RSG KL612 One-Piece Capsule Pak Refrigeration Installation Guide

KL612 One-Piece Capsule Pak Refrigeration
Installation Guide

TOOLS REQUIRED

TOOLS REQUIRED FOR UNCRATING AND INSTALLATION OF THE REFRIGERATION SYSTEM

• SAFETY GLASSES
• PRY BAR
• HAMMER
• ADJUSTABLE OPEN-END WRENCH (2)
• DRILL DRIVER
• PENCIL

REFRIGERATION SYSTEMS-GENERAL INFORMATION

RECEIVING INSPECTION

Congratulations on your purchase of a quality-built refrigeration system. When properly installed and maintained, this product will give many years of trouble-free service. It was shipped using trusted carriers with a history of careful handling, good customer service, and prompt delivery.
Even with all of these precautions, occasionally accidents may happen which result in shipping damage. When the product is picked up by the carrier, they assume responsibility for the product until they deliver it to you. Thus, any claims for shipping damages must be filed with the delivering carrier.
Always thoroughly inspect the delivery for visible damages and shortages. Should any damages or shortages be found, be sure to note them in detail on the delivery receipt before you sign it. Make sure the driver signs and dates the delivery receipt acknowledging the damages. This is critical in protecting yourself should a claim need to be filed. Consult the carrier’s website for their specific claim procedures. Remember, it is your responsibility to file a claim with the carrier.
In the case of concealed damages that are not discovered in the initial inspection but are found upon removing the packaging, time is critical. You should unpack and inspect the unit as soon as possible. If the concealed damage is found, stop unpacking and contact the delivering carrier immediately to alert them of the damages and get a claim number. Save all packaging for inspection by the carrier. Consult the carrier website for details in filing a concealed damage claim.
Please remember, that the carrier is your only source for reclaiming freight damages. The manufacturer should not be contacted to attempt a return of the product. No returns are accepted without a prior authorization

SAFETY INFORMATION

This manual may contain notices that identify situations that could cause death, serious injury, and /or damage to the appliance or property.
Please make note of the following definitions;
! WARNING: Indicates a hazardous situation that could result in death or serious injury.
NOTICE: Indicates a situation that could result in damage to the appliance or property.
IMPORTANT: Indicates important information about the use and care of the appliance.
! WARNING:
This appliance should be applied only for the use for which it has been expressly intended. Any other use would be considered improper and therefore dangerous. The manufacturer cannot be held responsible for injury or damage resulting from improper, incorrect, and unreasonable use. Failures to install, operate, or maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage.
To reduce the risk of death, electric shock, serious injury, or fire, follow basic precautions including but not limited to the following:

