Reach-In Refrigerators and Freezers Service Manual This manual contains important information regarding the installation and upkeep of your new Koolaire refrigerator or freezer. Please read the manual thoroughly prior to equipment handling, set-up, operation, and maintenance. Part No.
Safety Notices Procedural Notices As you work on a Manitowocâ Koolaire reach-in, 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. As you work on a Manitowocâ Koolaire reach-in, be sure to read the procedural notices in this manual. These notices supply helpful information which may assist you as you work.
Table of Contents Table of Contents Section 1 - Warranty Model/Serial Number Location.........................................................................................................................1-1 Warranty.............................................................................................................................................................1-1 Warranty Service ....................................................................................................................
Table of Contents Table of Contents (cont.) Section 6 - Before Requesting Service Troubleshooting Guide ......................................................................................................................................6-1 Section 7 - Electrical Specifications Main Power Switch ........................................................................................................................................... 7-1 Temperature Control .................................................
Section 1 Warranty Section 1 Warranty Model/Serial Number Location The Koolaire data plate, which includes the model number and serial number, as well as important electrical and technical information, is located on the left interior wall of the cabinet at approximately eye level.
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Section 2 Installation Section 2 Installation General CAUTION These instructions are of the utmost importance in assuring that the Manitowocâ Koolaire cabinet operates as designed, and must be followed closely. Positioning the Cabinet CAUTION When selecting a permanent location for the cabinet, observe the following guidelines. Failure to do so may cause reduced performance and efficiency, cause damage, and void your warranty.
Installation Section 2 Uncrating WARNING Never attempt to tilt the cabinet alone. Always use two or more people when tilting the cabinet to remove the shipping skid or to move it through doorways. 1. Remove the bottom shipping skid using one of the methods below: • Lay the cabinet on its back, elevated and supported by wooden blocks. Remove the skid mounting bolts and separate the skid from the cabinet. • Tilt the cabinet from side to side and remove the mounting bolts.
Section 2 Installation Leveling the Cabinet The cabinet must be leveled after it is positioned in its permanent location. This insures proper door alignment on all cabinets, and adequate condensate water drainage and proper refrigeration system operation. SHELF SUPPORT STANDARD SHELF CLIP Leveling the Cabinet CAUTION If casters are installed instead of legs, the floor must be leveled before final positioning of the cabinet. SER.3 Shelf Installation 1. Place a level on top of the cabinet. 2.
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Section 3 Start-Up Section 3 Start Up Electrical Requirements All cord-connected units should be plugged into a grounded and properly sized electrical outlet with appropriate overcurrent protection. Refer to the drawing below for electrical plug configurations. All permanently connected (hard-wired) units are fitted with a power junction box and 6” pigtail wires for power connection. Connect one end of the power line to the pigtail from the cabinet junction box.
Start-Up Section 3 Electrical Specifications REACH-IN REFRIGERATORS Full Door Model Voltage/ Phase/Cycles Total Amps Maximum Fuse Size ANSI Electrical Plug Configuration KR-1 115/60/1 230/50/1 115/60/1 230/50/1 9.9 ** 10.4 ** Minimum circuit amps 15.1 ** 9.9 ** 10.4 ** Minimum circuit amps 15.1 ** 14.7 ** 16.0 ** Minimum circuit amps 15.
Section 3 Start-Up Condensate Water Removal (Refrigerators and Freezers) 24 HOUR DIAL Manitowoc cabinets are equipped with a condensate vaporizer system. This system uses energy-saving hot gas supplied by the refrigeration system lines. No drain connection is required. 2 HOUR DIAL Defrost Systems GENERAL Refrigerator coils operate at temperatures below freezing (32°F). During compressor “off” time, the evaporator fan continues to circulate 38°F refrigerator compartment air through the evaporator coil.
