Welbilt KOLPAK Programming manual

Protecting Your Future
Refrigeration System
Original Instructions
Installation, Operation and Maintenance Manual
This manual is updated as new information and models are released. Visit our website for the latest manual.
Part Number: 550001058-14 8/21

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Read this manual thoroughly before operating, installing or
performing maintenance on the equipment. Failure to follow
instructions in this manual can cause property damage, injury
or death.
Ensure that all field wiring conforms to the equipment
requirements and all applicable local and national codes.
Installation and maintenance/servicing are to be performed
only by trained and qualified personnel familiar with
commercial refrigeration systems.
Indicates a situation that, if not avoided, could damage the
refrigeration system or result in minor injury.
Safety Notices
NOTE: Indicates useful, extra information about the
procedure you are performing.
DANGER
Indicates a hazardous situation that, if not avoided, will
result in death or serious injury. This applies to the most
extreme situations.
Notice
Indicates information considered important, but not hazard-
related (e.g. messages relating to property damage).
Disconnect all power sources before servicing the refrigeration
equipment.
Use appropriate eye protection during installation and servicing.
Sheet metal and coil surfaces have sharp edges. Use appropriate
protective gloves to prevent injury.
Indicates a hazardous situation that, if not avoided, could result
in death or serious injury.

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Table of Contents
Section 1
General Information
Receiving Inspection ........................................................ .......................................................... 4
Warranty Information................................................................................................................. 4
Section 2
Installation
Condensing Units ........................................................................................................................ 5
Evaporator Units ......................................................................................................................... 6
Section 3
Wiring
Wiring ......................................................................................................................................... 8
Section 4
Piping
Piping .......................................................................................................................................... 9
Cleanliness .......................................................................................................................... 9
Pipe Supports...................................................................................................................... 9
Oil Traps ............................................................................................................................ 10
Drain Lines ........................................................................................................................ 10
Pre-Charged Lines ............................................................................................................. 11
Leak Testing .............................................................................................................................. 12
PR Models ......................................................................................................................... 12
PC Models ......................................................................................................................... 13
PCL Models ....................................................................................................................... 13
System Evacuation .................................................................................................................... 13
PR Models ......................................................................................................................... 13
PC Models ......................................................................................................................... 13
PCL Models ....................................................................................................................... 14
Refrigerant Charging ................................................................................................................. 14
Section 5
Operational Start-Up
Pre-Start Checks........................................................................................................................ 15
Compressor Mounts.................................................................................................................. 15
Start-Up .................................................................................................................................... 16
Compressor Superheat.............................................................................................................. 16
Evaporator Superheat ............................................................................................................... 17
Johnson Control Thermostat..................................................................................................... 18
Three button Touch Pad ................................................................................................... 18
Parameter Codes And Modes of Operation...................................................................... 19
Basic Menu........................................................................................................................ 23
Advanced Menu................................................................................................................ 24
Setting Up A Regular Or Timed Defrost Off-Cycle............................................................. 26
Troubleshooting................................................................................................................ 29
Electric Defrost Timer................................................................................................................ 31
Section 6
Maintenance
Preventive Maintenance Tasks.................................................................................................. 33
P.O.E. Lubricants ....................................................................................................................... 33
Section 7
Troubleshooting
Evaporator ................................................................................................................................ 34
Condensing Unit........................................................................................................................ 35
System Start-Up Checklist........................................................................................................................... 37

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Section 1
General Information
Receiving Inspection
1. Check the shipment carefully and compare to the bill of lading.
2. Account for all items listed and inspect each container for damage.
3. Carefully inspect for any concealed damage.
4. Report any shortages or damages to the carrier, noteon the bill of lading, and file a freight claim.
5. Damaged material cannot be returned tothe manufacturer without prior approval.
6. A Return Material Authorization (RMA) must be obtained. Contact a sales representative at 800-826- 7036.
Warranty Information
For information regarding warranty guidelines, claim form, product registration, warranty verification, or
locating a service provider please visit our website at www.kolpak.com or call 800-225-9916.

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Section 2
Installation
Condensing Units
•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. Center of
condensing unit needs to be properly supported.
•Locate where there is a sufficient and unrestricted supply of clean ambient air.
•Locate where this 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.
•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. Center of
condensing unit needs to be properly supported.

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Example of Multiple Units with Horizontal Airflow
Evaporator Units
•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.
•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 in the ceiling from
the exterior of the walk-in ceiling panel.
NOTE: Nylon bolts are supplied to prevent thermal transfer between the exterior of the walk-in and the interior of the walk-
in. Do not use metal bolts.
•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!
CAUTION
Failure to observe clearance and air flow requirements will result in poor system performance and premature equipment
failure!
BUILDING WALL
(VIEWED FROM ABOVE)
MINIMUM
DISTANCE
24”
INTAKE AIR
MINIMUM DISTANCE 24”
24”
INTAKE AIR
MINIMUM DISTANCE 24”
24”
AIR
FLOW
AIR
FLOW

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Evaporator Coil Mounting Diagram

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Section 3
Wiring
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 and attached inside the electrical box cover.
•Evaporator coil wiring diagrams are and inside the evaporator cover.
•To view Basic Cooler/Freezer Evaporator Wiring Service Video, scan the QR code below.
•For the latest wiring diagrams, scan the QR code below.
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.

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Section 4
Piping
Piping
•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 not use short radius elbows.
•Suction lines must be insulated with a minimum ¾” thick insulation tubing 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.
•Do not remove base mount valve 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 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.

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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 1/2” 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.
•Freezer compartment drain lines must have heat tape wrapped around the copper drain line and must have ¾” thick
insulation tubing.
•Do not locate drain line P-traps within the freezer space.
•Do not reduce the drain line size.
•Locate a drain line P-trap outside of the cooler space.
•Any outdoor P-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.
•Freezer/cooler combo boxes can have one common drain line. However, there must be a P-trap located between the
freezer evaporator and the cooler evaporator located inside the cooler compartment.
•The cooler compartment P-trap should be located between the cooler evaporator and the external drain location.