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FEATURES OF KOOL STAR'S "UNIFOAM" COOLERS & FREEZERS:
- 4" Thick KOOL STAR "UNIFOAM" prefabricated modular panel construction.
- 34"x78" flush fiberglass reinforced plastic door jamb and door perimeter.
- Snap-in magnetic door gaskets.
- Kason #1256 cam lift hinges.
- Kason #1229C keyed door latch.
- Pre wired switch and pilot light and mounted vapor proof light fixture.
- Solar digital thermometer.
Wall closures and cove base included.
Heated air vent and 4 sided door heater cable. (freezer only)
Cooler and Freezer Specifications1. General:
KOOL STAR UNIFOAM walk-in coolers and freezers provided under this specification, related provisions and drawings shall be of prefabricated, modular design and construction. This
design shall allow for accurate and convenient field assembly which will facilitate future enlargement or relocation provisions. The walk-in coolers and freezers shall be provided complete by one manufacturer and
clearly labeled with code approvals and industry standard markings. The walk-in cooler and freezer manufacturer shall provide and submit: product data; scaled shop drawing
plans, elevations and details; rough-in drawings; cut sheets of buyout accessories; installation and maintenance manuals with copies of all warranties.
2. Modular Panel Fabrication: The prefabricated, insulated panels shall be of modular design with standard
sizing to be completely interchangeable in the field. Each panel shall consist of uniform and precise exterior and interior metal pans. All panel corners shall be a true ninety degree angle.
Vertical corner interior of corner panels and tee panels to be fabricated with a NSF radius. Panels are to be injected with "Foamed-in-Place" urethane insulation and have tongue and groove mating edges. The
tongue edge of each panel shall be provided with a NSF Listed gasket to provide an air tight joint. Panels shall be rigidly coupled by cam action locking device located a maximum of four feet on center apart from
each other. The cam locks shall be operated from the interior of the walk-in cooler or freezer by use of a hex wrench. Each hex wrench access port shall be covered with a snap-in button plug.
Maximum deflection of ceiling panels shall not exceed L/240 of span under a load of 15 pounds per square foot. 3. Insulation: Each prefabricated panel shall be "Foamed-in-Place" (injected) with U.L. Listed, Class 1 urethane foam insulation which
has a flame spread rating less than 25 and smoke density less than 450 when tested in accordance to ASTM E84 (UL 723). The thermal conductivity or "K" factor of the insulation shall be 0.12
BTU/hr./ft squared per degree Fahrenheit / inch of thickness. Overall panel thickness shall be 4". (5-1/2" thickness available) Foam insulation shall be dimensionally stable from -100 degrees
Fahrenheit to +200 degrees Fahrenheit. 4. Metal Finishes: Prefabricated panel exterior and interior metal finishes may be specified one or a combination of the following:
- 26 Ga. stucco embossed galvanized steel. (ASTM A527)
- 26 Ga. stucco embossed baked white enamel on galvanized steel. (ASTM A525)
- 24 Ga. smooth baked white enamel on galvanized steel. (USDA)
- .032 stucco embossed aluminum.
- .040 stucco embossed aluminum.
- 24 Ga. to 20 Ga. type 304, No. 4 finish stainless steel.
- 16 Ga. type 304, No. 2 finish stainless steel. (for floor only)
- .10 smooth aluminum with nonskid strips or aluminum tread plate. (for floor only)
5. Floor Construction:
(select one) Floorless: Finished floor and/or concrete slab is provided by the General Contractor or others. Wall panels are anchored to the concrete with
drive pins. This floor application is recommended for use only with walk-in cooler applications at temperature above freezing and no space or basement below the floor. Prefabricated floor:
Prefabricated floor panels shall be of similar construction to the other panels with a fully formed NSF interior radius and stamped corners. Floor panels shall be designed to withstand a uniformly
distributed weight load of 600 pounds per square foot. Wall panels shall be set in a continuous groove of floor panels and attached to the floor panels with cam locks.
Insulated concrete slab depression: FSEC shall provide a sub floor membrane of asphalt emulsion applied to a clean , smooth and level concrete sub floor depression and covered with foil coated Kraft
waterproof paper, Fortifier "Polyfoil Barrier" or equal (0.01 perm as determined by ASTM-E96-80) extending under wall panels. The joints shall be lapped by a minimum 6 inches. Two layers of two inch thick
rigid polyurethane board insulation (Trymer 1800 rigid foam insulation or equal) shall be installed before or after erection of wall panels depending upon specified technique. Joints shall be splined or
staggered. A vapor permeation separation of organic 15 pound felt protective slip sheet shall be applied over the insulation, flashed up the height of cove and joints overlapped a minimum of 6 inches.
