ROMA INSULATION SYSTEMS

Integrated
hinged doors
Installation and operating instructions

Installation and operating instructions for the

DEZI/DEZIA integrated hinged door

Table of contents

General overview of the standard hinged door ................................................... 02

Required tools ...................................................................................................... 02
Work preparation .................................................................................................. 02
Factory configuration .......................................................................................... 02
Scope of supply .................................................................................................... 03
Installation instructions for the DEZI/DEZIA door system ................................. 04
Auxiliary threshold ............................................................................................... 06
Fine adjustment ................................................................................................... 07
Security ................................................................................................................. 09
Door frame heating .............................................................................................. 10
Care and cleaning ................................................................................................ 10
Maintenance ......................................................................................................... 10
Troubleshooting ................................................................................................... 10
 2

General overview of the standard hinged door

Cold-store and deep-freeze room door for Metal mount
temperatures ranging from +1° C to 50° C - Injection-molded safety lock with silver
or -30° C to 50° C ions for enhanced hygiene
- Outside and inside handles are resistant
A ready-to-install hinged door system for to corrosion with a profile cylinder lock
easy subsequent installation. Type: DEZI/ and internal integrated emergency
DEZIA, single-leaf opening
- Flap hinge for flush doors, rising, die-cast
Door leaf zinc, RAL 7043 EPS-coated
- Door leaf with 60, 100 or 140mm insulation
thickness Coatings
- Highly elastic circumferential EPDM seal, - SAE 304 stainless steel with sheet gauges
replaceable of 0.6 or 0.8mm, either smooth-sanded or
- Vertical sheet metal stop with clearance polished
width of 1050mm - Galvanized sheet with coil-coating pro-
- Inside and outside handle are thermally cess finish, layer thickness 25µm, various
separated RAL coatings available from stock

Frame The surfaces are covered with a protec-

- Two-part thermally separated frame for tive film which must be removed by the
later installation customer after installation or, at the latest,
Image 1, only an - With polyurethane foam core for better prior to taking the doors into service. Film
approximation insulation left stuck to the component may result in
- Depending on application purpose, adhesive residue which cannot be repaired!
integrated frame heating with a direct
connection to 230V

Required tools Factory configuration

- Power drill - Upright clearance between outside frame
- 4.1mm tungsten carbide drill and door leaf ~ 6mm on the left and right
- TORX bit set - Top clearance between the outside frame
- Vise, mounting pliers Prior to beginning installation, please and door leaf ~ 10mm
- Mechanic‘s level check the delivered parts are complete - Clearance between the floor seal and top
- Riveting pliers with 4mm insert and inspect the surfaces and function. At edge of threshold ~ 1mm
- 1 set of Allen wrenches this point, deficient parts can still be easily - Overlap of door handle to closing pin ~ 6mm
- Non-pressing, one-component replaced. Replacement after installation - Center closing pin grid plate
PU insulating foam (OCF) and assumption of subsequent costs or - Hinge pin in hinge bracket ~ 3mm
- Silicone application gun installation costs is not possible. Parts - Center hinge bracket grid plate
with visible flaws should not be processed
further. In this case, please inform your These dimensions must be checked prior
Work preparation dealer. to installation and readjusted if necessary.
The clearance between the outside frame
- The installation area should be clean and and door leaf is adjustable vertically and
equipped with a soft base (cardboard, horizontally. In addition, the position of
solid fiber board, etc.) in order to avoid the closing pin is also adjustable. For more
damaging the door during installation. information, please see the installation in-
structions in the Fine Adjustment section.

For more functional dimensions, see image 2.

 3

6
7
2
110 Clearance width + 8 110

28
P

13
64

79
75
1
3
8
23
63 5

103
Clearance width + 145

37
Clearance width + 68

54 Scope of supply
60
A DEZI/DEZIA door system consists of the following components:
100
1 = 1 x outside frame
2 = 1 x inside frame
140
3 = 1 x door leaf
4 = 1 x threshold, mounted on the outside frame in the standard
version; versions “without a threshold” with auxiliary threshold,
not shown in drawing
5 = 1 x outside handle mounted on the door leaf
6 = 1 x inside press lever with door handle function mounted on
door leaf
7 = 1x closing pin mounted on inside frame
8 = Flap hinge for flush doors; number depends on size and appli-
cation, mounted on door leaf and outside frame
- Rivets (black) for fastening outside and inside frames into place
Image 2, figure similar
 4

Installation instructions:

i) The door system is delivered to you completely pre-mounted and pre-adjusted

(see Factory Configuration section).

i) The door system must be partially disassembled for installation situations such
as in existing panel or wall openings.

i) Installation is made easier if during the first steps the door is dismounted
horizontally. All dimensional and direction information is based on the door after it
has been installed.

