Perlick 4400 SERIES Power Paks Instruction Manual

Perlick 4400 SERIES Power Paks

IMPORTANT INFORMATION

To register your product, visit our web site at www.perlick.com. Click on Commercial, then Service. You will see the link to Warranty Registration Form. You must complete and submit this form or the installation date will revert back to the ship date. Permanently mount the enclosed Warning/Safety Instruction label in a visible location near the CO2 regulator. This manual has been prepared to assist you in the installation of your Century Remote Beer System and to acquaint you with its operation and maintenance. We dedicate considerable time to ensure that our products provide the highest level of customer satisfaction. If service is required, your dealer can provide you with a list of qualified service agents. For your own protection, never return merchandise for credit without our approval.
We thank you for selecting a Perlick product and assure you of our continuing interest in your satisfaction.

AIR COOLED

(519)
Height “C”| 251/2” (648)| 251/2” (648)| 251/2” (648)| 31” (782)| 31” (782)
A minimum of six inches of clearance should be allowed around the entire unit for proper performance. Additional clearance should be considered for above the unit and in front of the unit for servicability.
ELECTRICAL| Voltage| 120 V| 120 V| 120 V| 208/230 V| 208/230 V
Frequency| 60 Hz| 60 Hz| 60 Hz| 60 Hz| 60 Hz
Phase| 1 Ø| 1 Ø| 1 Ø| 1 Ø| 1 Ø
SINGLE PUMP| RLA (Rated Load Amps)| 15.1| 15.7| 17.1| 10.5| 21.9
MCA (Min. Circuit Ampacity)| 17.2| 18.0| 19.6| 12.2| 26.4
MOCP (Max. over Current Protection)| 25| 25| 25| 15| 40.0
DUAL PUMPS

(add -2 to model #)

| RLA (Rated Load Amps)| N/A| 21.8| 22.7| 13.3| 24.7
MCA (Min. Circuit Ampacity)| N/A| 24.1| 25.2| 15.0| 29.2
MOCP (Max. over Current Protection)| N/A| 30.0| 35.0| 20.0| 45.0
TRIPLE PUMPS

(add -3 to model #)

| RLA (Rated Load Amps)| N/A| N/A| N/A| 16.1| 27.5
MCA (Min. Circuit Ampacity)| N/A| N/A| N/A| 17.8| 32.0
MOCP (Max. over Current Protection)| N/A| N/A| N/A| 20.0| 50.0
COMPRESSOR| 1/3 HP| 1/2 HP| 3/4 HP| 3/4 HP| 1.5 HP
EVAPORATOR RATING @ 20°F (BTUH)| 3420| 3800| 6000| 6300| 12000
HEAT REJECTION (MAX)| 4080| 6080| 9600| 10080| 19200
REFRIGERANT| R-134a| R-134a| R-134a| R-134a| R-134a
SHIPPING WEIGHT LBS (kg)| 140 (64)| 153 (69)| 180 (82)| 205 (93)| 255 (116)
CABINET| Stainless Steel
CIRCULATING PUMP| 100 GPH/130 PSIG
RESERVOIR CAPACITY| 1.75 gal| 1.75 gal| 1.75 gal| 1.75 gal| 1.75 gal
REFRIGERATION| Constant Pressure Expansion Valve, Condensing Unit with Service Valves
REFRIGERANT CHARGE (grams)| 14.0 oz/397 g| 12.0 oz/340 g| 9.5 oz/269 g| 11.0 oz/312 g| 16.0 oz/453 g
GLYCOL CONCENTRATION| 30%| 30%| 30%| 30%| 30%
OPTIONAL ACCESSORIES| 4430   115V pump kit for 4410 Power Pak (field installed)                                              61790        Dual Tier Rack

4431   115V pump kit for 4414 Power Pak (field installed) 61791+1 Triple Tier Rack 4432 208/230V pump kit for 4414/230V and 4420 Power Paks (field installed) 61792+2 Quad Tier Rack

4435   BLM Receptacle C22296A-20 Cord Kit for 120V single pump Power Paks only (Field installed) 4408SS Wall Bracket for 4404 & 4410 only

C21499BSS Stainless Steel Table Stand

Requires four wires (2 hot, 1 neutral and 1 ground).

Perlick is committed to continuous improvement. Therefore, we reserve the right to change specifications without prior notice.

