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HIGH DENSITY RAILWalk-In Coolers & Freezers

THE KOOL STAR SYSTEMYOUR HIGH DENSITY SOLUTIONWhen your specifications call fora high density rail walk-in,Master-Bilt's Kool Star is the answer.Featuring polyurethane insulation,Kool Star panels have a perimeterof high density polyurethane foradded protection around the edges.Kool Star offers maximum versatilityand convenience for a varietyof applications including:• Convenience stores and otherretail settings• Restaurants• Hotels• Institutional kitchens• Schools and universitiesCOMPLETEAll Kool Star walk-in panels aresold with either a matching remoteor packaged refrigeration systemfor a complete answer to your coldstorage or retail needs. Refrigerationmay also be provided throughdual or multi-compressor modularremote systems.FLEXIBLEKool Star coolers, freezers andcooler/freezer combinations aren'tbased on standard sizes and can bebuilt to any dimension to the nearest1 /2". The only restriction on sizeis an overall height of not more than10 feet. L-shapes and glass doorfronts are also available.AGENCY LISTINGS ANDCLASSIFICATIONS INCLUDE:(on doors)• State of Oregon• UL Classified foam core materialAdditionally:• Meets requirements of FederalEnergy Independence andSecurity Act of 2007• Meets California Energy CodestandardsKool Star L-shaped walk-ins and glass door fronts(above) as well as cooler/freezer combinations(right) are available.2

PANELSPANEL BASICSKool Star panels are foamed-in-placewith polyurethane for the greatestcooling efficiency. Panel perimetersare formed of the same polyurethanebut in a higher density.Standard panels are four-inchesthick with an optional 5 1 /2 thicknessavailable. All wall, ceiling and floorpanels feature tongue and grooveconstruction with the tongue ofone panel fitting solidly inside thegroove of another creating the mostdependable seal. The tongue edge ofeach panel is provided with an NSFlisted gasket to help provide an airtightjoint.The standard wall and roof panelfinish is 26 gauge acrylic-coatedstucco galvanized with numerousoptions in interior and exteriorfinishes to match your designscheme or durability requirements.The standard floor finish, whenrequired, is .080 textured aluminum.Floor panels are designed towithstand a uniformly distributedweight load of 600 pounds persquare foot with a fully formed NSFinterior radius and stamped corners.Multi-compartment walk-insare available as fully floored, fullyfloorless, or with floor/less floor.L-shaped glass front walk-ins arealso available. Floor angles will beprovided to attach the wall panelsto a concrete slab for floorless applications.CAM-LOCK SYSTEMThe Kool Star cam-locking system,together with tongue and grooveconstruction and sealing gaskets,Featuring tongue and groove construction, Kool Star panels are foamed-in-placewith polyurethane. Panel perimeters are formed of the same polyurethane but inhigher density. (Right) Panels are assembled by means of cam-locks requiring onlya factory-supplied hex wrench to operate.provides an accurate, tight fit betweenpanels. The lock requires onlya factory-supplied hex wrench tooperate. When the wrench is turned,the lock is engaged and a gradual sealand panel alignment occurs. Plugbuttons are provided to cover eachcam-lock access hole.Should the walk-in need relocation,the cam-lock process is easy toreverse. Panels can be taken apart aseasily as they are put together.FOAMED-IN-PLACE INSULATIONThe polyurethane foamed-in-placeconstruction method used in KoolStar panels provides many advantagesover other panel types:• Increased energy efficiency due topolyurethane's greater temperatureretainingproperties, or R-value• Polyurethane foam permanentlyadheres to metal panels addingstrength and reliability• Superior moisture resistance dueto polyurethane's 97% closed cellcontent• Maximum walk-in storage spacebecause polyurethane foam allowsfor thinner walls• An environmentally-friendly245fa blowing agent with a zeroozone depletion potentialDuring the foaming process, thehigh-pressure foam is injected intothe panel interior and expansioncuredfor consistent density and nouninsulated areas within the panel.As further assurance againstfoam voids, Kool Star panels areconstructed on horizontal pressesso panels lie flat during the foamingprocess and the injected foamexpands evenly.3

DOORSCONSTRUCTIONThe standard Kool Star door size is34" x 78" with 30" x 78" and 36" x 78"options available. Swing entry doorsare a flush-mounted, infitting styleconstructed of a vinyl frame with 10gauge steel back-up, door perimetersand jamb. The door finish matchesthat of wall panels. The door and doorframe section are the same core thicknessand construction as specifiedfor other panels. Glass doors, withoptional LED lighting, are availablefor both low temp and medium tempapplications.STANDARD FEATURESKool Star doors are designed to meetcurrent federal energy standards byincluding:• Two heavy-duty cam lift hingeswith nylon bearings and a holdopenfeature• A door closer for positive closing• Standard compact fluorescent lightfixture (with bulb) connected tostandard single pole switch withinterior pilot lightOther standard features include:• A key-locking pull handle withpadlocking capabilities and noexposed fasteners• Heavy gauge steel back-ups at thedoor and frame connecting points• Dial thermometer• Four-sided frame heater and pressurerelief port (freezer only)• Easily replaceable magnetic gasketalong the top and sides and a wiperstrip along the bottom• 16 ga. stainless steel thresholds onall freezers and floor type coolers4