Start-Up Section 3 Temperature Control REFRIGERATORS AND FREEZERS The temperature controls are factory-set to maintain an average temperature of 38°F (3°C) in refrigerators, and an average temperature of 0°F (18°C) in freezers. The temperature variance is 6-8 F (2°-4°C) degrees. A freezer should run between -2°F to +4°F (3°C to 15°C). A refrigerator should run between +35° to +42°F (1°C to 5°C).
Section 4 Cleaning Section 4 Cleaning Exterior Interior Clean cabinet exterior surfaces with a solution of mild soap and water. To minimize streaking, follow with a fresh water rinse. Clean cabinet interior surfaces with warm water and baking soda, applied with a cloth or sponge. If stainless steel becomes discolored, scrub only in the direction of the finished grain. For high shine, see your kitchen equipment dealer for a high-quality stainless steel polish.
Cleaning Section 4 Cleaning the Condenser Coil WARNING Disconnect electric power before cleaning. A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces efficiency and shortens component life. The washable aluminum filter is designed to catch dust, dirt, lint and grease. This helps keep the condenser clean. For efficient operation, it is very important to clean the condenser coil surface and keep it free of dust, dirt, and lint.
Section 5 Adjustments and Calibrations Section 5 Adjustments and Calibrations Adjustments Cabinet doors may require some adjustment after a period of usage, depending upon the frequency of door openings. This is normal. Follow the appropriate procedure below: SOLID DOOR ADJUSTMENT 1. Remove the metal hinge covers that conceal the three hinge mounting screws. Gently pry it off with a flat-bladed screwdriver. GLASS DOOR ADJUSTMENT To adjust the spring tension: 1.
Adjustments and Calibrations Thermometer Calibration Occasionally, the rigors of shipping and installation can shift the thermometer out of proper adjustment. If the accuracy of the thermometer is in question, place another thermometer inside the cabinet at approximately mid-height and compare the readings. If the thermometer requires adjustment, follow the procedure below. 1. Gently pry off the clear thermometer cover lens with a small flat-bladed screwdriver. 2.
Section 6 Before Requesting Service Troubleshooting Guide Section 6 Before Requesting Service Before requesting any service on your Manitowoc cabinet, please check the following points. This guide is not comprehensive; it is intended as a reference for solutions to common problems. Symptom Cabinet not running Condensing unit runs for long periods or continuously WARNING Disconnect electric power before performing any service. Possible Cause Fuse blown or circuit breaker tripped. Power cord unplugged.
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Section 7 Main Power Switch Electrical Specifications Section 7 Electrical Specifications Temperature Control (Thermostat) Function Switches power to the reach-in on and off. Specifications Double pole single throw (DPST) Check Procedures 1. Check for proper line voltage (+/– 10%). 2. Inspect the switch for proper wiring. 3. Inspect the terminals for clean, tight connections. 4. Check across the switch terminals with a voltmeter.
Electrical Specifications Section 7 Light Switch Defrost Termination/Fan Delay Switch Function Turns the interior cabinet light on as the reach-in door is opened. Function Terminates the defrost cycle and delays the start of the evaporator fan(s) after defrost. Specifications Single pole push button switch. Specifications Thermodisc Open Temperature 55±60°F (12.8±15.6°C) Check Procedures 1. Check for proper line voltage (± 10%). 2. Inspect the switch for proper wiring. 3.
Section 7 Electrical Specifications Defrost Timer Defrost Heater Element Function Initiates the defrost cycle at preset times to prevent evaporator frost buildup. Function Defrosts the evaporator coil. Specifications Paragon 8145-00 See page 5-3 for defrost timer adjustment. Check Procedures 1. Inspect the terminals for clean, tight connections. 2. Verify that correct line voltage is at terminals X and 3.
Electrical Specifications Anti-Condensate Door Heaters Drain Pan Heater Element Function Warms the drain pan to allow moisture to drain Function Prevents condensation (sweating) on the cabinet and door surfaces. Specifications Specifications Model °F/°°C 20/-6.7 45/7.2 70/21.1 Section 7 Volt Amp Watt Ohm 115 115 230 3.5 3.5 1.73 400 400 400 30-34 30-34 130-135 Check Procedures 1. Turn off the electric power to the reach-in freezer. 2.
