimal performance.
The evaporator coils are located in the storage cabinet behind the coil can cover. With a phillips head
screwdriver, remove four screws and take off cover. Clean evaporator coils with a vacuum cleaner or soft
brush, do not use a wire brush. Replace coil can cover. Reconnect electrical supply.

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PREP TABLE
9. TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
1. Unit doesn’t run 4No power to unit
4Main power switch in OFF
position
4Plug in unit and check circuit
breaker
4Remove louver panel, reach inside
compressor compartment and ip
switch to ON position
2. Cabinet not maintaining
temp (base cabinet warmer
than 41°F)
4Base cabinet overloaded
with warm food product (food
temperature above 41°F)
4Door gasket not sealing
properly
4Air lter dirty
4Condenser coil dirty
4Inadequate air circulation due
to product loading
4Circulation fan faulty
4Remove warm food product and
replace with properly chilled product
(food must be colder than 41°F
before placement into base cabinet)
4Replace door gasket
4Clean or replace air lter
4Clean coil
4Shift pans/boxes to create
clearance for air circulation
4Check fan connections and
replace fan if necessary
3. Prep top not maintain-
ing temp (cvbvcvvvvv (liquid
temp) warmer than 35°F)
4Prep top overloaded with warm
food product (food temperature
above 41°F)
4Remove warm food product and
replace with properly chilled product
(food must be colder than 41°F
before placement into prep top)
4. Chiller plates are coated
in water and/or ice (thin
layer)
4Normal operation 4No action required. Condensation
on the chiller plates will occur
in most kitchen environments.
Occasionally, a thin layer of ice may
develop for a short period of time
5. Chiller plates develop
thick (1/8” or more) layer of
ice
4Control board set below
standard factory settings
4Excessive compressor runtime
4Adjust control board to factory
settings
4Clean lter and clean condenser
coil if necessary
6. Pans don’t t in prep top 4Incorrect pan model 4Check model specs for a list of
compatible pans
7. Clear water is dripping
from unit
4Catch pan is overowing or
missing
4Clean and replace catch pan in
channel located underneath the prep
table base, ensuring that the pan
reaches the drain lines in the back of
the cabinet.
SERVICE
For additional information, contact Kairak Parts and Service Department: [phone].

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PREP TABLE
10. TIPS
HOW TO ENSURE LONG LIFE AND GREAT PERFORMANCE IN KAIRAK
PREP TABLES
1. Make certain air intake lters below condensing unit are cleaned or replaced regularly. Depending
on the kitchen environment, this may be monthly or quarterly procedure.
2. Keep drain strainers clean and in place.
3. Please make sure that compressor area covers are in place at ALL times.
4. Do not store anything in the compressor area.
5. Do not use sharp utensils to clean the gaskets. Wiping them down daily ensures easy cleaning.
6. Make certain that casters get wiped down regularly, if they get clogged with grease, the will eventually
“at spot” and fail.
7. Units 36” and shorter have a rear mount compressor and should not be pushed against a wall. These units
should have a minimum clearance on both sides of at least 3”. They breathe from the rear and need
all the air they can get!
8. Do not place trash receptacles or any other “solid” object in front of compressor areas; air
ow is needed for proper breathing.
9. Be aware of condensate evaporator (some models) and plug underneath unit, particularly when
mopping or sweeping. Also make sure plug is fully sealed.
10. Evaporator coils in bases should be cleaned every 6 months. Unplug unit or disconnect power, then
access by removing the 4 Phillips head screws on the rear access cover and remove cover. Clean
with vacuum cleaner or soft brush.
11. Beware of conditions that hinder cooler operation. Items such as shelving with heat lamps above
refrigerated rail and adjacent cooking equipment may radiate heat which could hinder the
refrigerator performance. Airflow over open insert pans, typically from a ventilation system,
may dramatically increase food temperature in insert pans. These elements should be minimized
to ensure proper holding temps.
12. Carefully monitor food temps. Food must be below 41°F before inserting into Kairak Prep Tables.
KAIRAK PRODUCT REGISTRATION INFO
Please log onto www.Kairak.com/BLU/Registration to register your BLU Prep Table.
11. PREP TABLE REGISTRATION INFO

