Norlake Walk-In Operator’s Manual

Quality Refrigeration Since 1947

Walk-In

InstallatIon

Manual

for:

kold locker™

fast-trak®

fInelIne™

MInI rooMs

envIro-lIne

Printed in the USA.

Table of ConTenTs

Introduction 3 Product Safety Policy 4 Tools Required 5 General Information 6-10

Unpacking / Inspection 6 Foam Panel Storage 8 Construction Diagram 9 Section Latches 10

Walk-in Installation 11-33

Floor Installation 12 Site Selection, Base Preparation 14 Wall and Ceiling Panel Construction 22 Door / Door Section 25 Exterior Ramp 29 Interior Ramp 30 Membrane Roof 31 Electrical Connections 32 Wiring 32

Walk-in Maintenance 34-41

Door Parts 34 Electrical Connection 41

Final Checklist for Installation 42-43

InTroduCTIon

Your Nor-Lake Walk-In Cooler (Freezer) was quality engineered and produced under rigid factory controls.It features the very latest in manufacturing technology plus innovative design techniques that will provide the ultimate in user convenience.

Please maintain this service-reference material in a handy file for an immediate answer to any questions you may have concerning your Nor-Lake Walk-In. This manual was designed not only to provide guidance during the installation phase, but to serve its owner as a reference source for years to come. It contains information pertaining to the operation of its various components, electrical wiring details, maintenance procedures and adjustment techniques or replacement methods for certain parts.

Please take time to read all sections of this manual. You will be rewarded with a better understanding of your equipment and will gain product knowledge that will assist you in obtaining the performance that you should expect from your Nor-Lake Walk-In.

Sincerely,

NOR-LAKE, INCORPORATED

Kevin Fink President

ANY CORRESPONDENCE PERTAINING TO THIS EQUIPMENT MUST CONTAIN THE MODEL NUMBER OR JOB NUMBER AND THE SERIAL NUMBER AS THEY APPEAR ON THE DATA PLATE LOCATED ON THE INSIDE OF THE DOOR SECTION.

NOR-LAKE, INC.

727 Second Street Hudson, WI 54016 800-955-5253 Foodservice Sales 715-386-2323 800-388-5253 Parts/Service Fax: 715-386-6149 www.norlake.com

ProduCT safeTy PolICy

PRODUCT SAFETY POLICY OF NOR-LAKE, INC.

We strive to provide those who buy and/or use our product with equipment which is:

1. Developed by applying professional engineering principles in product research, development and user safety.

2. Designed to comply with or exceed industry performance and safety regulations.

3. Thoroughly reviewed and professionally tested for function, reliability and product safety.

4. Manufactured according to our professional purchasing, production and quality control standards designed to assure continued product reliability and safety.

5. Represented in our advertising and/or product literature in an informational and factual manner created to aid our customer in their product selection.

6. Accompanied by clear, complete installation, operation and maintenance instructions designed to assure many years of satisfactory product performance.

7. It is only through you, our satisfied customer, that we can continue our past successes in the design, development and manufacture of refrigeration equipment.

8. Nor-Lake, Incorporated reserves the right to improve upon our products without notice and without imposing on ourselves, any obligation to make such changes on products previously manufactured.

Warning: Walk-in oor must be kept free of any liquids, food particles or any items that could cause a slip hazard. Spilt liquids, food particles or any moisture on the walk-in oor can cause the oor to become slippery. Keep the oor surface clean and dry at all times.

• Inspect non-skid oor strips on ramps and oor surfaces and replace if worn.

• Inspect refrigeration system, door gaskets and hardware for proper operation to prevent moisture on walk-

in oor, ceiling or walls.

• Avoid leaving entry doors open for more than a ve minute period of time, which can cause a lm of ice to

form on oor, ceiling and wall surfaces due to the excessive condensation of warm moist air entering the

walk-in. Vinyl strip curtains can be used to reduce the amount of warm moist air entering the walk-in.

NOR-LAKE, INC.