WATER COOLED

A minimum of six inches of clearance should be allowed around the entire unit for proper performance. Additional clearance should be considered for above the unit and in front of the unit for servicability.
ELECTRICAL| Voltage| 120 V| 120 V| 120 V| 208/230 V*
Frequency| 60 Hz| 60 Hz| 60 Hz| 60 Hz
Phase| 1 Ø| 1 Ø| 1 Ø| 1 Ø
SINGLE PUMP| RLA (Rated Load Amps)| 15.4| 17.1| 17.4| 20.8
MCA (Min. Circuit Ampacity)| 17.7| 19.9| 20.4| 25.3
MOCP (Max. over Current Protection)| 25.0| 30.0| 30.0| 40.0
DUAL PUMPS**

(add -2 to model #)

| RLA (Rated Load Amps)| 21.5| 23.2| 23.0| 23.6
MCA (Min. Circuit Ampacity)| 23.8| 26.0| 26.0| 28.1
MOCP (Max. over Current Protection)| 30.0| 35.0| 35.0| 45.0
TRIPLE PUMPS

(add -3 to model #)

| RLA (Rated Load Amps)| N/A| N/A| 28.6| 26.4
MCA (Min. Circuit Ampacity)| N/A| N/A| 31.6| 30.9
MOCP (Max. over Current Protection)| N/A| N/A| 40.0| 45.0
COMPRESSOR| 1/3 HP| 1/2 HP| 3/4 HP| 1-1/2 HP
EVAPORATOR RATING @ 20°F (BTUH)| 3420| 4080| 6870| 13,800
HEAT REJECTION (MAX)| 2050| 2450| 4122| 6500
REFRIGERANT| R-134a| R-134a| R-134a| R-134a
SHIPPING WEIGHT LBS (kg)| 141 (64)| 143 (65)| 205 (93)| 255 (116)
CABINET| Stainless Steel
CIRCULATING PUMP| 100 GPH/130 PSIG
RESERVOIR CAPACITY| 1.75 gal| 1.75 gal| 1.75 gal| 1.75 gal
REFRIGERATION| Constant Pressure Expansion Valve, Condensing Unit with Service Valves
REFRIGERANT CHARGE (grams)| 14.5 oz / 410 g| 14.5 oz / 410 g| 22.0 oz / 623 g| 22.0 oz / 623 g
GLYCOL CONCENTRATION| 30%| 30%| 30%| 30%
PLUMBING REQUIREMENTS
INLET & OUTLET| All employ 1/2” O.D. Quick Connect Fittings
FLOW RATE (GPM) @ 75°F| 0.5| 0.6| 0.9| 1.2
PRESSURE DROP (psig)| 0.1| 0.2| 0.4| 0.5
MAX SUPPLY PRESSURE| All Models: Incoming Water Pressure not to exceed 150 psig
OPTIONAL ACCESSORIES| 4430 115V pump kit for 4410 Power Pak (field installed) 4431 115V pump kit for 4414 Power Pak (field installed) 4435 BLM Receptacle

4408SS Wall Bracket for 4404 & 4410 only 57782 Set of four adjustable legs

54838 Water hammer arrestor (add if incoming water is under 65°F) 61790 Dual tier rack

61791+1 Triple tier rack 61792+2 Quad tier rack

C22296A-20 Cord Kit for 120V single pump Power Paks only (Field Installed)

C21499BSS Stainless Steel Table Stand

---|---

Accessories

Power Cord Kit
C2296A-20–12/3 Cord, 20A, NEMA Plug 5-20P, Dedicated Circuit Models – See above electrical specifications
Power Pak Racks
61790, 61790+1, 61790+2 – All Models
Power Pak Wall Mounting Brackets
4408 – For Models 4404 & 4410 only Coolant Solution-63299-1 One gallon Perlick Coolant solution, 30% DowFrost HD/70% Distilled Water
Coolant Connector Kit
63335 – All Models
Leg Set – All Models
57782 . . . Set of four, 5 3/4”-71/2” adjustable legs
Pump Kits
4430 – Pump kit, 115V, 6.1 A, 100 gph, 130 psig Models 4410, 4410W 4431 – Pump kit, 115V, 5.6 A, 100 gph, 130 psig Models 4414, 4414W 4432 – Pump kit, 230V, 2.8 A, 100 gph, 130 psig Models 4414-230, 4420

PRODUCT DESCRIPTION

Power Paks have always been an integral part of a Perlick Century Beer System. The 4400 Series Power Pak product line has been expanded to satisfy longer beer runs. A Power Pak circulates coolant solution (food grade propylene glycol with distilled water) from the walk-in cooler to the dispensing station(s) and back, maintaining the desired dispensing temperature at the faucet. The 4400 series Power Pak incorporates a 1/3 hp ball bearing, maintenance-free motor with a 100 gallon per hour 150 psig positive displacement pump for optimum performance. The 4400 series Power Pak product line employs a direct expansion form of refrigeration increasing the units’ efficiency as well as making the units more compact. These units also employ an electronic temperature control with digital readout. This state-of-the-art control controls the performance of the unit as well as giving the user a visual indication of how the unit is working as well as giving the user a visual indication of the how the unit is working as well as early indication if something may be going wrong through the use of internal alarms.

