Walk-ins Installation, Use & Care Manual This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocfsg.com Specified #1 Among Walk-ins Part Number 11324 2/08
Safety Notices 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:! Warning 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.! Caution 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 proceeding, 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:! Caution Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your Manitowoc 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. Important Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.! Warning 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. Important 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 the procedure you are performing. We reserve the right to make product improvements at any time. Specifications and design are subject to change without notice.
Table of Contents 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 Storage Inside............................................... 1-1 Storage Outside............................................. 1-1 Section 2 Installation Instructions Installation Overview.............................................. 2-1 Posi-Loc Locking Device....................................... 2-3 Types of Floors.............................................. 2-4 Pre-fabricated Floor Section Installation.............................. 2-4 Floor Leveling............................................... 2-5 Installing Floor Sections....................................... 2-6 Multiple Compartment Walk-ins................................. 2-6 Wall Installation................................................... 2-7 Wall Panels................................................. 2-7 Door Frame Panel............................................ 2-8 Completing Wall Panel Installation............................... 2-8 Ceiling Installation................................................ 2-9 Installing Ceiling Panels....................................... 2-9 Ceiling/Wall Joint Alignment on Large Structures.................... 2-9 Finishing Work................................................... 2-10 Door Threshold Installation..................................... 2-10 Thermometer Bulb Installation.................................. 2-10 Panel Penetrations........................................... 2-10 Electrical Connections for Door(s)................................... 2-11 Post Installation Checklist.......................................... 2-13 Part Number 11324 2/08 i
Table of Contents (continued) Section 3 Operation Section 4 Maintenance 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 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.! Warning 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. 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.! Warning To avoid injury while assembling a Kolpak walk-in, you must wear protective gear, including eye shields, a hard hat and steel-toed boots.! Caution Until the walls are made stable by constructing the corners, support extended wall lengths by bracing them from both the inside and the outside.! Caution 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, store 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
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Section 2 Installation Instructions Installation Overview 1. Unpack and inspect the shipment. 4. Complete the first corner. 2. Prepare the installation area. 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. 3. If required, assemble pre-fabricated floor. 5. Extend the wall. 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. 8. Install the door frame panel. 6. Reach the second corner. 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 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. Important 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
Installation Instructions Section 2 TYPES OF FLOORS Installation instructions are provided for three basic types of walk-in floors: Pre-fabricated sections on an existing floor Pre-fabricated floor sections in a recessed pad Built-in insulation screed floor Instructions for installing screed-type and other types of flooring are available through the factory, or with the Special Installation Instruction Sheets which may be enclosed with your installation materials. Pre-fabricated Floor Section Installation Stationary floor loads of up to 700 pounds per square foot can be stored on Kolpak standard pre-fabricated floor sections. If mobile equipment is used (dollies, carts, etc.), the floor must be reinforced with a diamond tread aluminum plate. If forklift trucks are used, special construction techniques must be followed. If the walk-in is to be installed next to an existing wall, allow a minimum of 2" of clearance of airflow.! Caution Staining or discoloration of panels caused by quarry tile or concrete wearing floor is not covered by the warranty. The sheet metal panel facings may be susceptible to staining due to excessive moisture created by hydration of concrete-type materials. Therefore proper ventilation of each room is required. Special precautions must be taken when using muriatic acid. The hydrochloric acid fumes can have an effect on both aluminum and stainless steel. 2-4 Part Number 11324 2/08