• Only qualified service technicians should install and service this appliance.
• This appliance must be installed in accordance with applicable national, state, and local codes and regulations.
• To reduce the risk of electrical shock, do not touch the appliance or plug with wet hands.
• Disconnect the appliance from power before servicing.
• The appliance requires an independent power supply of proper capacity that matches the power cord plug supplied. See the appliance nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuse, damage to existing wiring, or component failure. This could lead to heat generation or fire.
• The appliance must be properly grounded. This appliance is equipped with a NEMA 5-15P, 6-15P or 6-20P three-prong grounded plug to reduce the risk of potential electrical shock hazards. It must be connected to a properly grounded, independent 3-prong wall outlet. Do not remove the ground prong from the appliance plug and do not use an adapter plug. Failure to follow these instructions may result in death, electrical shock, or fire.
• Do not use an extension cord to supply power to the appliance.
• Do not use the appliance should the power cord become damaged. The power cord should not be altered, jerked, pinched, bundled, and/or used to hang objects from. Such actions could result in electrical shock or fire. To disconnect the unit from power, be sure to grasp and pull on the plug, not the cord.
• Should the power cord require replacement or service, use only the manufactures replacement parts and be sure to connect the green ground wire to the appliance, in the same manner, the original wire was connected.
• Do not spray or splash water on the appliance as this may cause short circuits, electrical shock, corrosion, or failure.
• Do not make alterations or modifications to the appliance as these could result in electric shock, injury, fire, or damage to the appliance.
• Children must be properly supervised around this appliance.
• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning its use by a person responsible for their safety.
• Do not climb, stand, or hang on or into the appliance or its components. Death or serious injury could occur or the appliance could be damaged.
• Use caution when opening doors or lids and keep fingers out of pinch point areas.
• Do not use combustible sprays or aerosols around the appliance as they may catch fire.
• Do not store gasoline or other flammable substances in or near the appliance as they may catch fire.
• Keep the area around the appliance clean. Dirt, dust, or insects around the appliance could cause harm to individuals or damage to the equipment.
• Do not block air inlets or outlets as this would cause cooling performance to be reduced.
• Do not overload the storage capacity of the appliance. Allow space between stored items for airflow.
• Do not load warm or hot items into the appliance. Allow them to cool first or they will raise the cabinet temperature and could hasten the deterioration of other foods stored in the cabinet.
• This appliance is designed for the temporary storage of food products. Use proper sanitation practices.
• All food products should be covered or stored in sealed containers. Open foods may dry up, pass their smell to other foods and increase cross-contamination. Some food products may accelerate corrosion of the evaporator resulting in the failure of the appliance to cool.
• Component parts must be replaced with the manufacturer’s original equipment parts.
• The appliance requires an independent power supply of proper capacity that matches the power cord plug supplied. See the appliance nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuse, damage to existing wiring, or component failure. This could lead to heat generation or fire.

GENERAL INSTALLATION INSTRUCTIONS

SET-UP AND INSTALLATION

CEILING-MOUNTED SELF-CONTAINED REFRIGERATION SYSTEM
! WARNING
This appliance must be installed in accordance with all applicable national, state, and local regulations. This appliance is heavy. Use care when lifting and positioning. Work in teams when needed to prevent injury or damage. The store temperature should be at or below 90°F and relative humidity of 55% or less for indoor installations. At higher temperature or humidity conditions, the performance of these cases may be affected and the capacity diminished. These cases should not be positioned where it is directly exposed to rays of the sun or near a direct source of radiant heat or airflow. This will adversely affect the case and will result in reduced performance. Operating this appliance outside its range and installation requirements may affect performance and warranty coverage.
Locating the Appliance
This system requires open-air space around it to operate properly. A minimum of 4” above the unit and 24″ on all sides is required to operate. Allow space for heated discharge air to escape and a fresh air intake supply.
IMPORTANT

• Confirm that the ambient temperatures are within the tolerances allowed.
• Do not locate next to heat-generating appliances.
• Confirm the unit is installed level.
• Do not use an extension cord to connect the unit to power. The use of an extension cord will void all warranties.
• Do not tamper with the ground pin on the power cord and confirm that the power receptacle has a properly wired ground connection.
• The system must be isolated on a power circuit.
• Confirm that the power supply matches the required power supply noted on the cabinet serial plate.

GENERAL INSTALLATION INSTRUCTIONS
This section has the general instructions for installing the ceiling- mounted self-contained refrigeration system.
Note:

• Proper “temporary” support of the ceiling panel with the cut-out must be added during the installation of the refrigeration.
• Due to the weight of these systems (approximately 200 lbs.), it is highly recommended that proper lifting equipment, such as a forklift or material lift, be utilized during installation. Be sure to allow for sufficient airflow around the condenser. A 4″ minimum clearance is required above the unit with at least 24″ clear space on all sides. If multiple units are located in the same area, be sure they do not exhaust hot air into one another. Refer to the section titled “Locating and Mounting Condensing Units” for details. 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. Special care should be used when positioning the evaporator section over the ceiling cut-out. Be sure not to damage the gasket underneath the evaporator section.
Fasten latches and seal perimeter as described in the Latch and Diffuser Installation Instructions found on pages 9 and 10. When reinstalling the diffuser panel, make sure the ceiling section divider on the panel seals against the black gasket. Some adjustments 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.

