Bally Refrigerated Boxes 1000 Northwind Blast Chiller User Manual

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1-800-24 BALLY

Bally Refrigerated Boxes, Inc.

www.ballyrefboxes.com

IM-359-11 2011© Bally Refrigerated Boxes, Inc

Installation and Operation Manual

Northwind Blast Chiller

Models: 500 and 1000

Introduction

READ ENTIRE MANUAL BEFORE BEGINNING INSTALLATION!

• There are 9 steps to the installation process. This manual gives you a correct sequence to

follow as you prepare for and carry out installation.

• Prior to the day you make the installation, be sure to review the tool list and parts list, and

the illustrated plan so that you can complete the installation in a reasonable time without any problems.

• There is also a precise wiring diagram included for any complication and step-by-step

instructions to make the job that much easier.

• No manual can anticipate every field situation, but if there are any questions not answered

here, please feel free to call the Bally Northwind help desk at 800-242-2559. Our staff of troubleshooters will do their best to assist you.

Table of Contents

Title Page Number

Introduction 1

Tool List 4

Parts List 4

Step 1 – Locating the Blast Chiller 5

Step 2 – Panel Preparation 5

Step 3 – Erection of Vertical Panels 6

Step 4 – Installation of Ceiling Panels 7

Step 5 – Secure all Panel Sections 8

Step 6 – Installation of the Controller 8

Step 7 – Installation of Coil & Fan Assemblies 9

Step 8 – Cable Connections 12

Steps 9 - 11 – Final Assembly 12

Operation Introduction 13

1 - Controller Description & Operation 14

2 – The Probes 14

3 – Automatic Mode 14

4 – Defrost Mode 16

5 – Manual Mode 17

6 – The Red Light (Critical Failures) 17

7 – Maintenance Items 18

Major Component of the Blast Chiller Back Cover

Note: 012993’s are sometimes left out (see Chapter. 6.3)

Bally Northwind Tool List

Two people are required to assemble a Bally Northwind. The following list will assist you on the tools necessary in the assembly process.

1. Caulk Gun (tube type)

2. Utility Knife (for foam insulation)

3. Foaming Kit (in the general miscellaneous box*)

4. Speed Lock Wrench (in general miscellaneous box*)

5. Tape Measure

6. Level (at least 4 ft.)

7. 5/16 Nut Driver

8. Straight Edge (i.e., carpenters square)

*You will find two Miscellaneous Parts Boxes: the General Box, with parts for the normal walk-in portion of the job, and the Blast Chiller Miscellaneous Box, with dedicated parts of the Blast Chiller.

Bally Northwind 500 Parts List

1. 23” Panels [3]

2. 34 ½” Panel [1]

3. Corners [4]

4. Ceiling Panels [2]

5. 36” x 78”Door (with electrical junction box, complete with twist-lock plug wiring). [1]

6. Control Panel (with complete twist-lock plug wiring and buzzer with alarm switches) [1]

7. Fan rack (pre-assembled) with twist-lock plug wiring [1]

8. Evaporator Coil (pre-assembled) with twist-lock plug wiring [1]

9. Probes, thermocouple type K [3]

10. Ceiling Plenum with light and twist-lock plug wiring [1]

11. Top Coil Trim with J-box for Thermocouples[1]

12. Top Fan Trim Piece [1] (Angled piece, approx. 4 x 36”)

13. Coil and Fan Trim Pieces[2 each]

14. Top Diagonal Air Deflectors (for above Coil and Fan assembly) [2].

15. Universal food rack with tray supports [1]

16. Door Anchor [2] (UNLESS there is a floor)

17. ¾” Stainless steel plug buttons, type 304 (48)

18. Grey panel gasket for repair of damaged gaskets

1. Locating the Blast Chiller

1.1. Using a chalk line and a carpenter’s square, locate on the building floor, the exact dimensions of

the blast chiller as shown in the supplied print. After marking the exterior rectangular

dimensions, measure inward 4” around the perimeter to form an interior rectangle, which locates

the interior blast chiller dimensions.