727 Second Street Hudson, WI 54016 800-955-5253 Foodservice Sales 715-386-2323 800-388-5253 Parts/Service Fax: 715-386-6149 www.norlake.com

Tools requIred

TOOLS REQUIRED FOR UNCRATING AND INSTALLATION OF YOUR NOR-LAKE WALK-IN

• LEVEL

• CAULK GUN

• TAPE MEASURE

• SAFETY GLASSES

• HAMMER

• METAL SNIPS

• PRY BAR

• PHILLIPS SCREWDRIVER

• ALLEN WRENCH

• UTILITY KNIFE

• SQUARE

• DRILL DRIVER

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WALK-IN INSTALLATION GENERAL INFORMATION

This walk-in cooler or freezer was produced utilizing the latest in manufacturing technology, the highest quality materials available, along with innovations that make it a distinctive product in its field. Despite rigid controls in the production of the product, there is no substitute for thoroughly reading and UNDERSTANDING the instructions that follow. The result will be an orderly and efficient installation. Take the time to follow the steps explicitly! NOTE: The most important step is to start

with a level surface.

NOTE: Indoor walk-in(s) must be in an environmentally controlled space.

Relative humidity should be kept between 30% - 60%, maintaining a dew point of 50°F or less.

UNPACKING / INSPECTION

Check the Delivery Receipt for the number of pieces that made up the shipment and make sure that the number of pallets, boxes or crates agrees with that number. Each piece should be clearly marked with the same five-digit order number that appears on the Delivery Receipt as the shipper's number. Each individual walk-in is color coded.

Examine the general condition of the shipment and, as soon as unpacking is completed, carefully inspect all parts for possible shipping damage. If damaged parts are discovered, contact Nor-Lake immediately.

Delivery Receipt

Kold Locker™ Walk-in with Ceiling Mount

Capsule Pak™ Refrigeration System

Kold Locker™ Walk-in with Remote

Capsule Pak™ Refrigeration System

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Remove protective packaging and locate the hardware bag.

The hardware bag contains accessory parts for this walk-in together with a construction diagram, a layout of the screed assembly for floorless walk-ins, and a detailed packing list of all parts furnished for this individual walk-in. All parts should be compared to the packing list.

If discrepancies are found, contact Nor-Lake immediately.

Some walk-ins come with an additional orange hardware box.

Locate packing list and use as a reference during uncrating.

Packing List

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FOAM PANEL STORAGE

If foam walk-in panels require storage at the job site prior to installation, the following steps must be taken to protect the panels against both staining from moisture and sunlight, and denting by workers and traffic.

Whenever possible, the panels should be stored indoors, and should remain in the crating pallet they were originally shipped in. If the panels were uncrated as they were unloaded from the delivery truck, and they are being stored indoors, they should be stored vertically on skids with spacers between the panels.

When storing panels in a vertical position, always place the female rail (grooved) edge down (see illustration below.) This method of storing panels will provide proper ventilation, permit drain-off of condensation moisture and protect panels against the formation of white rust stains.

If the panels must be stored outdoors, follow the same procedure as indicated for indoor storage WITH THIS ADDITION: Cover the panels completely with an opaque polyethylene water-proof material to protect against rain, snow, heat and sunlight.

The illustration below shows the method for storage outdoors when panels are not left in palletized crates.

Note: Nor-Lake always recommends equipment to be installed once received but understands storage may be required. Nor-Lake does not guarantee issues related to storage, such as handling damage, storage damage, panel aging, etc. We would recommend the locks be oiled and the panels be wiped down with a white oil.

CONSTRUCTION DIAGRAM

The construction diagram, as furnished with each walkin, is a detailed plan that illustrates the placement of every wall, corner, ceiling and floor panel that comprises a complete, individual walk-in.

The construction diagram for all installations clearly shows the direction of the male and female formed profile of every wall panel and every corner panel.

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All sections used to construct your walk-in are marked with a specific part number on the section, corresponding with its location on the construction diagram.

If the walk-in is floorless, then a diagram showing the vinyl screed (floor sealer) arrangement is provided.

The vinyl screed combines the capability of retaining the wall panels in place while providing the inner and outer cove at the junction of the walls and the building floor (a requirement of Standard No. 7 of the National Sanitation Foundation (NSF).

IMPORTANT! Do not attempt to erect a floorless walk-in FREEZER on an existing building floor that has not been specially prepared and adequately insulated for below freezing storage temperatures!