Section 7 Electrical Specifications Compressor Overload Protector Start Relay Function Shuts down the compressor if an overcurrent condition exists. Function A relay used to disconnect the start winding. Check Procedures WARNING Disconnect the electric power to the freezer before proceeding with the following steps. Check the continuity of the external overload protector. 1. Disconnect the wires from the overload protector from other components. 2. Check the continuity of the overload protector.
Electrical Specifications Section 7 Compressor Windings 4. Check the resistance between terminal C and the compressor shell: Function Draws current during the running cycle. Results of check Check Procedures Resistance NOTE: The compressor must be at temperature. room 1. Disconnect the wires from the compressor terminals. 2. Check the resistance between terminals C and R: Results of check Resistance No resistance Action See step 5 1. Verify external overload is closed. 2.
Section 7 Electrical Specifications 1-2-3 Door Refrigerator KR-1 KR-2 KR-3 KR-101 KR-201 KR-301 115/60/1 7-7
Electrical Specifications 1-2 Door Freezer KF-1 KF-2 KF-101 KF-201 115/60/1 7-8 Section 7
Section 7 Electrical Specifications 3 Door Freezer KF-3 KF-301 208-230/60/1 7-9
Electrical Specifications 1 Door Glass Door Refrigerator KR-1GD 115/60/1 7-10 Section 7
Section 7 Electrical Specifications 2 Door Glass Door Refrigerator KR-2GD 115/60/1 7-11
Electrical Specifications 3 Door Glass Door Refrigerator KR-3GD 208-230/60/1 7-12 Section 7
Section 8 Refrigeration Charging Specifications BASE MODEL KR-1 KR-101 KR-1GD KF-1 KF-101 KR-2 KR-201 KR-2GD KF-2 KF-201 KR-3 KR-301 KR-3GD KF-3 KF-301 Section 8 Refrigeration Ambient Temperature °F/°°C 70/21.1 100/37.8 70/21.1 100/37.8 70/21.1 100/37.8 70/21.1 100/37.8 70/21.1 100/37.8 Average Interior Temperature 38 F 3.3°C 38 F 3.3°C 38 F 3.3°C 0F -17.8 C 0F -17.8 C Suction Pressure Discharge Pressure Compressor Size (H.P.
Refrigeration Section 8 Refrigerant Recovery / Evacuation & Recharging Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment by specific manufacturer’s recommendations. IMPORTANT We assume no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company. CONNECTIONS 1. Suction side of the compressor through the suction service valve. 2.
Section 8 Refrigeration Charging Procedures IMPORTANT The charge is critical on all Reach-In units. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Be sure the Main ON/OFF toggle switch is in the OFF position. 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 3. Open the high side manifold gauge valve and the high side service valve. 4.
Refrigeration Section 8 System Contamination Clean-up This section describes the basic requirements for restoring contaminated systems to reliable service. IMPORTANT We assume no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company. DETERMINING SEVERITY OF CONTAMINATION Either moisture or residue generally causes system contamination from compressor burnout entering the refrigeration system.
Section 8 Refrigeration MILD SYSTEM CONTAMINATION CLEAN-UP PROCEDURE SEVERE SYSTEM CONTAMINATION CLEAN-UP PROCEDURE 1. Replace any failed components. 1. Remove the refrigerant charge. 2. If the compressor is good, change the oil. 2. Remove the compressor. 3. Replace the liquid line drier. 3. Remove the liquid line drier. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation. 4. Replace the TXV.
Refrigeration Section 8 11. Follow the normal evacuation procedure, except replace the evacuation step with the following: FILTER DRIERS a) Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 PSI. The size of the filter-drier is important. Using an improperly sized filter-drier will cause the Reach-In unit to be improperly charged with refrigerant. b) Change the vacuum pump oil. c) Pull vacuum to 500 microns.
