How to install a cold room

What is a modular room?

Not everyone is familiar with the concept of modular cold rooms.

Basically, a modular cold room is a cooling chamber with walls, ceilings and floors of various sections or modules. All of these modules fit together and lock into place to provide a thermally insulated and structurally stable room.

It consists of 80mm thick modules of Keskinso cold rooms.

Because customers cannot always use standard cooling equipment, they are shipped with uncut panels in all modular rooms.

Installation of cooling units and / or cutting and / or drilling of pressure compensating valves must be performed by the installer.

Concept and benefits:

The basic concept of the Keskinso cold rooms lies in the size of the modules and the placement of interlocking cam mechanisms.

Our standard modular Cold Rooms can consist of ceiling and wall panels in the following widths: 40mm, 80mm, 100mm, 120mm. 150mm, 180cm, floor panels are available only in 80mm 100mm, and 120cm thicknesses.

Standard wall panels are 200 cm or 230 cm high.

All panels are locked with special cam locks that fit and lock together.

Modular rooms can be used as refrigerators as well as freezers. At temperatures below or below the freezing point, the door must be a heating cable and is referred to as a kapı negative door.. We also recommend installing a pressure compensation valve on one of the walls to equalize the internal and external pressure.

All Modular Cold Rooms have 80mm, 100mm, 120mm thick floors.

Installation Requirements

Before you start, make sure that there is enough space for room mounting, and make sure that the mounting area is level on the balance.

3.1 Power Requirements

Power requirements may vary for different room sizes and between cold and freezer as shown in the table below.

Size = Length x Width in meters

Note: Power requirements are based on the use of the standard sliding cooling system selected by Keskinso for the general use cold room. Replacing or replacing this unit could potentially change the power requirements.

3.2 Room Size

Note that all of the room sizes specified are external, not internal.

To calculate this, you must include the width and length dimensions as well as the height and tile ranges to determine the height.

Example: 2.6m long, 2.6m wide and 2.2m high will occupy a Cold Room…

Exterior Room Width: 2.6 m

Exterior Room Length: 2.6 m

Outside Room Height: 2.2 m

Total 2.6 meters wide 2.6 meters long 2.2 meters high (260cm wide x 260cm long x 220cm high)

Determine the minimum space required to apply to the Cold room size used in the example above, but it is always a good idea to have more space.

Since the real cold room is thermally more efficient when it is not in contact with other walls or structures, we recommend that you have the following clearance: 2.75 m x 2.75m x 2.45 m. (To ensure air flow, a clearance of 25 cm must be left in all cases above the room.)

Parts and Accessories

All basic modular Cold Rooms will have the following:

Track quantity Description

Floor Panels 1 or more Reinforced, complete with phenolic food-resistant resin coating on 1 side (walking surface)

Flooring Beams 3 or more Connect around the outer surfaces of the floor - used to attach the floor to walls.

NOTE: These are 85mm x 115mm and should not be confused with Ceiling joints of 85mm x 85mm.

Corner

4 At the 4 corners of the room, 2200mm or 2400mm

long.

Wall Panels 400mm, 800mm or 1200mm wide 3 or more 2000mm high standard white panel

Ceiling Beams 4 Connect around the walls and connect the ceiling panels to the walls. These are 80mm x 80mm and available in lengths to suit room size

Ceiling Panels 80mm standard white panels and 1200mm width and length to suit selected room size

Door 1

1 × 1.2m panel Size 1900mm x 800mm net clearance - Equipped with door frame heater used in freezer rooms.

The heater must be connected by a licensed electrical contractor.

In your room you will also receive a box of accessories including:

Kit Item Usage

End caps for spacers

Allen Wrench special tool for cam lock operation

Gasket covers White and gray - used to close cam lock holes. White covers for wall and ceiling panels, gray covers

floor,

Filler plugs Used to drill holes at the cam locking point - optional

For sealing silicone panel connections. Silicone should be used to seal all joints in freezer rooms.

Used in cold room applications at the discretion of the installer.

Sponge sealing tape ‘common tape’

Pressure Relief Port (Freezer room use only) This port must be installed in the location provided on one of the wall panels. The electrical connection of this port must be made by a licensed electrical contractor

Setup

5.0 Floor

Once you have the space for installation and make sure that all the components on the packing list have been reached and in good condition, you are ready to begin the actual installation process.

5.1 Floor Panels

Flooring Floor panels will always have a playmunt non-slip surface and a coated surface. For standard floors, a black phenolic resin coating is applied on the plywood.

Floor panels come in lengths of 80 cm, 120 cm, 160 cm, 200 cm and 240 cm.

The width will always be 80 cm or 120 cm.

The floor panels are 80mm thick.

5.2 Installing floor panels

Required material:

Flooring Panels

Allen key - found in Accessory Box (KITCMA)

Select the floor panel (s) and position it on the floor where the room will be built and in the correct direction.