Construction Diagram

Nor-Lake Inspection Label and

Panel Specific Part Number.

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SECTION LATCHES

All wall, corner, ceiling and floor panels are joined and locked together by the mechanical action of section latches which are integrally foamed into the panels near the perimeter edges. A section latch consists of two halves – a lock housing which contains a cam actuated locking arm, or hook, and a strike housing which contains the engagement pin. Both housing halves are securely anchored in the foam core of the panel. The lock housing is always located in the male-formed edge and the strike housing will be found in the female-formed edge of the panel.

TO OPERATE LATCHES

Hex wrench provided in hardware bag

1. Insert the hex wrench (packed in the hardware bag) through the access hole in the interior panel metal into the hex opening of the section latch. Turn wrench in a counterclockwise direction to ensure that the lock is fully unlatched

2. Push the sections tightly together and turn the wrench 1/4 turn in a clockwise direction. This will engage the locking arm (hook) over the pin in the strike housing.

Fully Extended Cam Lock

3. Continue turning the wrench to a full stop (approximately 3/4 of a complete turn from the unlatched position) to complete the locking operation.

Latches on some panels will have to be turned counterclockwise to activate the locking cam. These latches will be designated by a "TURN" sticker.

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SITE SELECTION, BASE PREPARATION AND LEVELING THE FLOOR WALK-IN COOLER OR FREEZER WITH A FLOOR

One of the most important considerations in the construction of a walk-in cooler or freezer is the building floor or the surface upon which the walk-in will rest. As with any structure, a firm and level foundation is essential to achieve a perfect end result. If the surface is not perfectly level and smooth, appropriate steps must be taken to provide the proper base. The positive action of self-closing doors, proper door gasket seal and condensate removal all depend directly upon the level and plumb installation of all panels.

If the walk-in is to be installed next to an existing building wall(s), make sure that a MINIMUM OF 2" REMAINS BETWEEN THE WALK-IN AND THE BUILDING WALL(S) to allow for irregularities of the building wall(s) and to permit a free flow of air between the two surfaces.

NOTE: Indoor walk-in(s) must be in an environmentally controlled space. Relative humidity should be kept between 30% - 60%, maintaining a dew point of 50°F or less.

In some cases, the surface upon which the walk-in is to be installed was especially prepared for installation and it is perfectly level and smooth. The walk-in floor, in this case, may be installed without further preparation. Before beginning, however, an appropriate vapor barrier should be placed over the surface that the walk-in will occupy. Asphalt felt paper (50#) or a 6 mil polyethylene film, are suggested materials. These are provided

by the installing contractor.

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FLOOR INSTALLATION (Shim Leveling Method) FOR WALK-INS SUBJECT TO LIGHT TO MODERATE LOADS

Locate the highest point within the perimeter lines. A transit or surveyor’s level or rotary laser level is an ideal instrument to use for locating this point. When the highest point is located, mark it directly on the floor and refer to the construction diagram to determine where the high point is located with respect to the walk-in floor plan.

One of the most important procedures that will be encountered in the construction of a walk-in with a floor is LEVELING THE FLOOR. It must be PERFECTLY LEVEL! If it is not, the wall panel will follow the irregularities of the walk-in floor which will directly affect subsequent procedures such as latching, panel gasket seal, ceiling panel assembly among others.

Using the construction diagram as a guide, select the floor panel that will be located directly over the highest point and place it in that position while observing the drawn outline on the building floor.

After the first floor panel is positioned, it must be properly leveled. To achieve this, shimming material of varying thicknesses must be used. Cedar building shingles are ideally suited for this procedure.

IMPORTANT! EVERY FLOOR PANEL MUST BE SUPPORTED ON ALL FOUR SIDES AND THE ENTIRE UNDERSIDE, AT LEAST EVERY 12" BY EITHER THE BUILDING FLOOR OR BY SHIMMING. HOWEVER, OTHER MATERIALS THAT ARE RESISTANT TO ROTTING OR COMPRESSION ARE ALSO ACCEPTABLE.

After the first floor panel has been leveled perfectly, trim away the excess shim material so that none projects from the panel at any of the four edges.