Section 9 Evaporator Fan Motor Replacement Procedures Section 9 Replacement Procedures 1 Section Refrigerators and Freezers If Mounting Bracket Is Not Broken 3. Using a ¼” nut driver, remove the (2) motor mounting screws and separate the motor from the bracket (Figure 9.3). 1. Remove air distribution duct from the cabinet interior ceiling (Figure 9.1). Figure 9.3 4. Reverse steps 1-3 to replace motor. 5. Reconnect power and return to normal use. Figure 9.1 2.
Replacement Procedures Section 9 Evaporator Fan Motor 1 Section Refrigerators and Freezers 3. Using a ¼” nut driver, remove the (2) motor mounting screws and separate the motor from the bracket (Figure 9.7). If Mounting Bracket Is Broken 1. Remove the air distribution duct from the interior ceiling (Figure 9.5). Figure 9.7 Figure 9.5 4. Remove the evaporator-housing lid, located on the cabinet top. (Figure 9.8) 2. Disconnect the (2) terminal connectors from the motor (Figure 9.6). Figure 9.
Section 9 Replacement Procedures Figure 9.9 Figure 9.11 6. When the coil has been moved, remove the evaporator drain pan by removing (4) mounting screws. 7. Remove the bracket mounting screws and replace bracket-motor assembly. 8. Reverse Steps 1-5 to complete motor installation. 3. Remove the (3) hinge mounting screws and carefully pull the hinge flange from the cabinet front. 4. Slide the light switch and switch retainer from the hinge. Unplug the switch (Figure 9.12). 9.
Replacement Procedures Section 9 Evaporator Fan Motor 2 & 3 Section Refrigerators and Freezers 1. Remove the evaporator-housing lid, located on the cabinet top, exposing the evaporator fan motor (Figure 9.13). 3. Remove the fan bracket mounting screws. Disconnect the wiring terminals from the motor. Remove the defective motor and replace with the new motor. Replace screws (Figure 9.15). Figure 9.13 Figure 9.15 2. Remove the wiring box cover. Locate and disconnect the fan motor wires (Figure 9.14). 4.
Section 9 Replacement Procedures Temperature Control Refrigerators & Freezers 1. Remove the front louvered hatch cover by lifting straight up and pulling straight out. 2. Lay the hatch cover on top of the freezer evaporator housing. IMPORTANT Do not disconnect the wires to the digital thermometer display. 3. Remove the (6) screws from the thermostat/wiring box front (Figure 9.16). Figure 9.17 6. Remove the temperature control sensor from the aluminum sleeve by pulling out slowly (Figure 9.18).
Replacement Procedures Section 9 Evaporator Drain Pan Heater Element WARNING Disconnect the electric power to the freezer before proceeding with the following steps. 3. Remove coil mounting screws and lift coil up slowly, not to detach lines or wiring (Figure 9.20). 1. Remove front louvered hatch cover by lifting up and pulling straight out. 2. Remove the evaporator box cover lid (Figure 9.19). Figure 9.20 4. Disconnect the heater wires located in the wiring box (Figure 9.
Section 9 Replacement Procedures Heater Element Heated Holding Cabinets 1. Turn off the main power to the cabinet. 2. Remove the right side blower panel by removing the (13) screws. NOTE: Blower motor wiring may be disconnected to allow easier blower panel removal. Figure 9.22 3. Disconnect the wiring leads to the element by loosening the nuts with a small wrench. 4. Replace the heater element. 5. Replace drain pan heater and reconnect wiring. 6.
Replacement Procedures Digital Thermometer Display and Probe 1. Remove the front louvered hatch cover by lifting straight up and pulling straight out. Section 9 4. Disconnect the (2) yellow wires from the probe harness. Remove the probe from the interior ceiling by loosening the mounting bracket screw (Figure 9.24) 2. Unplug the thermometer probe from the back of the digital display module. 3.
Section 9 Replacement Procedures 9. Carefully align the module with the rectangle cutout in the hatch cover. Press the module firmly into place. (Figure 9.25) 11. Reconnect the (2) yellow wires from the transformer with the gray leads on the probe. 12. Reinstall the hatch cover and secure any excess wire with a wire tie. 13. Check operation and return to normal service. Figure 9.25 10.