If your cold room contains various Crom, stainless, etc. floor panels, start at a corner and move outward according to the layout provided. When placing the second panel next to the first, align and lock each other as shown in the diagram below.

To lock the floor panels, take the Allen key and insert it into the cam lock hole on the coated side of the floor and turn it clockwise by approximately 45 °. Tighten when you feel some resistance.

You then do not need to turn the key further 45º to 90º (max.). When you feel resistance, just stop and try to separate the two panels to test whether the cam lock is really connected to the panel next to it.

NOTE: Do not attempt to tighten the adjacent cam lock on the second panel.

For each pair of cam locks aligned, only one must be turned to the locked position.

To better understand the concept behind the cam locks, please see the image below.

Once you have installed and locked all the floor panels together, you will be ready to install the floor beams.

5.3 Floor Beams

Once all the floor panels have been placed, you can start laying the floor layout around them according to the layout provided.

The slab beams serve as connection points for walls and come in the following lengths: 40cm, 80cm, 120cm, 160cm, 200cm and 240cm.

The floor beams are 11.5 cm high and have the same width as the panel used.

5.4 Installing floor beams

Required material:

Floor beams

Allen key - Located in the Accessory Box (KITCMA).

When setting the first floor beam, keep in mind that it will stand 3 cm longer than the floor panel.

Start by aligning the first floor beam with the cam locks on one side of the floor panels.

After aligning the cam locks, lock the tiles in place by pinching the floor panels together in the same way.

6.0 Walls

Once you have made sure that the floor panels and floor beams are clamped and firm, you will be ready to snap the walls into place. The wall panels and corner posts are removed at the same time, but you must first separate them from the ceiling panels and ceiling beams.

In the following section you will find information on how to properly remove corner posts, wall panels and doors.

6.1 Columns

The corner posts are to provide a connection point for two vertical wall panels to be attached to each corner.

They can often be mixed with ceiling beams, but they can be easily identified if you note the following:

Unlike ceiling beams, the distance from each side of the corner post (beam) to the center of the first cam lock is 20 cm. However, the actual distance will vary greatly and cannot be defined in this text. It is also important to note that the actual distance will be different at each end of the corner post.

Corner poles with square cross section of 85mm x 85mm

Their length shall cover the entire outer height of the cold room (minus spacers).

6.2 Wall Panels

Wall panels and ceiling panels are exactly the same in every way. You should note the distribution and layout of the panels in the order given. Any panel longer than the inner height of the cold room can be automatically considered as a ceiling panel.

It is also important to note that, unlike floor panels with cam locks at every 40 cm (and 20 cm on each side), wall and ceiling panels have cam locks that start at 20 cm from each edge and then are placed at a distance of 80 cm.

For rooms with 220 cm long wall panels, the top cam lock will remain 40 cm from the top edge. This panel cannot be applied upside down!

The bottom of the panel must contain a cam lock 20 cm from the bottom edge to properly align it with the other panels.

6.3 Installing Wall Panels and Corner Poles

Required material:

Corner poles

Wall panels

Door

Allen key - Located in the Accessory Box.

Adjusting the walls and corner pillars requires a minimum of 2 people as well as the ceiling, so please prepare someone to assist you from this point on!

The next removed wall panel should be a vertical panel to be locked to the same corner post. Work out these panels until the walls are completed.

If necessary, move around the room by connecting the wall panels and upright connectors.

IMPORTANT: When installing a Sliding Cooling system in the room, be sure to place the panel to be installed on the Sliding System. This is determined by the one most suitable for installation.

Open the enclosure of the cooling system and install it in accordance with the instructions in Section… .. a according to the instructions supplied with the unit.

7.0 Installing the Door

The door (s) should be treated as if it were a wall panel and placed accordingly.

NOTE: When the doors are locked, the keys are delivered taped to the inside of the door leaf. Please remove the keys from the door before completing the walls!

If you have decided to complete all the walls and ceilings and save the door from the end, you cannot go inside. In this case, an additional key must be ordered, so please remove the keys from the door before inserting them.

Support single panel in upright position.

In this position it holds the door in the correct position and connect it to the other side of the vertical connector, thus forming a 90 ° corner cross-section.

When connecting the door, note that the door panel contains the floor connector that must be connected to the floor panel.

8.0 Ceiling

IMPORTANT NOTE: If you are installing a Slide in a Cooling Unit in the room, the roof must be installed before installation.

Ceiling beams and panels are the next things to install before final touches are applied. Once again, please use suitable safety goggles to prevent the PVC flakes from falling into your eyes when raising the ceiling beams in place.

8.1 Ceiling Beams.

The ceiling beams are intended to provide a port shared by the wall and ceiling panels. Since they have a square cross-section whose width is the same as the panel thickness, they can often be mixed with corner beams.