INSTALLATION

IMPORTANT SAFETY WARNINGS!

• Follow all National and Regional Codes.
• Read Installation and Operating Instructions carefully before attempting to install, operate or maintain the product.
• Protect yourself and others by observing all safety information.
• Electrical hazards exist and can cause injuries if not serviced by properly trained personnel.
• Failure to comply with instructions could result in personal injury and/or property damage!
• Retain instructions for future reference.
• Never operate the circulating pump without coolant in the reservoir.

NOTE: Air-cooled Power Paks must be installed in areas with adequate ventilation to maintain ambient temperatures of less than 105°F to achieve optimum performance and satisfy warranty requirements.
INSTALLING THE POWER PAK
Prior to installing a 4400 Series Power Pak, it is imperative that the method of connecting it to the electrical service has been determined. Ensure that the electrical service to power the Power Pak will handle the load requirements. Perlick has a Power Cord specifically designed for a Power Pak, which has an RLA of 16 amps or less, and an MCA of 20 amps or less. All units with RLA greater than 16 amps and an MCA of greater than 20 amps should have the Power Pak hard-wired to electrical service.
ALL MODELS

• Determine the ideal placement of the Power Pak. Locate the connection point to the truck housing and place the Power Pak as close to this point as possible.
  NOTE: If the Power Pak is to be located on top of the walk-in cooler, it is imperative that proper ventilation is provided to prevent system failure due to overheating. Inadequate ventilation will void the warranty.

• Place the Power Pak and Ensure that it is level to provide proper overflow protection. REMINDER: Allow a minimum of six inches of clearance on the louvered ends of the cabinet for proper airflow. Allow accessibility room on the top of the cabinet for serviceability.

• Remove the top panels (2).

• Ensure Power Switches for Condensing Unit and Pump(s) are in the OFF position. Make the electrical connections per their illustrations.
  NOTE: Electrical circuit should be a dedicated circuit for use only with the Power Pak. The circuit should be sized in accordance with the electrical requirements of each unit as well as in compliance with all National and Local Codes.

• Plumb overflow port to a suitable reservoir/drain.

WATER-COOLED MODELS

• In addition to the above installation instruction:
• Care should be exercised in locating the Power Pak so that the unit will never be exposed to temperatures below freezing.
• If the Power Pak is installing more than 5 feet higher than the remote outlet drain point (i.e., location of the floor drain) of the condenser, a vacuum breaker or open vent line should be provided to prevent the discharge line from creating a partial vacuum condition in the condenser water system.
• If a water-circulating pump is used it should be placed on the water supply side of the condenser, so water is being pushed through the condenser.
• A potable water supply is required as well as a drain or reclamation system. Make water supply connection to fitting labeled as the water inlet. Make outlet connection to fitting labeled as the water outlet connection. Both the inlet and outlet fittings supplied with the Power Pak are 1/2” Quick Connect fittings.

CONNECTING POWER PAK TO TRUNK HOUSING
400 Series Power Paks require rigid fittings with a minimum pressure rating of 150 psig. Use Coolant Connector Kit #63335 to connect Power Pak to Trunk Housing.

• Inspect pump outlet port for debris. Insert barbed fitting #63307 into pump outlet port.
• Inspect Glycol Return Manifold inlet for debris. Insert barbed fitting #63307 into the return manifold inlet port.
• Cut supplied coolant tubing, #54588, to the required length to reach from Power Pak to Trunk Housing connection point.
• Cut tubular insulation sleeve, #C12700, in half and install over previously cut coolant tubing.
• Take Oetiker clamps, #54871-210, and install them over coolant tubing ends.
• Push coolant lines, one each over pump outlet barbed fitting #63307 and return manifold barbed fitting #63307.
• Position Oetikers over barbed fitting and clamp securely.
• Slide tubular insulation sleeves tightly against connection points. Use insulation tape as necessary to ensure an air-tight seal to prevent excessive heat gain or condensation problems.
• Drill a 3-1/2” diameter hole in the walk-in cooler to accommodate coolant lines.
• Install insulation donuts over holes (both inside and outside of cooler walls.
• Slide large insulation sleeve, #57478, over remaining coolant tubing exposed to warm air conditions including inside walk-in cooler from Power Pak to Trunk Housing connection point. Seal and tape all seams to prevent excessive heat gain or condensation problems.
• Slide coolant lines through 3-1/2” donut hole previously cut in walk-in cooler wall.
• Position Trunk Housing coolant lines and Coolant Connector kit lines in a horizontal position, to alleviate condensation runoff into Trunk Housing.
• Cut Trunk Housing coolant lines with tubing cutter to ensure clean burr-free ends.
• Take Oetikers clamps #54871-210, and install them over coolant connector kit tubing ends.
• Slide coolant connector kit tubing over the trunk housing coolant lines and secure using the Oetikers.
• Complete the insulation process by ensuring that all coolant lines are well insulated including all seams to prevent excessive condensation and heat gain.
• Seal the donut hole to ensure an air-tight seal to prevent walk-in cooler problems as well as condensation.