START-UP AND OPERATION

After meeting the set-up and installation requirements the unit is ready to start up. Once the power cord is connected to a live outlet and the power switch is in the ‘on” position the unit will start running. Allow the unit to run for two (2) hours and verify the walk-in is down to temperature prior to loading with the product.
TEMPERATURE ADJUSTMENT
These units come equipped with an electronic control system. The Temperature Control display and operator interface are located on the front of the unit and come pre-set to give walk-in air temperatures of approximately +35°F for coolers or -10°F for freezers. Refer to the accompanying electronic controller manual for detailed instructions on adjusting the controller settings.
STANDARD TEMPERATURE (COOLER) SYSTEMS
The electronic control system is a highly efficient electronic controller that regulates an electronic expansion valve in response to evaporator superheat and return air temperature, featuring demand defrost fan control technology. This system will operate differently from the previous system you may have worked with in the past. Refer to the controller instructions supplied with the unit for additional information.
Important: It is the installing contractor’s responsibility to check the operation upon start-up and make necessary temperature adjustments as required for proper operation.
Note: Capsule Pak Refrigeration Systems that are designed for outdoor installation will be fitted with electric crankcase heaters, electrically heated condensate drain tubes, and an automatic head pressure control valve.
Refrigeration Controller
Capsule Pak refrigeration systems are equipped with an electronic control system. See separate instructions on the operation of this electronic temperature control.
Defrost Cycle (Cooler System)
The electronic controller uses an automatic on-demand defrost algorithm that eliminates unnecessary defrosts typically associated with time-based alternatives which reduce energy consumption.
LOW TEMPERATURE (FREEZER) SYSTEMS
The low temperature, automatic electric defrost Capsule Pak refrigeration system utilizes the electronic controller with a programmable set point and a preset algorithm to cycle the fans and compressor in order to maintain a tighter room temperature.
Important: It is the installing contractor’s responsibility to check the operation upon start-up and make necessary temperature control adjustments as required for proper operation.
Note: Capsule Pak Refrigeration Systems that are designed for outdoor installation will be fitted with electric crankcase heaters, electrically heated condensate drain tubes, an automatic head pressure control valve, and the “pump-down cycle”.
Defrost Cycle
The electronic controller uses an automatic or demand-to-defrost algorithm that eliminates unnecessary defrosts typically associated with time-based alternatives which reduce energy consumption. For additional information see the controller instructions supplied with the refrigeration system.
Defrost Cycle Termination
The electronic controller will run the coil heater until the coil is above 32°F. At this point, it will work very differently than a traditional defrost cycle. The heaters will pulse on and off allowing the heat to radiate through the coil until both coil sensing probes reach 50°F or 40 minutes whichever happens first. The fan(s) in the evaporator housing will not start, however, until the fan delay cycle has expired. See the “Fan Delay” below.
Fan Delay
When a defrost cycle is terminated the evaporator fan(s) will not start until the evaporator coil temperature is reduced to about +20°F. Once this temperature is reached, the fan delay cycle will turn the fans back on continuing the refrigeration cycle.
The fan delay feature is an important part of defrosting. If the fan(s) was permitted to start immediately following a defrost period, the heat that accumulated in the evaporator housing would be circulated throughout the walk- in, raising the temperature considerably. In addition, any droplets of moisture that remained clinging to the fins of the evaporator coil would be blown into the storage space. The fan delay feature provides for a short refrigeration cycle WITHOUT the evaporator fan(s) to prevent these conditions.
Note: During the initial startup of a Capsule Pak Refrigeration System on a warm walk-in, the evaporator fan(s) will not start until the evaporator coil reaches +20°F. Further, the evaporator fans may cycle “on” and “off” several times until the evaporator coil reaches and maintains +20°F.
Drain Tube Heater
Low-temperature ceiling-mounted Capsule Pak refrigeration systems employ a low wattage, electric heater wire. This heater is spirally wound around the condensate drain tube that extends from the drain pan below the evaporator through the Capsule Pak evaporator section housing wall. This heater is energized continually to allow the free flow of the condensate water to the outside of the evaporator section.
Medium temperatures mounted Capsule Pak employ the same condensate drain tube that extends from the drain pan below the evaporator through the Capsule Pak evaporator section housing wall but has no heater wire.
Drainage of Condensate Water
Indoor Models
In indoor self-contained Capsule Pak systems, the condensate drain tube is factory plumbed to discharge the condensate water into an evaporative drain pan located under the compressor in the condensing unit. The compressor discharge line is routed inside this pan to heat the condensate water to aid evaporation.
In locations where high moisture content exists, it is possible that the evaporative drain pan may overflow. In this case, the drain line must be plumbed to an optional electric condensate pan evaporator (part number 133141 or 132962).
Outdoor Models
On outdoor self-contained Capsule Pak systems, the condensate drain line must be plumbed by the installer. The installer will need to provide a drain line connected to the drain tube exiting the evaporator section, route it thru the provided knock-out holes on either side of the Capsule Pak system, and wrap the line with suitable heater wire and insulation if subject to below-freezing temperatures and install a P-trap at the termination. The line can flow to an optional condensate evaporator pan or to a drain.
LOADING PRODUCT
Once that cabinet has been operating at the desired temperature for a sufficient period of time, the product can be loaded into the cabinet.
IMPORTANT

