Perlick 4400 Series Power Paks Installation and Operation Instructions

Important Information

To register your product, visit the Perlick website at www.perlick.com. Navigate to Commercial, then Service, and find the link for the Warranty Registration Form. Completing and submitting this form is required; otherwise, the installation date will revert to the ship date.

Permanently mount the enclosed Warning/Safety Instruction label in a visible location near the CO2 regulator.

This manual is designed to assist with the installation of your Century Remote Beer System and to provide information on its operation and maintenance.

Perlick is dedicated to customer satisfaction. For service needs, contact your dealer for a list of qualified service agents. For your protection, do not return merchandise for credit without prior approval.

Thank you for choosing a Perlick product. We are committed to your continued satisfaction.

Table of Contents

• Sizes & Specifications: Pages 2-3
• Air-Cooled Models: Page 2
• Water-Cooled Models: Page 3
• General Information: Page 4
• Installation: Page 5
• Connecting Power Pak to Trunk Housing: Page 6
• Connecting to Trunk Housing: Page 7
• Power Pak Start-Up: Page 8
• LEDs: Page 9
• Preventative Maintenance: Page 9
• Replacement Parts: Page 10
• Wiring Diagrams: Page 11

Specifications - Air-Cooled Models

Specifications - Water-Cooled Models

General Information

Accessories

• Power Cord Kit: C2296A-20 (12/3 Cord, 20A, Nema Plug 5-20P) for Dedicated Circuit Models. Refer to electrical specifications.
• Power Pak Racks: Models 61790, 61790+1, 61790+2 (All Models).
• Power Pak Wall Mounting Brackets: Model 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: #57782 (Set of four, 5 3/4"-7 1/2" adjustable legs) (All Models).
• 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

Perlick Power Paks are integral components of the Perlick Century Beer System, designed to facilitate longer beer runs. A Power Pak circulates a 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 Paks feature a 1/3 HP ball bearing, maintenance-free motor coupled with a 100 gallon per hour, 150 psig positive displacement pump for optimal performance. These units utilize direct expansion refrigeration, enhancing efficiency and compactness. They also incorporate an electronic temperature control with a digital readout, which manages the unit's performance and provides visual feedback on operation, including early indications of potential issues through 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 on Air-Cooled Paks

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

Before installing a 4400 Series Power Pak, determine the method of connecting it to the electrical service. Ensure the electrical service can handle the load requirements. Perlick offers a Power Cord specifically designed for a Power Pak with an RLA of 16 amps or less and an MCA of 20 amps or less. Units with RLA greater than 16 amps or MCA greater than 20 amps should be hard-wired to the electrical service.

All Models Installation Steps

• Determine the ideal placement of the Power Pak. Locate the connection point to the trunk housing and position the Power Pak as close to it as possible.
• NOTE: If the Power Pak is placed on top of the walk-in cooler, ensure proper ventilation is provided to prevent system failure due to overheating. Inadequate ventilation will void the warranty.
• Place the Power Pak ensuring 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. Ensure accessibility room on the top of the cabinet for serviceability.
• Remove the top panels (2).
• Ensure Power Switches for the Condensing Unit and Pump(s) are in the OFF position.
• Make electrical connections according to the illustrations. NOTE: The electrical circuit should be dedicated solely to the Power Pak. Size the circuit according to the electrical requirements of each unit and in compliance with all National and Local Codes.
• Plumb the overflow port to a suitable reservoir/drain.

Water-Cooled Models Installation

In addition to the above installation instructions:

• Exercise care when locating the Power Pak to ensure it is never exposed to temperatures below freezing.
• If the Power Pak is installed more than 5 feet higher than the remote outlet drain point (e.g., floor drain), a vacuum breaker or open vent line should be installed to prevent the discharge line from creating a partial vacuum in the condenser water system.
• If a water-circulating pump is used, it should be placed on the water supply side of the condenser, pushing water through the condenser.
• A potable water supply is required, along with a drain or reclamation system. Connect the water supply to the fitting labeled as the water inlet. Connect the outlet to the fitting labeled as the water outlet. Both 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 the Power Pak to the Trunk Housing.

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

Connecting Trunk Housing Coolant Lines to Dispensing Head

• Position the trunk housing to allow for minimal cutting when connecting beverage lines.
• Split the trunk housing approximately 12 inches from the end to provide working room for connections.
• Cut and deburr copper coolant lines coming from the trunk housing and dispensing head. Stagger the lengths.
• Connect the trunk housing coolant lines to the dispensing head coolant lines using clamps, hose, and a 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.

Power Pak Start-Up

System Start-Up

• Use only Perlick Approved Coolant Solution, #63299-1. Other solutions or mixtures will void the Perlick warranty. The Coolant Solution is pre-mixed for optimum performance and wear 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 the 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 the coolant level in the reservoir to drop below the heat exchanger tube inlet, as this will allow air into the lines.
• Fill the Power Pak reservoir until both the return line fitting port and the overflow tube port are submerged under Coolant Solution. Monitor the return line fitting port, as additional Coolant Solution may need to be added.
• Thoroughly check all field connection points for leaks.
• Monitor the Power Pak Temperature read-out to ensure the Power Pak is working properly. The time it takes for the Power Pak to cut out on the temperature control depends on the length of the trunk housing run(s) and ambient conditions.

Digital Temperature Controller

The 4400 Series Power Pak is equipped with a factory-programmed Electronic Thermostat with a display. The thermostat has numerous factory settings that should not be adjusted or tampered with to ensure proper operation. It is programmed to cut-out at 30°F with a hysteresis/differential of 4°F.

Front Panel Commands – Normal Operation

• SET: Displays the target set point.
• DEFROST: Initiates a manual defrost. (This feature is available, but its actuation parameters are pre-programmed, meaning defrost may not be available.)

Front Panel Commands – Programming Mode

• SET: Selects a parameter or confirms an operation.
• UP ARROW: Browses parameter codes or increases the displayed value.
• DOWN ARROW: Browses parameter codes or decreases the displayed value.

LEDs & Preventative Maintenance

Meaning of LEDs

Display Message Meanings

NOTE 1: Refers to a faulty probe, loose connection, or broken wire. The Power Pak will continue to operate with a faulty probe. The controller is 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 Set point value.
• Press and immediately release the SET key again, 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 Set point value.
• The set point value will be displayed, and the SNOWFLAKE LED will start blinking.
• To change the Set value, press the UP or DOWN ARROW keys, depending on the desired new set point value.
• To memorize the new set point value, press the SET key again or wait 15 seconds.

WARNING: If a 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 displaying the probe temperature.

Replacement Parts

Replacement Parts

Common Components

Wiring Diagrams

The document includes wiring diagrams for two configurations:

• Wiring Diagram for 4404, 4410, 4414 115V Power Paks: This diagram illustrates the connections for 115V models, showing the flow from the power source (Neutral, Ground, Hot) to the condensing unit, pump motor, electronic temperature control, and receptacle. It includes notes on cord sets, hard-wiring, and optional accessories, along with a DANGER warning for electrical shock.
• Wiring Diagram for 4414-230, 4420, 208/240V Power Paks: This diagram covers the higher voltage models, detailing similar connections but adapted for 208/240V power. It also includes notes on cord sets, hard-wiring, optional accessories, and the electrical shock hazard warning.