Finished floor wearing surfaces shall be supplied and installed by others. 6. Doors and Hardware: The standard swing door clear opening size shall be 34" wide
by 78" high and hinged per the FSEC supplied drawings. Swing doors shall be flush, infitting style constructed of fiberglass reinforced plastic door perimeters and jamb. Doors shall
be finished to match the metal finish of wall panels unless otherwise specified. Each door shall be provided with a three sided snap-in magnetic gasket with an adjustable sweep gasket to seal the
bottom of the door. The door and door frame section shall be of the same core thickness and construction as specified for the other panels. Doors shall be mounted with a minimum of two Kason #1256 or
equal cam lift hinges, one Kason # 1229C or equal keyed door latch with interior safety release, one Kason model.#1094 or equal door closer, one 2" solar power digital thermometer and one pre
wired pilot light and switch to interior mounted 100 watt vapor proof light fixture with protective globe. Freezer door jamb shall be provided with one four sided heater cable with a stainless steel
threshold and one heated air vent to equalize pressure between the interior compartment and exterior spaces.
7. Available Optional Accessories:
- Hermetically sealed 15" x 20" triple paned view port windows. (heated for freezers)
- Interior and exterior kick plates in stainless steel or aluminum diamond plate finish.
- Flush mounted stainless steel cased temperature alarm with digital LED display and audio and visual alarms with 30 minute delay and silencer button.
- Built-in interior ramp for prefabricated floor.
- Exterior ramp for prefabricated floor.
- Entrance door strip curtains.
- Double acting traffic doors.
- Sliding & custom swing doors.
- 4" Surface mounted dial thermometer.
- Fire axe with stainless steel mounting bracket.
- Flush mounted 3-way switch and pilot light.
- Bumper rail.
- Stainless steel or aluminum diamond plate corner guards and wainscot.
- Luminair LVP1212-STSC-GASK-CLBS light fixture with night light feature or equal.
- Ceiling enclosures to match walk-in wall panel finish to 24" in height.
- Escutcheon plates.
- Fluorescent light fixtures with low temperature ballast for freezer applications.
- Locking bar.
- Outdoor roof cap or membrane.
- Suspended ceiling hangers / structural support for oversized walk-in compartments.
- 30" wide by 30", 40" or 60" solid reach-in doors.
- Glass reach-in doors provided with lights and shelving.
- Wire shelving, cantilever shelving and dunnage rack.
8. Standard Walk-in Panel Sizing: KOOL STAR
standard panel walk-in coolers and freezers are configured with standardized component panels. The standard corner size is 11-5/8" x 11-5/8". Standard wall panels are manufactured in 46-1/2", 23-1/4" and
11-5/8" widths. Tee panels for partition wall are 23-1/4". Standard wall panel heights are 94", 106" and 118". The following conversion chart may be used
to translate nominal sizing to KOOL STAR actual size. All dimensions are O.D.
|
Nominal Size |
Actual Size |
|
4' 0" |
3'- 10-1/2" |
|
6' 0" |
5'- 9-3/4" |
|
8' 0" |
7'-9" |
|
10' 0" |
9'- 8-1/4" |
|
12' 0" |
11' -7-1/2" |
|
14' 0" |
13' - 6-3/4" |
|
16' 0" |
15' - 6" |
|
18' 0" |
17' - 5-1/4" |
|
20' 0" |
19'- 4-1/2" |
|
22' 0" |
21' - 3--3/4" |
|
24' 0" |
23' - 3" |
|
26' 0" |
25' - 2-1/4" |
|
28' 0" |
27'- 1-1/2" |
Actual walk-in cooler and freezer heights for floorless applications are 8'-1-1/2";
9'-1-1/2"; and 10'-1-1/2" O.D. Actual walk-in cooler and freezer heights for prefabricated floor applications are 8"-6", 9'-6", 10'-6" O.D.
9. Quality Assured: Each KOOL STAR UNIFOAM prefabricated panel uses only the highest quality of
materials and U.L. Listed and recognized component parts.Each panel is subjected to a five point quality check system to delivery a product of the highest standards. 10. Installation Instructions:
A complete set of shop drawings , parts lists, packing slips and set of instructions covering the assembly of the walk-in panels and accessories shall be supplied.
11. Panel Warranty:
KOOL STAR warrants to the original purchaser that the foamed-in-place panels it manufactures shall be free from defects in materials and workmanship under the intended
normal use and service for a period of ten years from the date of the original installation, not exceeding
ten years and six months from the date of the original shipment. All metal
and painted surfaces shall be warranted for a period of eighteen months from the original date of shipment.