Section 2 Installation Instructions FLOOR LEVELING The leveling method shown below uses shims spaced 24 inches on center under the floor panels.! Caution A level walk-in floor is essential. Take care to ensure a level floor. Wall and ceiling panels will not align properly, causing installation and operation problems. In cases where the floor is level and no shimming is required, lay a 6 mil polyethylene sheet or 50 pound asphalt paper (not supplied) between the floor sections and the existing floor. In cases where the floor is not level, determine the high point of the installation area and level from this point. Kolpak recommends using a transit level (rather than a spirit type). One method of leveling uses shims (redwood or western red cedar) and wooden supports as shown below. Always shim between the building floor and the wooden supports. Leveling with Spaced Shims If a heavy product load will be stored in the walk-in, support the entire underside of the floor with dry sand poured level with the shims. Also, add a sealer strip around the perimeter of the walk-in. Leveling with Shims and Wooden Supports Leveling for a Heavy Product Load Part Number 11324 2/08 2-5
Installation Instructions Section 2 INSTALLING FLOOR SECTIONS Refer to the blueprint in the installation packet. The blueprint shows the panel identification for installation of the walk-in. 1. Begin with an edge section corresponding to the blueprint and place it in position in the installation area. 2. Check the floor section to be sure it is level. MULTIPLE COMPARTMENT WALK-INS Special tee floor panels are supplied with a multiplecompartment walk-in. Be sure that these panels are installed in the correct positions according to the blueprint. Be careful to note that the tongue and groove edges are the same as shown on the blueprint when installing tee panels. Typical Tee Floor Panel Checking the Levelness of the Floor Section 3. Move the next panel into position and check to be sure it is level. 4. Engage the Posi-Locs between the two floor panels. (See Posi-Loc Locking Device on page 2-3.) 5. Repeat this procedure until the floor is fully installed. Important Be sure the floor panel(s) with the door cut-out (if applicable) are installed in the correct position(s) according to the blueprint. This will ensure that the door can be installed properly later. 2-6 Part Number 11324 2/08
Section 2 Installation Instructions Wall Installation WALL PANELS To install the wall panels: 1. Start installing wall panels with a corner panel. Follow the blueprint to select the correct panel. 2. Place the corner panel in position, but do not Posi-Loc it to the floor yet. NOTE: All panels are marked TOP for correct orientation. 3. Following the blueprint, select and install the next adjacent wall panel. 4. Engage the Posi-Locs to their fully locked position. (See Posi-Loc Locking Device on page 2-3.) 5. Make sure the tops of the corner and wall panels are flush. NOTE: If walls panels have a stair step effect, take wall panels down and level floor panels or concrete pad. 6. Repeat Steps 3 5 to continue adding wall panels in both directions from the corner panel. Do not Posi-Loc the wall panels to the floor yet. 7. When you reach a corner, follow the blueprint to select and install the correct corner panel. 8. Repeat Steps 3 7 until all of the wall panels are installed. Do not Posi-Loc the wall panels to the floor yet. NOTE: Plan to 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. Part Number 11324 2/08 2-7
Installation Instructions Section 2 DOOR FRAME PANEL During installation of the wall panels, you will eventually reach the door frame panel. To install: 1. Follow the blueprint to place the door frame panel correctly. 2. Posi-Loc the door frame panel to the adjacent wall panel. 3. Check for plumb using a spirit level on the face of the door frame panel. COMPLETING WALL PANEL INSTALLATION After all of the wall panels are installed: 1. Check all panels for flush fit across the tops of the vertical seams. 2. Posi-Loc the wall panels to the floor panels or screeds. Checking for Plumb 4. Adjust the position of the door frame panel (if necessary) before installing the next wall panel.! Caution Do not remove the door from the jamb. The door frame panel has blocking between the door and the frame to protect them from twisting during shipping. Do not remove the blocking until the door frame panel is locked to both adjacent wall panels. Do not discard the threshold plate mounted to the blocking. 2-8 Part Number 11324 2/08
Section 2 Installation Instructions Ceiling Installation INSTALLING CEILING PANELS To install the ceiling panels: 1. Start installing ceiling panels with an end or outside panel. Follow the blueprint to select the correct panel. Important On multi-compartment walk-ins, start with a tee ceiling panel instead of an end or outside ceiling panel. 2. Place the end ceiling panel in position on top of the wall panels. Important Be sure any ceiling panels with cut-outs for the refrigeration systems are installed in the correct position(s) according to the blueprint. CEILING/WALL JOINT ALIGNMENT ON LARGE STRUCTURES When installing the ceiling on a large structure, it may appear that there is a problem aligning the final row of ceiling panels with the wall panels. The ceiling may appear to be longer than the walls. This condition is not due to a manufacturing defect. It is a result of the manufacturing tolerances in the panels and uneven pull-up at the panel joints. Since, in large structures, there are many more wall panels than ceiling panels, this condition shows up as the final row of ceiling panels is installed. There is a simple way to correct this condition. If the distance from the end of each ceiling panel to the nearest wall joint (called stagger ) is maintained along the entire length of the structure, all of the panels will fit and Posi-Loc properly. 