CONNECTING TRUNK HOUSING COOLANT LINES TO DISPENSING HEAD

• Position the trunk housing so that beverage lines can be connected with minimum cutting.
• Split trunk housing approximately 12 inches from the end to allow working room for the connections.
• Cut and deburr copper coolant lines coming from trunk housing and dispensing head. Stagger the lengths.
• Connect trunk housing coolant lines to dispensing head coolant lines using clamps, hose, and 3/8” x 1/2” union, included in the Head connecting kit, #63486. Ensure that coolant lines are fully clamped to guarantee a leak-free connection.

INSTRUCTION DRAWING FOR 4400 SERIES POWER PAK COOLANT CONNECTOR KIT INSTALLATION INSTRUCTIONS

NOTE: POSITION BEER LINES TO MAKE CONTACT WITH COOLANT LINES AND NOT OVER THE EARS OF THE CLAMP.
CAUTION: MAXIMUM PRESSURE 150 P.S.1.G.

CONNECTOR KIT

(1/2″ O.D. TO 3/8″ O.D.) #634865

ITEM DESCRIPTION                                            PART NO.
STEPLESs CLAMP (NO. 15.70)                                 C31958
BRAIDED HOSE (F/3/8″ O.D.)-3.0″                        C14230B
HOSE UNION (3/8″ TO 1/2″)                                  63331
STEPLESS CLAMP (F1/2″ O.D.)                               54871-198
BRAIDED HOSE (F/1/2″ O.D.)-3.0″                        54589-1

START-UP

SYSTEM START-UP
Use only Perlick Approved Coolant Solution, #63299-1, all other solutions and mixtures will void the Perlick warranty. The Coolant Solution has been pre- mixed for optimum performance and wears protection. The Power Pak reservoir holds approximately 1.75 gallons of solution. It takes approximately 1 gallon of Coolant Solution to fill every 60 feet of Perlick Trunk Housing.

• Never operate the circulating pumps without coolant in the reservoir.

• Fill Power Pak reservoir with Perlick Coolant Solution.

• Turn the condensing unit switch and pump switch to the ON position. The coolant solution level will begin to drop in the reservoir.

• Continue adding Perlick Coolant Solution until no air bubbles are apparent from the Coolant return line.
  NOTE: Never allow for the Coolant level in the reservoir to drop below the heat exchanger tube inlet. Allowing the level to drop below the inlet will allow air into the lines.

• Fill Power Pak reservoir until both the return line fitting port and the overflow tube port are submersed under Coolant Solution. Watch return line fitting port for additional Coolant Solution may need to be added.

• Thoroughly check all field connection points for leaks.

• Monitor Power Pak Temperature read-out to ensure Power Pak is working properly. Dependent on the length of trunk housing run(s) and surrounding ambient conditions, these factors will determine how long it takes for the Power Pak to cut out on the temperature control.

DIGITAL TEMPERATURE CONTROLLER
The 4400 Series Power Pak comes equipped with a Factory Programmed Electronic Thermostat with the display. The Thermostat has numerous factory settings, which should never be adjusted or tampered with to ensure proper operation of the Power Pak. The Thermostat has been factory programmed to cut out at 30°F with a hysteresis/differential of 4°F.
Front Panel Commands–Normal Operation
SET: To display the target set point.
DEFROST: To start a manual defrost. (This feature is available, however, the parameters for actuation are programmed, such that, no defrost is available).
Front Panel Commands–Programming Mode SET: Selects a parameter or confirms an operation.
UP ARROW: browses the parameter codes or increases the displayed value.
DOWN ARROW: browses the parameter codes or decreases the displayed value.