1 Remove the protective cap and – if already installed – the lift-off guard on all the
hinges (see Fine Adjustment section). Remove the door leaves. The door must be
opened at least 90° to do so. Move the door wing along the vertical axis about
80mm upwards. The hinge flap is no longer around the hinge pin and the door
wing is free. Do not place the door on the seal (see image 3).
Bild 3
Image 3

2 Remove the inside frame (counter-frame,

see image 4)

Caution: The inside frame should be

evenly lifted at all four corners. Other-
wise, torsion may occur.

Image 4

3 Place the outside frame in the existing

opening (see image 5).

For door systems without a threshold, the

auxiliary threshold must first be removed.
The auxiliary threshold is only designed
to ensure safe transport and has no other
function (see Auxiliary Threshold section).

After removing the auxiliary threshold,

the outside frame is prone to bend due to
torsion forces exerted on it.

Image 5, Execution of
“threshold for cell”
 5

If frame heating is being installed, make sure

the heating line is lying in the correct opening
and the wall opening has enough space for
the heating line. Otherwise there is a danger
of damage to the heating line.
Image 6

4 The outside frame must be set perpendi-

cular (horizontally and vertically) and pa-
rallel to the wall. Small wood wedges and
liners are helpful for this (see image 7).

Image 7

5 Anchor into place at points 500mm apart using

non-pressing, one-component PU insulating
foam (OCF) – not included in scope of supply –
between the outside frame and the wall at the
corners. After this, close the door and check that
the gap is the same size on the closing edge at
the top and bottom. If necessary, adjust the fra-
me again. Open the door again and use a board
to support the frame horizontally halfway up.
Now apply foam to the remaining gap space all
the way around the frame. This serves to anchor Image 8
the frame into place and also provides optimal
insulation. Carry out the foaming with extreme
care. After a sufficient drying period, the board
can be removed (see image 8).

6 Slide the inside frame (counter-frame) into the

groove of the black plastic profile
(see image 9)
Image 9

7 Check that the outside and inside frames

are parallel with the wall or panel and fix in
place with screw or installation clamp (see
image 10).

Image 10
 6

8 Use a drill (Ø 4.1mm) to drill through the

thermal profile and inside frame spaced
300mm apart. Use the stamped groove
for the optimal position. If necessary, the
installation clamp must be readjusted (see
image 11).

Image 11

9 Remove the installation clamps

and mount the door leaves. Place
the door into position.

Be sure the hinge bracket and hinge

leaf are in the correct position.
Otherwise the door will not close
properly (see Fine Adjustment
section).

Image 12

Auxiliary threshold
The auxiliary threshold is fastened in place
on the left and right by a total of 4 welding
points and can be removed by striking
forcefully with a hammer once or twice.
Sand down the edges with files or an angle
grinder and seal the resulting finish with
corrosion protection (zinc spray).

1
Behelfsschwelle

After removal of the auxiliary threshold,

the outside frame may become distorted
or twisted and bend due to forces it is
exposed to. Image 13
 7

Fine adjustment

With the factory adjustment, the door should now easily open and close and achieve the
desired frame and floor seal contact pressure to ensure optimal tightness. Because con-
struction conditions are not always optimal (wall thickness varies or wall is at an angle,
not level, other deviations), it is absolutely mandatory to check all the functional dimen-
sions and clearances and especially the compression of the frame seal once more and, if
necessary, carry out fine adjustments.

Removing the door leaf is only necessary if the vertical axis is out of position.

Scope of supply for each Varioflex hinge: 4

5

1 = 1x hinge leaf
2 = 1 x hinge bracket
3 = 1 x protective cover on bottom (bracket)
4 = 1 x protective cover on top (bracket)
5 = 4 x cover plugs (leaves) 1

6 = 1x hinge pin 2
7 = 1 x lift-off guard (orange, must be removed
prior to disassembly)
8 = 4x Allen keys 3

9 = 2 x screw-on plates
10 = 1 x locking wedge
Image 14

7
6

9
10

Image 15
8

10 First, check the clearances between the

door leaf and outside frame. Refer to the
Factory Configuration section for the cor-
rect clearances.

Proceed as follows if it is necessary to

correct clearances:
Slide the locking wedge (10) in the lower
part of the hinge brackets approx. 10mm
outward. Remove cover cap (3);
(counter-frame, see image 16).