• When loading products use caution not to block airflow to achieve maximum cooling performance.
• Do not load product where it would block the air intake or discharge at the back inside wall of the cabinet.
• Do not load warm products into the cabinet as it will affect the cabinet temperature and products previously stored in the cabinet.
• Products should be in covered containers or wrapped to prevent cross-contamination.

CAPSULE PAK LATCH AND DIFFUSER INSTALLATION INSTRUCTIONS

1. Remove diffuser from ceiling panel before installing ceiling panel (Figures 1 and 2)
2. Lift Capsule Pak into position on top of the walk-in. Note: Do not slide Capsule Pak into position as cowl gasket damage will occur. If the Capsule Par” must be slid into position, place Capsule Pak on a piece of cardboard prior to moving to prevent gasket damage.
3. Inspect the cowl gasket to ensure proper placement (Figure 3)
4. Secure interior latches (Figure 4)
5. Seal cowl to the ceiling at gasket seam above diffuser panel using provided silicone (Figure 5)
6. Replace the diffuser panel removed in step 1.

When reinstalling the diffuser panel, make sure the ceiling section divider on the panel seals against the black gasket. Some adjustments 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.
OPTIONAL FEATURE – ELECTRIC CONDENSATE VAPORIZER
Indoor Capsule Pak Applications Only (do not use condensate vaporizer for an outdoor application)
The vaporizer is intended to be mounted in the orientation shown below. Note the location of the condensate drain coming from the evaporator and locate the vaporizer so the condensate water will drain into it. Use the supplied plastic tubing and copper elbow and extend the drain into the vaporizer. Cut the plastic tubing to the desired length.
Provide power to the electric vaporizer per local national electrical codes. Avoid locating vaporizers below any electrical enclosures. LOCATING AND MOUNTING CONDENSING UNITS
Condensing units (CU’s) must be located where there is an unrestricted supply of clean, fresh air. Do not locate units where air discharge from one will enter into the air intake of others nor where the airflow is toward a wall or obstruction. Avoid locating units in restricted spaces where heat will build up and can enter the condenser. There must be room around the unit for regular inspection and service. We recommend 200CFM in any area where condensing units may be located. Air flow should be sufficient to maintain an ambient temperature of no more than 90°F.
Walls or Obstructions
The units should be located so that air may circulate freely. For proper airflow, all sides of the unit should be a minimum of the width of the condensing unit away from any wall or obstruction. It is preferred that this distance be increased whenever possible. Multiple units
For units placed side by side, the minimum distance between units should be the width of the largest unit. If units are placed end to end, the minimum distance between units should be 4 feet. Roof-mounted condensing units must have adequate support for their operating weight. Corrosive atmospheres require custom design condensers.