2. Panel Preparation

2.1. Remove all protective paper from

panels. Leave all special labels on the

skins.

2.2. During the course of installation, the

panels must be caulked for proper seal.

This detail is to be applied to all panel

joints throughout this instruction.

Using the tube of clear silicone

supplied, run two [2] vertical beads of

caulk (see drawing 1.1) on the interior

foam seams.

3. Erection of Vertical Panels

Panel assembly sequence of a Northwind 500

3.1 BEFORE ATTEMPTING TO ERECT ANY PREFAB SECTIONS, FAMILIARIZE YOURSELF WITH THE

FOLLOWING CHAPTERS IN THE STANDARD INSTALLATION MANUAL (IM-268-11, Revised

2011):

• Page 4, Section 1

• Page 5, Section 2

Operation of the Bally Speed-Lok

• Page 7, Section 3

Bally Boxes without Floors

3.2 Start by erecting a vertical rear corner

section. When erecting, the holes for the

Speed-Lok wrench must always be on the

left-hand side when facing the interior section.

This is important; crews have installed boxes

upside down.

• The Coil Frame Assembly is installed in the box

before the door is added since the coil is taller than the opening of the door. You’ll have to slide the coil out of the way to lock the last corner panel.

• When erecting the front sections of the box, note

that the door latch corner and the door frame section have a cut out at the top of the panels, which, when joined, will provide a slot through which the collar of the control panel will be inserted.

• Install this cut out corner first, making sure that the

two bottom surfaces in the notch area are perfectly level.

For the NW 1000 sequence, look in the Appendix.

3.3 On each panel, check for proper

Installing Ceiling Panels on the Northwind 1000

and remove the cardboard.

alignment and level. Leveling can be

accomplished by placing wooden shims

under the vertical panels (cross-

reference IM-268-11, Section6).

3.4 Remove the shipping strap attached to

the bottom of the door opening. When

attaching the door, hold a level on the

face of the door section, and when

plumb, Speed-Lok to adjacent corner

section. IT IS VERY IMPORTANT THAT

THE DOOR SECTION IS ALWAYS LEVEL

AND PLUMB.

4. Installation of the Ceiling Panels

4.1. Bring the rear ceiling panel on top of

the front half of the blast chiller.

4.2. Caulk on both sides of the tongues of all the

appropriate rear wall panels.

4.3. Pick up the ceiling panel, bring it back, and

drop it in place. Engage a couple of locks on

the back wall. Do not fully lock.

4.4. Caulk the groove or tongue of the rear

ceiling panel and the rest of the wall tongue

area.

4.5. Bring up the front ceiling panel and lock it to

the back ceiling panel, fully engaging the

Speed-Loks to the lock position on the seam

between the two ceiling panels.

4.6. Make sure the ceiling panels are secured

squarely on the vertical panels. Do not fully

• Install the middle ceiling panel first. The large

panel will align more panels quicker.

• Instead of caulking the tongues, place the

caulk in the corners of the grooves in the ceiling panel, then lay the ceiling panel on a piece of cardboard trimmed to size.

• Lift the ceiling and cardboard onto the

verticals, locate the ceiling panel, tilt it up,

lock. Align and adjust accordingly.

4.7. Fully engage the Speed-Loks to the lock

position on the vertical panels to the

ceiling panels.

5. Secure all Panel Sections

5.1 After all Speed-Loks are secured, install access hole

plug buttons to all Speed-Lok locations.

5.2 Anchor both sides of the doorframe inside the box to

the floor with “L” braces with 5/16” expansion bolts

and 5/16”hex head self-tapping screws with

shoulders to the door panel.

5.3 Using the silicone supplied, caulk both interior and

exterior of box at floor joints.

5.4 Install SS continuous angle floor anchor (Bally PN

019045) around inside periphery of the box.