From the construction diagram, determine which floor panel will be installed next and where it will be situated on the floor plan. Prepare shimming material for the second panel at each point where shimming material was used beneath the first floor panel. The shimming material thickness must be such that it will support the second floor panel at exactly the same height as the first panel along the entire length of the joint. NOTE: In many cases, the shimming material will be the same thickness as the adjacent shimming under the first panel.

Place the second panel in position next to the first floor panel but

DO NOT LOCK!

Shim the second panel, where necessary, using the same procedure as was used on the first panel. When all four edges of the second floor panel are properly shimmed, lock the two panels securely together. Using the same technique for leveling, check the levelness of the two sections in all directions by placing the level across the joint at several points and, again, check the levelness of the floor panels in the direction of the panel joint.

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Refer to the construction diagram and install the remainder of the floor panels using the same procedure as was used for the first and second floor panels. When all of the floor panels are installed and leveled perfectly, check the section latches for full and complete locking.

Trim excess vapor barrier.

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SITE SELECTION, BASE PREPARATION WALK-IN COOLER WITHOUT A FLOOR INSTALLED ON 1” VINYL SCREED

IMPORTANT! Do not attempt to construct a floorless walk-in FREEZER on a existing building floor that has not been specially prepared and adequately insulated for below freezing storage temperatures. Note: All thermal breaks in floor slab must be exposed, including the partition wall.

To install a vinyl screed assembly on an existing floor, proceed as follows:

Locate the screed (floor sealer) diagram which was packed in the hardware box and, using it as a guide, draw an outline of the outside dimensions of the installed screed directly onto the building floor where the walk-in will be situated. These dimensions will be 1 1/2” larger than the overall dimensions of the walk-in in both directions.

If the walk-in is to be installed next to an existing building wall(s), make sure that a MINIMUM OF 2” REMAINS BETWEEN THE DRAWN OUTLINE AND THE BUILDING WALL (s) to allow for irregularities of the building wall (s) and to permit a free flow of air between the two surfaces. CAREFULLY CHECK FOR SQUARENESS by insisting that the two dimensions between opposite corners are equal (Figure 1).

One of the most important procedures that will be encountered in the base preparation is LEVELING THE SCREED. It must be PERFECTLY LEVEL! If it is not, the wall panels will follow the irregularities of the building floor which will directly affect subsequent procedures such as panel latching, panel gasket seal, ceiling panel assembly and others.

After the outline of the screed assembly is completed, locate the highest point within the outline on the floor where the screed will be installed. Screed sections are 5 1/2” wide. A transit or surveyor’s level is an ideal instrument for this purpose. Mark the highest point on the floor (Figure 2) and, referring to the screed diagram, identify and locate the appropriate screed section and position it directly over the highest point.

1’’ VINYL SEALER

EXISTING WALL

2” MINIMUM

EXACT DIMENSIONS OF SCREED ASSEMBLY (REFER TO SCREED DIAGRAM)

2” MINIMUM

NOTE: DIMENSIONS “X-X” MUST BE EQUAL!

4’’

5 1/2’’

Figure 1

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EXISTING WALL

2’’ MINIMUM

HIGHEST POINT (EXAMPLE ONLY)

Figure 2

2’’ MINIMUM

EXACT DIMENSIONS OF SCREED ASSEMBLY (REFER TO SCREED DIAGRAM)

Note: All

sealers lettered

alike are

interchangeable.

LEVEL

8’-1 1/2’’

OVERALL SCREED WIDTH THAT CONTACTS THE FLOOR IS 5 1/2’’

5 1/2’’

Sealers may also be

numbered by part

number

(Screed Diagram)

HIGHEST POINT (EXAMPLE ONLY)

39 1/2’’

Note: Corners are shipped in two pieces. Installer to silicone together during the installation

LEVEL THOSE SHOULDERS IN BOTH DIRECTIONS

SHIMMING MATERIAL

Figure 3

After the first screed section is positioned, it must be LEVELED PERFECTLY not only over its length but, across its width, as well. To achieve this, shimming material will most likely be required. Vinyl floor tile is ideally suited for this purpose. However, other materials that are resistant to rotting or compression are acceptable. IMPORTANT! EVERY SECTION OF SCREED MUST BE SUPPORTED AT LEAST EVERY 12’’ BY EITHER THE BUILDING FLOOR OR BY SHIMMING (Figure 3).