3. Following the blueprint, select and install the next adjacent ceiling panel. 4. Adjust the panel position to align the end caps.! Caution If the wall panel tops were not leveled (made flush) at the seams earlier, the ceiling panels will not install correctly. The wall and ceiling panels will not align properly, causing gaps. This will lead to operational problems. Correct any level problems at this time. 5. Posi-Loc the two ceiling panels together. (See Posi- Loc Locking Device on page 2-3.) Do not Posi-Loc the ceiling panels to the wall panels yet. 6. Make sure that all joints and seams are flush. 7. Repeat Steps 3 6 to continue adding ceiling panels. Do not Posi-Loc the ceiling panels to the wall panels yet. 8. After all of the ceiling panels are installed and locked together, check all wall to ceiling joints for flush fit and proper alignment. 9. Posi-Loc the ceiling panels to the wall panels. Measuring the Stagger Single Compartment Structures 1. During the wall installation process, install just enough wall panels to allow installation of the first ceiling panel. 2. Install the first ceiling panel. Align it with the corner and lock down the corner Posi-Loc. 3. Measure the stagger from the end of the ceiling panel to the nearest wall joint. Part Number 11324 2/08 2-9
Installation Instructions Section 2 4. Compare the measured stagger to the stagger dimension on the blueprint. NOTE: The stagger dimension on the blueprint is always a multiple of 11-1/2" (11-1/2", 23", 34-1/2"). 5. If the measured stagger is not long enough, loosen the top wall panel Posi-Locs on the adjacent two panels. Allow the gasket in the seam to push the two wall panels apart until the measured stagger matches the stagger dimension on the blueprint. 6. Engage the Posi-Loc on the ceiling panel at the stagger end to lock it to the wall panel. 7. Posi-Loc the wall panels together again. 8. Engage all remaining Posi-Locs on the ceiling panel to lock it to the wall panels. 9. Repeat this process throughout the installation until all of the ceiling panels are installed. Multi-Compartment Structures The procedure for multi-compartment structures is the same as the procedure for single compartment structures, except that ceiling construction must begin over the partition wall. Add ceiling panels in both directions from the first panels, measuring stagger in each direction as panels are added. Finishing Work DOOR THRESHOLD INSTALLATION Refer to the Special Installation Instruction Sheet enclosed with your installation materials for information on your specific installation. THERMOMETER BULB INSTALLATION A coiled length of lead wire with a thermometer bulb is located on the inside of the door frame panel. Uncoil the wire. Using the plastic clip and screw provided, fasten the bulb to a wall panel located away from the door frame panel, at 42" above the floor. Important Do not locate the thermometer bulb on the door frame panel. The thermometer will display a false reading due to the heater wires in the door jamb, and warm air entering the walk-in when the door is opened. PANEL PENETRATIONS In some cases, it will be necessary to penetrate the walk-in to run electrical and refrigeration lines. When making a penetration, be careful to avoid panel seams and Posi-Locs. Area to Avoid When Making Panel Penetrations! Caution Ceiling penetration may only be made on indoor walk-ins. Do not make ceiling penetrations on outdoor walk-ins. Water damage from rain in the walk-in and/or inside the ceiling panel may result. To make a penetration into the walk-in: 1. Determine the exact location and size of the hole needed. 2. Mark the location and the size on the outside and inside of the walk-in. 3. Use a drill to make the penetration if a drill bit of the correct size is available. For holes too large to drill, use metal shears to cut the panel skin. 4. After making the penetration, carefully remove any insulation from the hole. 2-10 Part Number 11324 2/08
Section 2 Installation Instructions 5. Run the line(s) through the hole. 6. Seal the penetration with the sealant provided in the hardware box.! Caution Be sure to seal all panel penetrations completely. Operational problems and damage to the walk-in may result. Electrical Connections for Door(s) Make the electrical connections for the door area near the light base on the inside of the door frame panel(s). Kolpak recommends using a junction box located next to the light base, as shown in the drawing below. Connect the power supply to the door frame panel as shown in the wiring diagram on the next page.! Caution Do not leave the heater wire power on when the refrigeration system is not running. Excessive heat build-up will damage the heater wire and door gasket. Damage of this type is not covered by the warranty. Typical Electrical Connections at the Door Frame Panel Part Number 11324 2/08 2-11
Installation Instructions Section 2 Wiring Diagram 2-12 Part Number 11324 2/08