Hardware, and accessory components, excluding service items such as lights, ballast, starters and mechanical refrigeration systems which are covered by a separate
warranty, shall be warranted against defects in materials and workmanship under its intended normal use and service for a period of one year from the date of the original
installation, not exceeding fifteen months from the date of the original shipment. KOOL STAR shall repair or replace any panel or component, F.O.B. Gardena, California, found
by the manufacturer or manufacturer's agent to be defective within the warranty period. This warranty shall not apply to equipment which has been subject to abuse, alteration,
improper installation, accident, flood, fire, any other act of God, nor labor and service charges for replacement or repair of the defective part.
System Specifications1. Refrigeration System:
The refrigeration system shall be U.L. Listed and of standard manufacturer as supplied by KOOL STAR. The system shall be contained within a galvanized steel
housing for all weather protection with a control panel for all electrical components. 2. Condensing Unit: The system shall be equipped with a factory new hermetic or semi-hermetic
compressor motor as manufactured by Copeland or equal. Each unit shall be supplied with a crankcase heater, liquid line with filter drier and sight glass, suction line with filter,
receiver with fusible plug and shutoff valve, compressor start kit for single phase units, contactor for three phase units, time clock (for freezers only) and high/low pressure
control. Each condensing unit shall employ refrigerant R-22 and R-404A for medium and low temperature application respectively. All condensing unit selections are based on
capacities engineered to operate in 100 degree Fahrenheit ambient conditions. All condensing units are shipped with a holding charge of dry nitrogen. 3. Evaporator Coil:
The condensing unit is capacity matched to a NSF, U.L. Listed evaporator coil constructed of a rust-free aluminum housing consisting of staggered copper tubes
expanded into corrugated aluminum fins for increased heat transfer. Medium temperature applications employ "off-cycle" defrost using 115 volt fan motors. Low temperature
applications employ electric defrost method using 230 volt fan motors and heating element. Evaporators are supplied with mounted TX valve and solenoid valve. Thermostat is shipped loose.
4. Installation Instructions:
A complete set of manufacturer's instruction and maintenance manuals covering the installation and service of the condensing unit and evaporator coil shall be supplied. It is
recommended to use only a bonded, EPA certified and licensed refrigeration contractor for a safe and proper installation of the refrigeration system. 5. Warranty:
KOOL STAR warrants the mechanical refrigeration system to the original purchaser that the system is free from defects in the materials and workmanship for the normal use
and service as intended and specified by the manufacturer. Warranty shall extend for a period of one year from the date of the original installation by a factory authorized
agency, but not exceeding a period of one year and three months from the date of the original shipment and be limited to the repair and replacement of parts of the refrigeration
equipment F.O.B. the factory which has been determined as defective upon the inspection disclosure by KOOL STAR or by its authorized agent.
This warranty does NOT apply to loss of food or refrigerated contents due to equipment failure for any reason. This warranty does NOT apply to the refrigeration
equipment or any part which damage has been caused by accident in transit, alteration to by service, neglect, abuse, misuse or its original specified intended purpose, incorrect
voltage, altered or defaced serial numbers or by damage of flood, fire or any other act of God. Warranty does NOT cover refrigeration fluids, oils and other expendable items such
as filters and the like. This warranty is in lieu of any other warranties expressed or implied by KOOL STAR or its agent.
An optional four year extended compressor warranty is available covering the replacement of the compressor motor only to the original purchaser extending compressor
motor coverage for a period of five years from the date of original shipment. 6. Heat Load Calculations for Refrigeration Equipment Selection:
The following charts are heat load calculations for walk-in cooler and freezer requirements for product storage set according to the following list of engineering perimeters:
- Wall and infiltration gains are designed to ambient condition of 100 degrees Fahrenheit.
- Cooler and freezer construction is 4 inches thick Class I polyurethane insulation.
- Walk-in cooler and freezer compartment height is 8 feet.
7. Heat Load Selection Charts:
¨ Unknown specific product load calculated to a product holding temperature only. No product heat load pull-down temperature requirement is considered.
¨ Infiltration and heat load due to reach-in doors, glass reach-in doors or glass view windows of any type are not considered. ¨ Allowances for sun effect is not considered.
¨ Allowances for elevation not considered. ¨ Heat gains due to process equipment motor loads are not considered. ¨ Refrigeration system equipment running time is 18 hours per day.
* With the continuation of product engineering and improvements, KOOL STAR reserves
the right to change the specifications and details of its product without prior notice
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