OUTDOOR SYSTEMS

OUTDOOR SYSTEMS UTILIZING A MEMBRANE ROOFING MATERIAL

1. After the walk-in is completely assembled, place the curb face down on top of the ceiling sections (curt is fastened to crate base during shipping and must be removed and installed prior to membrane roof installation). To ensure proper opening alignment, mark the outside portion of the curb on the ceiling sections with a marking pencil

2. Remove the paper from the gasket and position the curb, gasket side down, on the pencil line. Press down firmly. Note: Movement of the curb is very difficult after the gasket adheres to the ceiling section. Refer to Figure 1.

3. Lay the membrane roofing material over the walk-in ceiling sections and curb leaving a six-inch overhang on all four sides of the walk-in. Using a utility knife, cut a hole in the membrane roof approximately 1-1/2″ in from the edge of the opening. (The resulting hole in the membrane will be smaller than the ceiling opening). Fold the 1-112″
   membrane flaps into the opening, notching the membrane around the locators and divider. Use either sheet metal screws, caulk, glue, etc. to fasten the membrane roofing material to the inside edge of the curb frame. Refer to Figure 2. Do not make any penetrations at the top of the membrane roof. Any needed penetrations should be through the side wall to maintain the integrity of the roof.

4. Set the Refrigeration System over the opening in the curb. Remove Diffuser Panel from the ceiling inside the walk-in to gain access to four latches located along the inner perimeter of the cowl. Refer to the Latch and Diffuser Installation Instructions found on pages 8-9. Use the Lock Extensions supplied with the curb to bridge the distance between the latches and strikes. Seal the latched seam as described in the instructions. When reinstalling the Diffuser Panel, make sure that the ceiling section divider located on the panel seals against the black gasket. Some adjustments 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. Before proceeding to step 5, pull the membrane straight and smooth before installing the trim.
   Note: Seal gasket at top of the curb with silicone.

5. Fold all four corners of the membrane roofing material over the walk-in corners as shown in Figure 4.

6. Attach the trim and door hood (if your walk-in is equipped with them) by using the provided pan head sheet metal screws. Ensure the trim and membrane roof material cover the joint between the ceiling and wall panels. Refer to figure 5. Note: The trim may have to be cut to fit.

7. Trim off all excess membrane roofing material from under the trim with a utility knife. Do not allow the knife to cut the metal panel, as this will damage the coating and cause rust.

NOTE: In outdoor installations, the condensate line should be plumbed to the nearest drain and a P-trap installed near the end. Check local building codes. Outside drain lines must also be wrapped with a suitable heater wire and insulated if they are ever subjected to below-freezing temperatures.

MAINTENANCE

WARNING: When servicing any Capsule PakT” Refrigeration System or performing any maintenance procedure, always disconnect the main power supply.
The condensing unit is accessible by removing the condensing unit housing. The evaporator coil section is accessible by unlatching and removing the evaporator section housing cover.
Cleaning the Condenser and Evaporator Coils
The efficiency of the refrigeration system, to a great extent, depends upon the unrestricted f.flow of air through the condenser and evaporator coils. For this reason, both coils should be as clean as possible at all times and should have an unrestricted supply of air.
Cleaning the condenser should be done a minimum of every 3 months.
A vacuum cleaner with a bristle attachment can be used to clean the coil. If debris on the coil cannot be removed easily, a bristle brush can be used to loosen it by gently brushing in the same direction as the fins so as not to damage them and restrict airflow. An air compressor can be used to clean the condenser coil also. The airflow should be directed through the coil from the fan motor side. A damp hand towel can be blocked against the opposite side so that the majority of the dust will be captured in the towel minimizing the mess in the room.
NOTE: Do not use corrosive cleaners as they may damage the copper tubing or welds.
Hot Gas Vaporizer Pan (Indoor Models)
Condensate from the evaporator pan is discharged into a hot gas vaporizer pan, which is located in the condensing unit housing. Here the hot discharge gas from the compressor elevates the temperature of the water and it vaporizes into the atmosphere. This pan should be cleaned periodically to remove solids that remain after the moisture is evaporated. Do not scrub the copper tubing very hard or use corrosive cleaners as this may damage the copper lines or welds.