10

Image 16

11 Horizontal axis: Loosen all the screws on

the screw-on plate (9). Move the hinge
bracket (no. 2. on page 7) to the desired
9

position and retighten the screws (see

image 17).

Caution: The screws should not be com-

pletely removed when loosened. 1 – 2
turns are sufficient. Image 17

12 Vertical axis: The desired height can be

set using the M16 Allen screw (8-piece
Allen wrench set). The door rises when
movement is counterclockwise. The door
descends when movement is clockwise
(see image 18).

Caution: All hinges must be tightened to

the same tightening torque, as otherwise Image 18
a stronger load will be exerted on individu-
al hinges. This may cause band rupture.

Repeat these steps for all the hinges.

13
7
Once the door is correctly adjusted, attach
the lift-off guard (7) at the rear of the hin-
ge leaf (can only be attached in the open
position). And put the cover cap back into
place (see image 19).

Image 19
 9

Adjusting the contact pressure

To ensure optimal tightness, the contact
pressure must be adjusted. The door leaf
frame seal should be in contact in the
“closed” position all around, and pres-
sed shut by about 1–2mm. A paper sheet 11

can be used to test this. Place a sheet

of paper between the door leaf and door
frame and move the door to the “closed”
position. If the sheet can be moved easily,
the seal has no contact, if the sheet tears,
then the contact pressure is too strong.
This test should be carried out at various
heights on the door handle and the door
hinge side.

Image 20

14 Adjusting the contact pressure

Loosen the screw connection and move
the closing pin (11) to the desired position
(see image 20).

15 Finally, the door frame should have

high-grade special silicone (ROMASIL)
sealer or a similar sealant applied to it
(see image 21).

Image 21

Safety

There is a statutory requirement that it should

always be possible to escape from the cold-store
and deep-freeze areas. This means it must also
be possible to use a handle to open the door from
the inside when it is locked (from the outside) (see
image 22).

When installing the door, general care must be

taken with the escape direction. Installing door
fittings without an emergency opening mecha-
nism is not permitted. If you have any further Image 22
questions, please contact your specialist dealer. View of press lever from inside; thick red arrow is direction of escape.
Door frame heating
Door frame heating for deep-freeze room doors must be connected to the power supply (230V). Standard delivery for cold-store room
doors with a thermally separated frame does not include door frame heating. If cold-store room doors to be operated at temperatu-
res above zero are equipped with door frame heating, we recommend having the frame heating include an On/Off switch so it can be
turned on when necessary (230V).

Care and cleaning

- Cleaning the door with wet media is only permitted a minimum of three days after the sealing has been applied. Clean the pla-
stic-coated surfaces with mild soap or standard detergent solutions or cleaning agents which have a pH value between 5.0 and 9.0.
- Cleaning agents should be used in standard dilution and should never be used in concentrated form. Never use paint thinners or
cleaning agents containing active chlorine.
- Cleaning agents should be rinsed off with clear water to ensure that surfaces dry without any residue. Avoid standing moisture.

Maintenance
- T he frame seal profile should be regularly cared for and protected. A standard car cleaning and care product should be used for
this. Regular use reduces wear and helps maintain the quality of the frame seal.
- If the frame seal profile is damaged, it must be replaced with a new seal profile.

Troubleshooting
Ice formation on the door or inside frame The door cannot be moved easily
- Check the contact pressure of the frame - Check the height of the door leaf. The floor seal may be pressing too strongly on the
seal (see Fine Adjustment of the Cont- threshold (see Fine Adjustment View of press lever from inside; thick red arrow is
act Pressure). direction of escape).
- Check if the door frame heating is - Check the adjustment of the hinges. Incorrect adjustment may cause stronger loads
connected or switched on. to be exerted on individual hinges. The load must be distributed evenly on all the
hinges (see Fine Adjustment section).

This information is non-binding and prepared to the best of our knowledge while taking relevant
standards and regulations into consideration. Drawings and pictures serve informational pur-
poses only. All rights reserved. Reproduction in whole or in part only by consent of Romakowski
GmbH & Co. KG, Buttenwiesen, Germany. Our General Business Conditions (AGB) also apply.

Romakowski GmbH & Co. KG

Herdweg 31
86647 Buttenwiesen, Germany
For more information about our products, please Phone +49 (0) 8274.999-400
visit our website: Fax +49 (0) 8274.999-258
www.roma-kuehlzellen.de [email protected]