REFRIGERATION SYSTEMSSYSTEM CHOICESKool Star walk-ins are paired with aremote condensing unit and matchingevaporator coil, a packaged systemor a multi-compressor system.Condensing units and evaporatorcoils are equipped with energy-savingfan motors (PSC for condensingunits, ECM for evaporator coils).M-SERIES REMOTECONDENSING UNITSM-series remote condensing unitsoffer a wide variety of componentoptions including a pre-chargedsystem with quick-connect liquid andsuction line sets up to 40 ft. M-seriesunits vary from 1 /2 to 6 H.P. with awide selection of temperature ranges.M-Series units can be configuredwith hermetic, semi-hermetic orscroll compressors. Generouslysizedcondensers and receivers assurequick temperature recovery inhigh ambient conditions and amplepump-down capacity for longerrefrigeration line runs.Other options include:• Coated condenser coil• Pump down switch• Circuit breaker• Heated and insulated receiver• Adjustable low pressure control• Suction line accumulator• Oil separator• Suction line filter• Phase monitor• Fan cycle control• Henry relief valve• Dual pressure control• Medium temp timer (mounted orloose)E-SERIES & L-SERIESEVAPORATOR COILSRemote condensing units arecombined with matching E-Seriesor L-Series evaporator coils. Coilsare ready to mount in position andare available in either air or electricdefrost. Each is furnished with aproperly sized expansion valve androom thermostat. Electric defrostmodels feature defrost terminationfandelay controls and drain lineheaters.PRS-2 SERIES PACKAGED UNITSThe PRS-2 series combines acondensing unit and evaporatorcoil into one unit with everythingready to mount on your walk-in.Designed to maximize space, theevaporator section mounts flush ina standard 4" thick ceiling panel.Standard features include:• Power cords for most indoormodels• Condensate evaporator pan onindoor models• Crankcase heater, drainlineheater, head master and weatherhood on outdoor modelsMRS OR DRS SERIESMULTI-COMPRESSORREMOTE SYSTEMSKool Star refrigeration may also beprovided through an MRS seriesmodular multi-compressor remotesystem or DRS dual compressorsystem. These systems allow the remotingof refrigeration from walkinsand other equipment to a singleunit. Benefits include reductions ininside heat, air conditioning loadand noise levels.Kool Star refrigeration choices include an M-Series remote condensing unit(top left) paired with an E- or L-Series evaporator coil (top right) or a packagedrefrigeration system in either indoor or outdoor (bottom left) version. Multi- anddual-compressor systems, like the DRS series (bottom right) are also available.5

OPTIONS & ACCESSORIESKool Star options include (clockwise)door kickplates, temperature alarms,membrane roof caps for outdoorapplications, external ramps andinternal ramps.WALK-IN ENHANCEMENTAdd to the efficiency and conveniencein your Kool Star walk-inwith our many options and accessories.Choices include:• 5 1 /2" thick panels for added energyefficiency• 36" wide entry door• Swinging glass doors• LED lighting for glass doors• Flush mounted temperaturealarm with digital LED displayand audio and visual alarms• Energy-saving entrance door stripcurtains with 2 /3 overlap• Third door hinge• Membrane roof cap for outdoorapplications• Interior and exterior kick plates,36" high, in .100 aluminum diamondplate finish• Drop-in interior ramp for prefabricatedfloor• Exterior ramp for prefabricatedfloor• 4' fluorescent light fixtures withlow temp ballast for freezer applications(including energy efficientT-8 fixtures and bulbs)• Vapor-proof light fixture• Trim strips• Enclosure panels• Metal cove base molding6

FINISH OPTIONSAcrylic-coated stucco galvanizedis the standard finish for Kool Starpanels. It provides the most durablesurface for prolonging the life, performanceand appearance of yourwalk-in. The standard floor finish,when required, is .080 texturedaluminum. However, we also offernumerous other finishes to choosefrom. With our assortment you caneasily fulfill your budget and durabilityneeds.Wall and roof finish options:• 26 ga. stucco galvalume• .040 smooth aluminum• .040 stucco aluminum• .040 white aluminum• .040 white stucco aluminum• 26 ga. stucco galvanized steel• 26 ga. white stucco galvanized steel• 24 ga. galvanized steel• 20 ga. galvanized steel• 22 ga. stainless steel• 22 ga. stucco stainless steel• 20 ga. stainless steelFloor finish options:• .100 diamond aluminum• .125 diamond aluminum• .188 diamond aluminum• 16 ga. galvanized steel• 16 ga. stainless steelMASTER CONTROLLERREVERSE CYCLE DEFROST SYSTEMThe Master Controller Reverse Cycle Defrost (MCRCD)electronic control system brings a new level of efficiencyand reliability to your refrigeration system by replacingcertain mechanical parts with solid state electroniccomponents.Lab tests show a Master Controller Reverse CycleDefrost-equipped system can save up to 27% moreenergy over a conventional system de-pending on theapplication.Installation time and labor costs are significantlyreduced because all electrical components are factorypre-wired.The MCRCD control board, mounted to an evaporatorcoil, is part of a refrigeration system also containingan electric expansion valve, a single or multi-compressorcondensing unit and one or more evaporators.Integrated reverse cycle defrost is a patented innovation(U.S. patent no. 7,073,344) that uses a reverse cyclevalve to switch the direction of refrigerant flow duringdefrost and eliminate frost buildup while reducingdefrost energy usage by up to 80%.Standard demand defrost technology initiatesreverse cycle defrosts only as needed, allowing furtherenergy savings.The Master Controller Reverse Cycle Defrostinterface is mounted to an evaporator coil.Master-Bilt'sWeb2Walk-In programprovides completeaccess to the MCRCDsystem from anywhereon the globe. Theinternet-based applicationcan be accessedalmost anywhere bycomputer or Android based smartphone.7

908 Hwy 15 NorthNew Albany, MS 38652Sales: 888-478-8600Service: 855-815-4567www.master-bilt.com/koolstar-walk-insDue to continuous product enhancements, we reserve theright to change specifications without notice.7/13-web ©2013 Master-Bilt Products, an unincorporated division ofStandex International Corporation. All rights reserved. Printed in U.S.A.