Section 2 Installation Instructions Post Installation Checklist Complete these checks before operating the walk-in for the first time. Put a check mark in each box as you complete each task. Verify that all Posi-Locs are fully engaged and that all gasket joints are tight.! Caution Do not leave the heater wire power on when the refrigeration system is not running. Excessive heat build-up will damage the heater wire and door gasket. Damage of this type is not covered by the warranty. Be sure that all plug buttons are installed in the Posi-Loc access holes. Important Metal plug buttons are used on the Posi-Loc access holes in the floor panels. Plastic plug button are used on all other Posi-Loc access holes. Verify that all panel penetrations have been sealed properly and that all fittings have been tightened. Make sure the heater wire around the door jamb is operating. Feel the metal surface on the door jamb to see if it is warm. Make sure the self-closing door operates correctly. If the door does not operate correctly, check whether the jamb and door are plumb using a spirit level. If the door is not level, loosen the Posi-Locs around the door frame panel, adjust the panel until it is plumb, and relock the Posi-Locs. If the door is level and still does not operate correctly, see Posi-Seal Door Closure on page 3-2). Verify that all of the gaskets around the door jamb perimeter seal properly. Make sure that the thermometer bulb has been secured to the inside wall of the walk-in. Part Number 11324 2/08 2-13
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Section 3 Operation Component Identification Ceiling Panels Corner Panels Posi-Seal Door Closure Door Hinge Side Panels Floor Sections Door Part Number 11324 2/08 3-1
Operation Section 3 Operational Checks and Adjustments POSI-SEAL DOOR CLOSURE The Posi-Seal door closure is a spring-loaded hydraulic device which ensures a firmly closed door at all times. No lubrication is required. The closure has been mounted and adjusted at the factory. It has been adjusted so the rubber roller just touches and rotates slightly as it passes the top of the hook when the door is closing. DIAL THERMOMETER TESTING AND RECALIBRATION If you suspect that the dial thermometer is not displaying an accurate walk-in temperature, perform this test: 1. Remove the thermometer probe from the clip. 2. Place the probe in a solution of water and ice (slush) for five minutes. 3. Check the temperature reading. It should read exactly 32 F. If the dial thermometer fails this test, follow the procedure below to recalibrate it. 1. Keep the thermometer probe in the slush solution. 2. Remove the plastic lid covering the face of the thermometer with a small standard screwdriver. 3. Hold the pointer in place while inserting the head of a standard screwdriver into the adjustment slot. 4. Turn the adjustment screw clockwise to lower the temperature reading, or counter-clockwise to raise the temperature reading. 5. Release the pointer and check the temperature reading. 6. Repeat Steps 3 5 until the temperature reading is exactly 32 F. 7. Install the plastic lid on the face of the thermometer. 8. Install the thermometer probe in the retainer clip. Proper Door Closure Adjustment Adjustment of the hook position may become necessary. Add washers to the upper fastener screws to lower the hook, or add washers to the lower fastener screws to raise the hook. Recalibrating the Dial Thermometer 3-2 Part Number 11324 2/08
Section 3 Operation DIGITAL THERMOMETER TRANSFORMER The thermometers are factory set and tested for accuracy. Should it become necessary to check the accuracy or recalibrate the thermometer, follow this instruction diagram carefully.! Caution Care must be exercised in recalibrating thermometers as low voltage current carrying parts are exposed. Recalibrating the Digital Thermometer Part Number 11324 2/08 3-3
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Section 4 Maintenance Cleaning INTERIOR/EXTERIOR SURFACES To clean the interior and exterior surfaces of the walk-in, use water with a mild soap and a clean, soft cloth. To remove fingerprints or other stains, use a mild, nonabrasive cleanser such as Bon Ami. Wipe with the grain on satin-finished stainless steel panels. DOOR GASKETS Clean the door gaskets on a regular basis. Use a solution of baking soda and warm water to wash the gaskets. Wipe them dry with a soft cloth. Inspect the gasket around the inside of the door (and frame on some installations) periodically. Verify that the gaskets are properly seated in their retainers. Also, inspect for wear and tear. If a gasket becomes torn or broken, replace it immediately. Inspection HEATER WIRE Check the heater wire around each door opening periodically. If you notice frost or sweating, contact a local service contractor to verify that the heater wire is operating correctly. PLUG BUTTONS Check the interior of the walk-in periodically for missing plug buttons. Replace any missing plug buttons immediately to prevent moisture from entering the insulation inside the panel. Extra plug buttons are provided in the hardware box. Keep them for future use as replacements. DOOR HINGES Check and tighten all screws in the hinges, latch and foot treadle. The door hinges are lubricated with petroleum jelly at the factory. Relubricate them every two months. Typical Door Hinge Part Number 11324 2/08 4-1
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2008 Manitowoc Continuing product improvements may necessitate change of specifications without notice. Part Number 11324 2/08 Kolpak 2915 Tennessee Avenue North Parsons, TN 38363, USA Ph: 731-847-5365 Fax: 731-847-5387 Visit us online at: www.manitowocfsg.com