LEDS & PREVENTATIVE MAINTENANCE

Meaning of LEDS
DISPLAY MESSAGE MEANINGS

NOTE 1: Faulty probe, loose connection, broken wire. (Power Pak will continue to operate with a faulty probe. The controller has been factory programmed to continue operation with the compressor cycling on and off in 5-minute intervals.

How to see the SETPOINT

• Press and immediately release the SET key: the display will show the Setpoint value.
• Press and immediately release the SET key or wait for 5 seconds to display the probe value again.

How to change the SETPOINT

• Press and hold the SET key for more than 2 seconds to change the Setpoint value.
• The value of the set point will be displayed and the SNOWFLAKE LED starts blinking.
• To change the Set value, press the UP or DOWN ARROWS, dependent on the new set point value.
• To memorize the new set point value, press the SET key again or wait 15 seconds.

WARNING: IF THE MESSAGE OR INFORMATION SHOWN ON THE READOUT IS UNFAMILIAR, ALLOW THE CONTROL TO SIT FOR A MINIMUM OF 15 SECONDS, AND THE CONTROLLER SHOULD RETURN TO DISPLAY PROBE TEMPERATURE.

REPLACEMENT PARTS

C22634

| ****

C22645

| ****

C22668

| Compressor| 262FG92UB.2| 269HG9290AF| AJ250AT-188-J7| RRT10K1E- PFV-959| ZS19KAE- PFV-818
| Cond Fan Motor| 1450076| 1450095| TFM351| 950-0344-00| 950-0265-00
| Fan Blade| 2455003| 2455003| 51541-1| | 083-0033-01
| Start Components| US-PBNE6210Z1| US-PBNEK6214Z1| | |
| Water Regulator| N/A| N/A| N/A| N/A| N/A
Pump Motor| 63292| 63292| 63293| 63293| 63293
Heat Exchanger| 63303A| 63300A| 63301A| 63301A| 63301A
Gasket, Heat Exchanger| 61758A| 61758A| 61758A| 61758A| 61758A
Grille| 64197-1SS| 64197-1SS| 64197-1SS| 64285-1SS| 64286-1SS
Front Panel| 64407-1SS| 64407-1SS| 64407-1SS| 64285-1SS| 64286-1SS
Contactor| N/A| N/A| N/A| 63359| 63359
Relay, Pump| N/A| N/A| N/A| 63358| 63358
COMPONENT/MODEL| 4404W| 4410W| 4414W| 4420W
---|---|---|---|---
Condensing Unit| C22640| C22641| C22642| C22666
| Compressor| ARE51C4E- CAA-901| RRT62C1E- IAA-901| RRT10K1E- PKA-959| CS18K6E- PKV-970
| Cond Fan Motor| N/A| N/A| N/A| N/A
| Fan Blade| N/A| N/A| N/A| N/A
| Start Components| | | |
| Water Regulator| 510-0049-00| 510-0049-00| 510-0049-00| 510-0049-00
Pump Motor| 63292| 63292| 63293| 63293
Heat Exchanger| 63300A| 63300A| 63301A| 63302A
Gasket, Heat Exchanger| 61758A| 61758A| 61758A| 61758A
Grille| 64197-1SS| 64197-1SS| 64197-1SS| 64285-1SS
Front Panel| 64407-1SS| 64407-1SS| 64407-1SS| 64286-1SS
Contactor| N/A| N/A| N/A| 63359
Relay, Pump| N/A| N/A| N/A| 63358

Common Components

WIRING DIAGRAMS

WIRING DIAGRAM FOR 4404, 4410, 4414 115V POwER PAKS

NOTE: CORD SET (TO WALL OUTLET) C22297-20 FOR STANDARD UNIT ONLY, SUGGEST HARD-WIRED AS NORMAL MODE OF ATTACHMENT SUPPLIED BY OTHERS.
DANGER: ELECTRICAL SHOCK HAZARD. DISCONNECT ALL POWER BEFORE SERVICING.

WIRING DIAGRAM FOR 4414-230, 4420, 208/240V POWER PAKS
NOTE: SUGGEST HARD WIRED AS NORMAL MODE OF ATTACHMENT sUPPLIED BY OTHERS.
DANGER: ELECTRICAL SHOCK HAZARD. DISCONNECT ALL POWER BEFORE SERVICING.

Support

8300 West Good Hope Road Milwaukee, WI 53223 
Phone: 414.353.7060 
Fax: 414.353.7069
Toll Free: 800.558.5592 
E-Mail: perlick@perlick.com 
Website: www.perlick.com

References

• Perlick Corporation - Commercial Refrigerator and Bar Equipment Supplier - Perlick Corporation

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