6. Installation of the Controller

6.1 Have a partner hold the controller up and feed

the connectors through the controller slot in

the front of the box. Then push the

rectangular collar of the control assembly into

the slot until the base of the controller is

against the face of the blast chiller. Back out

the three screws that hold the front cover onto

the controller base. Remove the controller

cover, and screw the controller base to the wall

panel.

6.2 Two interlocking stainless steel harness covers

lock around the incoming cables of the control

panel. Secure the cover plates to the box front

panels by preparing a pilot home with 1/8” drill

and finishing with ½” stainless steel, self-

tapping, Phillips head sheet metal screws. Fill

the volume with canned foam. Fill any gaps

between the wall panels and the plastic

wrapped chute with canned foam.

6.3 Install the two top ceiling deflectors in the

upper top corners of the sides of the box

deflecting the flow of air from the fan frame

Orientation of the Trim Pieces

assembly to the coil frame assembly. Prior to

installing, prepare 1/8” pilot holes and use ¾”

stainless steel, self-tapping, Phillips head sheet

metal screws.

Some tall (over 106”) boxes may not have ceiling deflectors. Check the packing list for PN 012993.

7. Installing Coil and Fan Assembly Frames

7.1 Before you stand up any of the frame assemblies, extend the

legs out to 5.0” (by spinning the foot pads).

7.2 Installing the Coil Frame Assembly

1. Remove the Coil Top Trim, 013121.

2. Install the coil frame into the appropriate side.

3. Center the frame within 1/16” between the two walls.

4. Install screws into the rear top back brace. This will force the

frame against the wall permanently.

5. Reinstall the top coil trim piece. Attach the grey plastic probe

receptacle box (from the controller) into the rectangular hole.

The Bally box design follows certain rules. One of the results is that a wall that two corners on it will be 1½” narrower than a wall made of a corner and a breaker. As a result of this, there is more room in a NW1000 than a NW500. To make up for this extra space, the trim pieces are turned with the long legs against the frame on a NW1000, long legs against the walls on a NW500.

7.3 Installing the Fan Frame Assembly

1. First remove the fan guard.

2. Install the frame in the appropriate side and screw

the back braces to the side wall using the same

stainless steel sheet metal screws.

3. Plug in the Air Probe (see connector at top of

picture).

4. Install the two shorter side trim angles on each side

by screwing them to the walls.

5. Replacing the front cover will capture the side trim

pieces between the front cover and the frame.

6. Place the Top Fan Trim Piece between the same

front cover and the frame.

7.4 Installing the Condensate Drain

1. A tube must be installed to drain condensate from

each coil assembly.

2. Find the pan, which is approximately four inches

above floor level on the coil frame. Locate the 90°

Elbow beneath it.

3. You must supply a drain line starting from the ¾” NPT

plastic elbow. You may plumb the line to the front,

rear, or side, as per your convenience. You may use

plastic tubing, PVC pipe, or other pipe. If you are

installing a NW1000, you may join the two runs or

plumb them separately.

4. Drill a hole in the appropriate panel. Caulk the

hole(s) after finishing the plumbing.

7.5 Installing the Plenum Supports and Plenum

Interior Plenum Supports on both sides of the

1. At this point, the Front Plenum Support, Fan

Seal Strip, and Coil Top Trim should be in

place. Adjust the side pieces so that they

match the front in height (usually 78”).

2. Add the Interior/Rear Plenum support(s) to the

interior wall of a NW1000. The plenum is

installed on the far side of the wall.

Plenum Installation - The plenum is installed

interior wall (on a NW1000) and rear walls. You

will find screw holes in the walls from our initial

assembly. Use these first.

3. Install the Plenum and see if the

holes line up. Screw the Plenum

to the:

(1) Front Plenum Support, then

(2) The Coil Top Trim*, then

(3) The Fan Top Trim, and finally

(4) The Rear Support (or the

Interior Support for the

NW1000).

with the electrical plug toward the coil frame. Lift

the plenum diagonally over the fan assembly.

Have somebody else plug in the connector, then

raise it until the lowest corner is above all the

plenum supports, then lower it flat.