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PREP TABLE
12. WARRANTIES
Kairak’s warranty coverage warrants that Kairak-branded products are free of defects in materials and factory
workmanship. The following applies to all Kairak Model and Serial numbers.
Kairak’s warranty is extended only to the original purchaser and shall not apply to any failures resulting from
damage in transit, improper installation, alteration, normal wear, misuse, abuse, improper voltage, accident
or negligence. The warranty excludes; T-stat adjustments, time clock adjustments, gaskets, cutting boards,
lters, clogged drains, ice build-up with no mechanical failures, and the loss of contamination of food due to
mechanical or electrical failure. Warranty does not apply outside the United States.
In order to be covered under this warranty, prior authorization to perform the necessary and appropriate service
must be obtained from the factory. Model and Serial number must be provided at the time of service request.
Kairak does not assume responsibility for any expenses, including labor, parts or travel expenses incurred
without such prior authorization. Kairak shall not be liable, whether in contract or in tort or under any other legal
theory for loss of use, revenue or prot, substitute use or performance, incidental, indirect or special and/or
consequential damages, loss of refrigerant or for any other loss or cost of similar type. Such related charges
will be back charged to the responsible party. The decision of the Kairak Service and Warranty, as to whether
a defect is within the terms of this warranty shall be nal.
Failure to object or provision contained in a customer’s purchase order or other communication shall not be
deemed as a waiver of terms or conditions of their warranty, nor shall it be considered acceptance of such
provisions. This warranty supersedes and is in lieu of all other warranties, expressed or implied and of other
obligations of liabilities, on the part of Kairak.
In case of freight damage, do not refuse shipment, but call agent’s attention to its condition, making careful note
of the details on freight bill before freight charges are paid. File claim for damages with freight agent immediately.
BLU FIXTURES manufactured by Kairak hold a 3-year parts and labor warranty. Kairak holds a 5-year compressor
warranty, with a one-time compressor only replacement after the rst year. Kairak will warranty the labor to
replace the compressor for the rst three years, 30 days from the ship date. After the rst three years, labor, tax,
shipping and miscellaneous parts will not be included. Please contact our warranty department for compressor
replacement procedures during the warranty period. BLU remote Fixtures are designed to operate with Kairak
remote systems only. Violation of these terms will void all warranty.
REFRIGERANT FIXTURES manufactured by Kairak hold a 1-year parts and labor warranty. Kairak holds a 5-year
compressor warranty, with a one-time compressor only replacement after the rst year. Kairak will warranty
the labor to replace the compressor for the rst year, 30 days from the ship date. After the rst year, labor, tax,
shipping and miscellaneous parts will not be included. Please contact our warranty department for compressor
replacement procedures during the warranty period.
REMOTE SYSTEMS manufactured by Kairak hold a 1-year parts and 90-day labor warranty on the remote system,
with an option to purchase 1-year labor warranty at the time of purchase order receipt. This warranty does not
apply to motors, switches, controls, accessories or parts manufactured by others and purchased by Kairak,
unless the manufacturer warranties the same to Kairak. Kairak holds a 5-year compressor warranty, with a one-
time compressor only replacement after the rst year. Kairak will warranty the labor to replace the compressor
for the rst year, 30 days from the ship date. After the rst year, labor, tax, shipping and miscellaneous parts
will not be included. Please contact our warranty department for compressor replacement procedures during
the warranty period.
TO REQUEST AUTHORIZED SERVICE, CALL THE KAIRAK SERVICE AND WARRANTY HOTLINE: [phone].
After-hour requests must be urgent in nature and documented with Kairak’s after-hours service line prior to
service being performed. Kairak is responsible for straight time only, unless otherwise approved by the warranty
department.

NOTES