Ceiling beams come in the following lengths: 120cm, 160cm, 200cm and 240cm.

8.2 Installing ceiling beams.

Required material:

Ceiling Beams

Allen key - Located in the Accessory Box.

Adjusting the ceiling beam, placing them on the wall and tightening the cam locks from the wall panel is as easy as attaching the beam.

Place the ceiling mounts on the wall panels so that the mounts face into the room. Reinstall all ceiling mounts, noting that they will fit tightly and may require a small amount of force to secure them.

After aligning and securing the roof beam, try to lift it from the wall to ensure that all cam locks are properly secured. Work in your room until all ceiling beams are positioned according to the order provided with your cold room.

8.3 Ceiling Panels:

Ceiling panels are longer than wall panels for their intended use. Always be installed as shown by the diagram provided.

Its structural forces are designed to support a person and a toolbox. Of course, the weight of men and tool boxes can vary greatly. However, the actual maximum weight allowed depends on the panel thickness as well as the length.

For specific information, please contact your supplier directly.

Ceiling panels come in the following widths: 40cm, 80cm and 120cm.

8.4 Installing the ceiling panels:

Required material:

Ceiling panels

Allen key - Located in the Accessory Box.

1 person holds the first ceiling panel in a suitable place at the end of the cold room, thus allowing the cam locking holes to face into the cold room, while the other person is fastened to the ceiling beam by tightening the cam locks.

After replacing the roof panel, remove the remaining roof panels and snap them into place to ensure that all cam locks are locked in place.

All ceiling beams must be supported on at least two sides before the weight is applied. (The support offered by other panels is not enough.)

Therefore, the ceiling panels generally pass over the entire width of a cold room.

For example: If you order a 160 cm x 240 cm cold room, you will receive two 120 cm x 160 cm panels that will spread over the width of the Cold Rooms.

8.5 Silicone Room sealing

After the completion of the modular room installation, you should now close all areas that may be necessary, especially the sealing between the panel connections.

Freezer Rooms - Silicone should be used to insulate ALL joints.

Cold Rooms - Silicone sealing is at the discretion of the installer, apart from the floor that must be covered with any cavities.

Additional Room Components

9.0 Doorbells

Provides a Doorbell with Modular room kit if requested by a customer. These are usually a manually designed Doorbell with a key from the interior where the bell can be operated, which fits outside the cold room door.

Installing the Door Bells

Required material:

Door

Key Ring

Drill or hole saw

First, determine the position on the door where Bell is to be installed and mark where the hole is made for the “key“.

Drill the hole and install the bell assembly according to the installation requirements.

9.1 Cold Room Flooring (Internal Only)

Local area Health codes may require the installation of Internal Coving.

When requested by the customer, Bromic supplies a 6.5 m long aluminum coating. The number of lengths supplied with the room depends on the room size.

When arriving in a room, please contact Bromic if your destination and interior space are recommended.

Cold Room Hygienic Accessory

Required material:

coving

Corner Clips

Hack-saws

Silicon

How to install Coving.

Replace the 4 corner clips

Measure the inside edges of the room and cut the flooring to the desired length

Lock the floor in place using the corner clips

Silicone seal the sleeve along all edges so that no foreign matter can enter

9.2 Shelf

Shelves are an optional Modular Cold room accessory supplied by Keskinso and are available in a variety of sizes to suit a specific room size.

Supplied with a modular room and is in the form of a ready-to-install kit according to the instructions provided.

If you are required to enter the room and place a shelf on arrival, please contact Bromic.

Keskinso Monoblock Cooling Units Installation

10.0 Installing the cooling unit

Materials needed:

angle grinder or drill with jigsaw and 22 mm hole saw

lifting equipment

10mm x 10mm cable tray for electrical cables

Special notes:

Cut the cold room wall / ceiling panel before installation.

This is best done using angle grinder (jigsaw can also be used)

Before installing the roof, it should be able to mount the slides in the systems.

The explosion port must not be installed next to the evaporator because it will be drawn into the outside air and cause freezing (in the evaporator).

Before starting the monoblock cooling unit, the room panels must be cleaned to ensure that there are no marks on the panels and that all plastics are removed.

When installing, allow enough free space to open the door, use it in the right conditions and maintain easy maintenance in safe conditions.

Installation Overview:

Prepare cuts and holes in the cold room panel wall where the monoblock cooling unit will fit using a marker and a ruler to mark the cutting position.

Cut the marked holes from the panel using Angle Grinder (or Puzzle) and use a Drill, Drill the drain pipe.

Lift and secure the unit in place using at least two people (or lifting equipment).

Drops in units, silicone in and on the room around the unit, should be covered with silicone around cutouts in the slide panel in the units.

Check that all components, including the control panel, are wired

Switch on the test operating unit and move the room to the customer set temperature set point

Let the door heater work in freezer rooms

Finish installation with test light and defrost

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How to install a cold room

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