Assuming that the first screed section has been perfectly leveled, refer to the screed diagram and select an adjoining screed section and level it perfectly in both directions, shimming wherever necessary. Continue leveling the remainder of the screed sections until the entire assembly is in position. Check the assembly to make sure that the outer edges are located exactly on the drawn outline on the building floor.

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When the entire screed assembly is leveled and supported by shimming, as required, CAREFULLY AND WITHOUT DISTURBING THE SHIMMING MATERIAL, lift the screed sections, tip them upside-down and apply a heavy bead of construction sealant to the bottom of the screed section along both of the edges that contact the building floor surface. The diameter of the sealant bead should be larger than the thickest shimming material to ensure a complete, air-tight seal along the entire length of the screed (Figure 4). NSF approved sealant is provided and will be found in the hardware box.

Immediately after applying the construction sealant to a screed section, replace the screed section to its original location on the building floor WITHOUT DISTURBING THE SHIMMING MATERIAL and place a sealer splice every joint in the screed assembly (Figure 4). Since the sealer splice is intended to keep adjacent screed sections in alignment, approximately one-half of the sealer splice should lap each section. It need not be fastened in place (Figure 4). NOTE: Seal all screed joints with sealant. Make a final check for squareness, levelness and whether the screed assembly is located properly with respect to the drawn outline on the building floor.

Follow by securing the screed assembly to the building floor with fasteners that are appropriate for the building floor. These fasteners are not provided and must be obtained by others.

Fasteners should be applied down the center line of the inside of the screed at intervals of approximately 36’’; however, where shimming is used, apply the fasteners through the shimming material, NOT BETWEEN the shimming. When the entire assembly is secured in position, trim away all excess construction sealant and shimming on both edges of the screed. Trim flush with the sealant lip of the screed and touch up any areas where the construction sealant is not making a perfect seal (Figure 4).

NOTE: In the event that the building floor was specially prepared for the installation and no low or high points are detectable, it is possible that no shimming will be necessary. It will then only be necessary to apply construction sealant to the bottom of the screed and secure the screed directly to the building floor. The entire procedure, as described, must be followed explicitly, however, except for the details that pertain to the shimming.

TAPE z

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SHIMMING MATERIAL

SEALANT

Figure 5

ALTERNATE SHIMMING METHOD FOR 1’’ VINYL SCREED

If the surface that the vinyl screed will occupy is level, except for an occasional low point, the screed may be secured directly to the building floor and compensation for the low points may be achieved by shimming the support shoulders on the inside of the screed.

When employing this method, the low points should be marked on the building floor in the vicinity of the drawn outline for reference. After the screed has been sealed and secured, leveling may proceed with special attention being focused in the areas marked as being low points.

Vinyl floor tile is often chosen as shimming material and strips (5/8’’ wide maximum) are cut and placed on top the supporting shoulders of the screed to provide a level surface for the wall sections to rest upon. Strips of tape should be applied to hold the shimming material in place (Figure 5).

IMPORTANT! Shimming the support shoulders on the inside of the screed is ideally suited for minor irregularities on the building floor and has the advantage of complete screed-to-floor contact over the entire perimeter of the assembly. IT IS NOT RECOMMENDED, HOWEVER, FOR EXTREMELY IRREGULAR BUILDING FLOORS. Excessively thick shimming material on the support shoulders may elevate the wall panels to a point where the effectiveness of the uppermost screed sealing flanges would be compromised. Shimming thickness of more than 3/4’’ should be avoided! If shimming the support shoulders of the screed is selected, the entire procedure, as described, must be followed explicitly to ensure squareness and levelness over the entire screed assembly.