MAINTENANCE ANALYSIS

2. Fuse has blown or removed
3. Overload tripped
4. Control stuck open
5. Wiring incorrect| 1. Plug in the service cone or turn the power on
2. Replace the fuse
3. Determine reasons and correct
4. Repair or replace
5. Check to wring against the diagram
The compressor will not start hums but trips on the overload protector

| 1. Improperly wired
2. Low voltage to the unit
3. Starting capacitor defective
4. Relay failing to dose| 1. Check wiring against the diagram
2. Determine the reason and correct
3. Determine the reason and replace
4. Determine the reason, correct or replace
The compressor starts and runs. but short cycles on overload protector| 1. Low voltage to the unit
2. Overload defective
3. Excessive head pressure
4. Compressor ha – warm ambient conditions| 1. Determine the reason and correct
2. Check current, replace overload protector
3. Check ventilation or restriction in the refrigeration system
4. Check refrigerant charge, fix the leak if necessary
The compressor operates long or continuously| 1. Short of refrigerant
2. Control contact stuck
3. Evaporator coil iced
4. Restriction in refrigerated system
5. Dirty condenser -warm ambient  conditions
6. Warm ambient| 1. Fix leak. add charge
2. Repair or replace
3. Determine the cause. defrost manually
4. Determine the location and remove the restriction
5. Clean condenser
6. Address ambient conditions
The compressor runs fine. but short cycles| 1. Overload protector
2. Cold control
3. Overcharge
4. Air in the system
5. Undercharge| 1. Check the wiring diagram
2. Differential too close – widen
3. Reduce charge
4. Purge and recharge
5. Fix leak, add refrigerant
Starting capacitor open. shorted or blown| 1. Relay contacts stuck
2. Low voltage to the unit
3. Improper relay| 1. Clean contacts or replace the relay
2. Determine the reason and correct
3. Replace
Relay defective or burned out| 1. Incorrect relay
2. Voltage too high or too low| 1. Check and replace
2 Determine reason and correct
Refrigerated space too warm|

1. Control setting too high
2. Refrigerant overcharge
3. Dirty condenser
4. Evaporator cod iced
5. Not operating
6. At flow to condenser or evaporator blocked
7. Warm ambient conditions

|

1. Reset control
2. Purge refrigerant
3. Clean condenser
4. Determine the reason and defrost
5. Determine reason, replace if necessary
6. Remove obstruction for free at flow – no storage on top of the walk-in
7. Ambient conditions should be 90′ or less

The standard temperature system freezes the product| 1. The control setting is too low| 1. Reset the control
Objectionable noise| 1. Fan blade hitting fan shroud
2. Tubing rattle
3. Vibrating fan blade
4. Condenser fan motor rattles
5. General vibration
6. Worn fan motor bearings|

1. Reform or cut away a small section of the shroud
2. Locate and reform
3. Replace fan blade
4. Check motor bracket mounting, tighten
5. Compressor suspension bolts not loosened on applicable models – loosen them
6. Replace fan motor

Water overflowing Nom evaporator drain pan or condensate vaporizer par|

1. Air leak between refrigeration system and walk-in panel.
2. Oran toe from evaporator drain pan to condensate vaporizer is Mocked with foreign material
3. Dran lire from evaporator drain pan to condensate vaporizer is Mocked with Ice.
4. Walk-in operating In a high humidity environment (heavy door usage)-

|

1. Check that the refrigeration system is properly set in the panel opening.
2. Clean blockage from inside of drain line.
3. Check that the drain line heater (on freezers)
is working and repaired or replace as required.
4. Plumb drain line from the evaporator to floor
drain or replace high gas vaporizer with an electric vaporizer. Consult the factory for further information.

Refrigerated Solutions Group
727 Second Street
Hudson, WI 54016
800-955-5253 Nor-Lake Foodservice Sales
800-388-5253 Nor-Lake Parts/Service
800-647-1284 Master-Bilt Sales
800-684-8988 Master-Bilt Parts/Service
Rev. D 171375

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