Replacement Procedures Section 9 Digital Thermometer Transformer WARNING Disconnect the electric power to the freezer before proceeding with the following steps. 1. Remove the front louvered hatch cover by lifting straight up and pulling straight out. 3. Disconnect the black and white wires on the transformer from the power and neutral wires in the wiring box. (Figure 9.28). 4. Disconnect the yellow wires on the transformer from the (2) gray wires on the transformer probe (Figure 9.28) 2.
Section 9 Replacement Procedures Door Handle (solid doors) 1. Remove the foot from the door lock assembly (Figure 9.29). Figure 9.31 Figure 9.29 3. Remove out the two mounting screws and remove the door handle (Figure 9.32). 2. Pry off gray plug button (located in the rear center of the door) and a small section of the door gasket nearest the lock assembly (Figures 9.30 and 9.31). Figure 9.32 Figure 9.30 4. Reverse steps 1-3 to install the new door handle.
Replacement Procedures Section 9 Door Handle (glass doors) Door Hinge (solid doors) 1. Pry or lift off a small section of door gasket behind the door handle, exposing the (2) handle mounting screws (Figure 9.33). 1. Remove the door by lifting straight up (Figure 9.34). Carefully set the door aside. Figure 9.33 2. Remove the two mounting screws to release the handle. 3. Replace door handle. 4. You may need a rubber mallet to re-install gasket. Figure 9.34 2.
Section 9 Replacement Procedures 3. Remove the (3) three hinge mounting screws from each hinge on the cabinet front (Figure 9.36). Replace the hinge and reattach with the screws. Door Gasket (solid doors) 1. Remove the old gasket by pulling the gasket from the foamed in retainer in the door. (See figure 9.38) Figure 9.36 Figure 9.38 4. Remove the (3) three hinged mounting screws from each flange on the door (Figure 9.37) and replace hinge. 2.
Replacement Procedures Door Gasket (glass doors) 1. Remove the old gasket by pulling the gasket from the foamed in retainer in the door. (See figure 9.39) Figure 9.39 2. Starting the upper left corner of the door, place the locking male lip into the retainer of the door. 3. Firmly press into place until the gasket locks. 4. If necessary, gently tap into place with a rubber mallet.
Section 9 Replacement Procedures Vinyl Breaker Strips (door jambs) WARNING Disconnect the electric power to the freezer before proceeding with the following steps. 1. Remove the flat vinyl breakers by gently prying off with a flat-blade screwdriver. (Figure 9.40) 3. Replace the breakers by starting each end into the corner blocks and snapping into place. 4. Gently tap the breaker into place if necessary, using a rubber mallet. (Figure 9.
Replacement Procedures Section 9 Anti-Condensate Door Heater Wires Defrost Termination/Fan Delay Switch WARNING Disconnect the electric power to the freezer before proceeding with the following steps. WARNING Disconnect the electric power to the freezer before proceeding with the following steps. 1. Remove the vinyl door breakers as described previously. 1. Remove the evaporator-housing lid. (Figure 9.43). 2. Carefully, pull the heater wire connections from the inside top corner. 3.
Section 9 Replacement Procedures 3. Remove the wiring box cover on the front of the evaporator housing on 2 & 3 section cabinets (Figure 9.45). Wiring connections for 1 section cabinets are located inside evaporator housing (Figure 9.46) 4. Trace and disconnect the defrost termination / fan delay switch from the wiring bundle. Reconnect the new switch. 5. Attach the new switch to the suction line. 6. Replace the evaporator-housing lid. 7. Connect the power and resume normal operation.
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MANITOWOCâ â Koolaire We reserve the right to make product improvements at any time. Specifications and design are subject to change without notice. 81 West Holly St. Parsons TN. 38363 Phone: (887) 582-5086 Service Fax: (901) 847-5552 Web Site - www.manitowocice.