*The priority should be in that order, if the Coil Top Trim holes won’t match up when the plenum is

8.1 Interior Wiring Color Code

screwed to the Front, unscrew the Coil Frame from the wall and shift it over until it fits. The Fan trim piece

can shift side to side with respect to the frame, and you can redrill the holes in the back wall.

8. Cable Connections

• All of the interior wiring is done utilizing

color-coded, twist-lock, watertight plugs

and type J thermocouple plugs. Make sure

all plugs bottom out.

• All interior wiring must be done before the

ceiling plenum is installed.

1. TWIST LOCKS from-

Controller to:

2. “Grey +” = “Back side of NW1000”. For

Grey & Red  rear defrost heaters

3. Type J Thermocouples

Three Cables Terminating at Outlet

Air probe Cable (single black receptacle)

4. Match all of the plugs together according to

Red  defrost heaters Blue  solenoid valve & defrost

Green  fan motors Yellow & Brown door junction box

Door junction box to:

White  ceiling plenum light

example:

Box(es)

the color code provided. Ty-Wrap all of the

cords to the bases attached to the walls for

that purpose. You will want to leave the

Plenum down for the refrigeration

technician, and it will not matter as far as

the electricity is concerned if you leave the

plenum out of the blast chiller.

termination

9. Hooking up the System

A properly licensed electrician must next hook

up the system to a shut off attached to a

nearby wall. The electrical specifications are

located on a sticker attached to the controller.

10. Installing Refrigeration

After the unit has power, the refrigeration

technician can install the refrigeration, running

½” and (usually) 1- 1/8” copper tubing through

the provided hole in the ceiling panel. Make

sure the suction tubing is properly wrapped

with Armaflex, and all work is done in good

practice according to local code. Coils arrive

with a holding pressure of 60 psi nitrogen.

11. Setting the Ceiling Plenum

The ceiling plenum can now be set in place,

plugged in, and mounted using black thumb

screws. I you have trouble lining up the holes,

remember that the fan side upper trim is

clamped in place and can be slid forward or

backwards, and you can loosen the trim piece

over the coil frame as well. Also remember

that the interior plenum support angle can be

relocated if need be.

OPERATIONAL MANUAL: BALLY NORTHWINDS BLAST CHILLER

BEFORE TURNING THE CONTROLLER ON, ensure that all wire connections are secure and correctly color coded.

Inspect all of the external wiring according to the wiring specications.

WARNING: DO NOT OPERATE THE NORTHWINDS CONTROLLER WHEN THE CONTROL COVER HAS BEEN REMOVED.

1. The Control Panel:

A. On/O Power Switch for the unit.

B. Backlight for screen is always on, unless power is shuto at

the breaker box.

C. Operational Alarm displays red in a critical failure. (See #11)

Push to silence Alarm.

D. F1 thru F4 are referenced from the screen.

E. Previous/Next are shown when you can page through

multiple screens. (See Auto & Manual Mode)

2. The Probes

Air Probe: Monitors air temperature Product Probe: Monitors food temperature that the Blast Chiller

used in Auto Mode.

Auxiliary Mode: Monitors food temperatures in other locations for

data collection only.

3. The Stages

Chilling: This is where the Blast chiller chills the food as quickly as possible. The air temperature is driven to 5°F.

• If the air temperature goes below 5° the refrigeration will turn o for 3 minutes.

• If the door is opened, the fans and refrigeration will turn o. When the door is closed, the fans turn on and

the refrigeration turns back on for 3 minutes after the door was originally opened.

Holding: The unit is holding the food until the user removes it from the blast chiller. The air temperature is kept below 45°F.

• If the air temperature goes above 45° the refrigeration will turn on for three minutes.

4. Modes of Operation

The Northwinds blast chiller has 3 dierent Modes or Cycles of operation.

Automatic: Default Cycle. Fans and refrigeration cool food to 36°F using the Product Probe (inserted in the middle of the product) to determine when the cycle is complete.