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SITE SELECTION, BASE PREPARATION WALK-IN COOLER OR FREEZER WITHOUT A FLOOR INSTALLED ON FOAMED SEALERS

IMPORTANT! Do not attempt to erect a floorless walk-in FREEZER on an existing building floor that has not been specially prepared and adequately insulated for below freezing storage temperatures. Note: All thermal breaks in floor slab must be exposed, including the partition wall. To install a foamed sealer (screed) assembly on

an existing floor, or on a properly prepared floor for freezers, proceed as follows:

Locate the floor sealer (screed) diagram that was packed in the hardware box and, using it as a guide, draw an outline dimensions of the installed sealer (screed) assembly directly onto the building floor precisely where the walk-in will be situated. These lines will be exactly the same dimensions as the dimensions of the walk-in in both directions. If the walk-in is to be installed next to an existing building wall(s), make sure that a MINIMUM OF 2” REMAINS BETWEEN THE DRAWN OUTLINE AND THE BUILDING WALL(S). This space will allow for irregularities in the building wall(s) and will permit a free flow air between the two surfaces. CAREFULLY CHECK FOR SQUARENESS by insisting that the dimensions between opposite corners are equal (Figure 1).

Since the foamed sealer (screed) is retained in position by a 3/8” thick plywood sealer guide, which will be secured to the building floor, it is imperative that the sealer guide be accurately located, as well, on the building floor. Refer to the sealer guide diagram which was also packed in the hardware box. On the diagram, you will notice that the sealer guide is located 78” INSIDE the drawn outline which represents the outside dimensions of the sealer (screed) assembly. Further, Fig. 1 illustrates that the sealer guide is 2 1/4” wide centered beneath a 4” wide sealer leaving a border of 7/8” along each edge. Draw another outline of the outside dimensions of the sealer guide directly onto the floor. There should be exactly 7/8” between the new sealer guide outline and the previously drawn sealer (screed) outline (Figure 2, on next page).

2" MINIMUM

Figure 1

)LJXUH

2” MINIMUM

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2” MINIMUM

Figure 2

2” MINIMUM

Figure 3

One of the most important procedures that will be encountered in the base preparation is LEVELING THE SEALER (SCREED). It must be PERFECTLY LEVEL! If it is not, the wall panels will follow the irregularities of the building floor which will directly affect subsequent procedures such as panel latching, panel gasket seal, ceiling panel assembly and other.

After the outline of the sealer (screed) and the sealer guide is completed, as shown in Figure 2, locate the highest point within the outline on the floor where the screed (sealer) will be installed. (Sealer sections are 4” wide). A transit or surveryor’s level is an ideal instrument for this purpose. Mark the highest point on the floor as illustrated on Figure 3.

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SEALER GUIDE INSTALLATION

Locate the SEALER GUIDES. They are bundled together and packed along with the walk-in corner or wall panels and are labeled accordingly. Sealer guides are strips of 3/8” plywood 2 1/4” wide as shown in Figure 1.

Refer to the SEALER GUIDE DIAGRAM. Select the proper sealer guides and position them as shown by the circled letters on the diagram. Each length of sealer guide is marked with a circled letter that corresponds to the circled letters on the sealer guide diagram.

Each sealer guide, when positioned properly, will have its outer edge precisely over the INSIDE OUTLINE drawn on the building floor, Figure 2, and its outer edge will be exactly 7/8” from the outline which represents the foamed sealer outer edge. The quality of workmanship performed in locating and securing the sealer guides will be transmitted directly to the location of the foamed sealers (screeds) and, subsequently, to the overall construction of the complete walk-in. BE EXACT! Refer to Figure 1 and Figure 2.

When all sealer guides are in position, make a final CHECK FOR SQUARENESS and secure them to the building floor with fasteners that are appropriate for the surface. NOTE: This can either be a mechanical fastener or construction grade adhesive. If the sealer guide is positioned over a polystyrene or polyurethane thermal breaker, a compatible construction adhesive may be used.

FOAMED SEALER (Screed) INSTALLATION

Refer to the FOAMED SEALER DIAGRAM. Identify and locate the sealer section that will be positioned directly over the highest point which was determined earlier and marked on the building floor (Figure 3).

NOTE: All foamed sealers are male-formed on one end and female formed on the opposite end. The configuration of the ends is clearly indicated on the diagram. Also, make certain that the strike housing portion of the section latches is visible on the upper edge of the sealer when it is in position (see Figure 1 and Figure 2).

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Figure 5

After the first sealer (screed) section is positioned over the sealer guide and over the highest point, it must be LEVELED PERFECTLY not only over its length but, across its width, as well. to achieve this, shimming material will probably be required. Vinyl floor tile cut in strips 7/8” wide by 6” long make ideal shimming strips that can be placed beneath the sealer, wherever necessary, to achieve levelness.

IMPORTANT: EVERY SECTION OF SEALER (SCREED) MUST BE SUPPORTED AT LEAST EVERY 24” BY EITHER THE BUILDING FLOOR OR BY SHIMMING. Avoid using shimming strips less that 6” long whenever possible (see Figure 4).

Assuming that the first sealer (screed) section has been perfectly leveled, refer to the sealer diagram and select an adjoining sealer section and level it perfectly in both directions, shimming wherever necessary. NOTE: Sealer (screed) sections 8” high or more employ section latches for end-to-end locking. CAREFULLY flush the upper edges and the inner or outer surfaces of adjoining sealer sections while locking them together (Figure 5). Continue leveling the remainder of the sealer sections until the entire assembly is in position.

When the entire sealer assembly is leveled, apply NSF approved sealant to achieve a vapor seal between the bottom edge of the sealer and the building floor. This sealant is provided and is packed in the hardware box. The sealant must be applied to the inner and outer surfaces of the sealer (screed) assembly. Make certain that the sealant produces a complete, air-tight seal, without gaps, and that special care is taken to seal the shimming material appropriately.

After the sealant has had an opportunity to set up, trim away all excess material flush with the edges of the sealer (screed) assembly and touch up any areas where the sealant is not making a perfect seal (Figure 5.).

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WALK-IN INSTALLATION WALL AND CEILING PANEL CONSTRUCTION

The installation instructions that follow apply to any walk-in cooler or freezer where the wall panels are supported either by foamed walk-in floor panels or by a floor sealer (screed) assembly which has been accurately located and properly leveled. NOTE: The procedure for constructing wall and ceiling panels will be identical in all cases. NOTE: The walls do not lock to vinyl sealers, but will lock to foam sealers when used.

To aid in the construction process, the floor plan furnished with your walk-in has part numbers listed for each wall, corner, ceiling and floor section. Match the part number on the floor plan to the label on the interior of each panel to determine the current placement for each panel.

Notice, also, that the section latch access holes on the vertical edge of the panel are always on the interior of the panel.

Select the first panel to be installed, typically beginning with a CORNER PANEL. Notice that the panel is labeled "Top" along with a part number indicating that when the panel is in its proper position, the labeled end will be up.

Position the corner panel in the proper location on the walk-in floor or vinyl screed assembly and, IF THE WALK-IN HAS A FLOOR, flush the corner panel with the corner of the floor panel in both directions and lock it securely to the floor panel.

If the first corner panel is supported by a 1" vinyl sealer (screed), seek assistance to support the corner panel in a vertical position until succeeding wall panels are installed. Wall and corner panels do not lock to the vinyl sealer (screed).

Select the next panel as indicated on the floor plan and position it on the floor or sealer (screed) close enough to the first panel installed so that section latch engagement is possible.

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Making sure that the two panels are perfectly aligned at the TOP EDGE and that the VERTICAL JOINT of the two panels are perfectly flush, turn the section latches on the vertical edge of the panel until they are completely engaged.

IMPORTANT! Insist that the top edges of the adjoining panels are aligned perfectly.

If misalignment is encountered, merely lift the lowest panel edge while locking to achieve alignment and, when all latches are engaged, permit the locked panels to resume their normal position on the walk-in floor or sealer (screed).

DO NOT SHORT-CUT! TAKE ENOUGH TIME TO PROPERLY ALIGN ALL SECTIONS.

Correct

Misalignment

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As each wall panel or corner panel is constructed and locked in an adjoining panel along the vertical joint, engage the section latches to the floor panels by turning the hex locking wrench ONLY ABOUT 1/4 TURN CLOCKWISE.

Make certain that the wall or corner panel is perfectly aligned with the floor panel or foamed sealer before engaging the section latches.

Continue constructing panels according to the part numbers shown on the floor plan, and follow, explicitly, the technique described for panel alignment.

CEILING PANELS will be constructed at specific intervals to facilitate the installation. The intermittent ceiling panel construction is scheduled to allow the ceiling panels to serve as supporting ties between opposite walls as the installation progresses. CAUTION! DO NOT SLIDE CEILING PANELS INTO POSITION! To avoid gasket damage, elevate the ceiling section clear of the wall section while bringing it into position.

When adjoining ceiling panels are in position, adjust the exterior edges so that they are perfectly flush with one another and with the wall panels directly below them. Lock the ceiling panels securely to each other. DO NO LOCK ceiling panels to wall panels at this time.

NOTE: If local conditions, such as existing building walls, make it difficult to align ceiling panels with each other from the exterior, locate a step ladder near the interior walls to visually inspect the alignment and adjust as necessary.

DOOR/DOOR SECTION

A standard door/door section consists basically of a single wall panel that contains an entrance door and several accessories. The electrical components contained in this panel were prewired at the factory. They include the anti-condensate door opening heater, the pilot light, and switch and a vapor proof interior light.

The door was factory installed on the door panel framing fixture, checked for squareness and for proper operation under controlled conditions.

CAUTION! While installing the door/door section, extreme care must be taken to avoid twisting the panel or handling the assembly in such a manner that it is not square when it is installed. The self-closing feature, door closure operation and a perfect gasket seal all depend a great deal upon a SQUARE and PLUMB door/door section.

Walk-In InsTallaTIon

After all the wall and door panels have been constructed and locked securely together and all the ceiling panels have been positioned above the wall panels, the ceiling panels have been locked securely to each other, re-check the position of the ceiling panels with respect to the wall panels.

Now lock all ceiling panels securely to the wall panels.

Recheck the position of the wall panels with respect to the floor panels and lock them securely together.

NOTE: When a 1" vinyl floor sealer (screed) is used, no attachment to the wall panels is required.

Completed

Walk-in with floor

Completed Walk-in floorless- shown

with vinyl floor sealer

Walk-In InsTallaTIon

NOTE: If, for some reason, conditions on the site prohibit the installation of the walls and ceilings in the recommended order, install the wall and ceiling panels in a logical sequence that will permit accessibility for installation of the last panel. Remember to schedule ceiling panel installation at the proper intervals to serve as supporting ties between installed wall panels.

Locate the plug buttons which were packed in the hardware bag and, after checking to make sure that the hex wrench comes to a full stop on each section latch, insert a plug button into every latch access hole.

SLAM BRACES

The door/door section frame on most floorless walk-ins will be fitted with slam braces, one on each of the interior, vertical frame members. These braces will require attachment to the building floor.

Their purpose is to positively locate the lower extremities of the door frames and prevent any movement that might occur at the point where the door frame rests on the floor sealer (screed). When 1" vinyl floor sealers are furnished, they will be notched to accommodate the slam brace location.

The slotted holes in the vertical leg of the slam brace permit adjustment in either direction to allow the slam brace to contact the building floor properly. Fasteners suitable for securing the slam braces to a concrete building floor are packed in a bag and attached to one of the slam braces. For other types of building floors, the appropriate fastener must be provided by others.

IMPORTANT! Make sure that the door/door section is PERFECTLY PLUMB before attaching the braces to the building floor. The holes in the slam brace for attachment to the building floor are intentionally round so that no shifting can occur after they are secured. Make sure the slam braces have been secured to the building floor.

The recommended hole size for PARABOLT ANCHOR is 3/8” X 2-1/4”

Install anchor Attach slam brace with fastener

provided

IMPORTANT!

MAKE SURE THAT THE DOOR/DOOR SECTION IS PERFECTLY PLUMB BEFORE ATTA CHING THE SLAM BRACES TO THE FLOOR.

ALK-ININSTALLATION

-D

OOR

OORSECTION

APPLY SEALANT UNDER THRESHOLD

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THRESHOLD ATTACHMENT

The threshold was attached at the factory to the lower portion of the door section and it is positioned in such a manner that no adjustment is required. It must, however, be attached to the building floor to complete the installation.

Figure 11

Note: Add sealant between threshold and floor to seal.

Apply Sealant Under Threshold

Figure 12

IMPORTANT! Make sure that the slam braces are securely fastened to the door section and to the building floor before attaching the threshold to the building floor. Both edges of the threshold should be attached with fasteners that are appropriate for the building floor and, since the floor surfaces vary so greatly in composition, no fasteners are provided and should be obtained by others (Figure 12).

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