Manual: Instead of inserting the Product Probe, a chilling time is entered in the controller. After the time is up the Northwind enters Auto mode.

Defrost: Melts the ice that may have accumulated on the coil, then returns to Auto mode.

5. Automatic Mode

a. Put food cart into the Northwinds. b. Insert Product probe and Auxiliary Probes in the middle of the tray of food. c. Close the door. d. Turn the Northwinds on. e. The fans and refrigeration will turn on until the Product probe temperature reaches 36°F. f. The system moves into the Holding stage. The refrigeration is o, but the fans stay on.

6. The Display Screens in Automatic Mode:

While in automatic, you can push the Next/Previous buttons on the display to page through information appropriate for this mode. When the automatic mode begins, you will see the word “AUTO” and the product temperature. As you push the next arrow, you will see the following screens:

Screen Reads Appears When

Probe Temperatures: Show temperatures for the Air, Product, and Auxiliary Probes.

Chill Time: Indicates time since the food probe temperature went below 140°F.

Refrigeration Status: This is an on/o indicator

Fault Page Indicates if there are any faults (such as broken thermocouple circuits).

Special Screens

Product temperature is close to air temperature Product temperature and air are within 15°F of each other at the start.

Product Temperature Reached Chill process has ended and the unit is in holding mode.

7. Defrost Mode

During the Defrost Cycle heaters in the evaporator coils will turn on (they stay on even if the door is opened). The Defrost Cycle will end after 20 minutes or by the Defrost Termination Switch (DTS, see #8). Following the completion of the Defrost Cycle, a timer countdown will be shown on the display screen while the refrigeration turns on for 3 minutes before the fans. This causes any water on the coil ns to freeze.

To enter Defrost:

a. After the Chilling cycle has been completed, remove the food cart, and push F2. b. You will be prompted to insert the password, which is: 22. c. Push and hold the +/-10’s button until you see 20. d. Push the +/- 1’s buttons to reach 22. e. After 22 is showing on the screen, hit F2 again. f. The Defrost Cycle will begin.

8. Defrost Termination System (DTS)

The defrost termination switch is a “switch with a memory” that turns on when it senses a temperature of 60°F, and stays on until it senses a temperature down to 20°F. It stays o until the temperature goes back up to 60°F again. In the blast chiller, once the air temperature gets down to 20°F during a cycle, you should be able to go into defrost immediately after using it. If the unit sits for a while and gets warm enough to melt all the ice on the coil without defrosting it, then the unit will let you know by displaying “Defrost not Needed” when F2 is initially pushed.

• If the evaporator coil lls up with ice it can diminish the performance of your Northwinds.

NOTE:

• If the unit runs for three to six hours a day then remains idle, the Defrost Cycle typically isn’t needed because the temperature rise will thaw and drain any ice on the evaporator coils.

9. Manual Mode To use Manual Mode:

a. Turn the Northwinds on. b. Push F3. c. Insert the code, which is 22, as described in “Defrost”. d. Push F3 again. e. Adjusting the Chilling Time to t your needs (see Manual Time, #10). f. Put the food cart in the Northwinds. g. Insert food probes - Optional. h. Close the door.

The Chill Time chosen will be the length of time that the refrigeration system will run. When the chill time is up, the unit returns to Automatic Mode. If the product probe is in the food, it will continue to chill the food if the food is still above 36°F. Otherwise, the unit will be in holding stage.

10. The Display Screens in Manual Mode:

Manual Mode: Air temperature in large letters on the top line, followed by the total chill time in small letters, and the current time (Time since chilling started). As you push the down arrow, you will see the following screens in this order:

Screen Reads Appears When

Measured Temperatures: Show temperatures for the Air, Product, and Auxiliary Probes.

Manual Mode Time Set the time for the manual cycle to run by following instructions on the screen. Any

time changes take eect immediately.

Refrigeration Status: This is an on/o indicator

Fault Page Indicates if there are any faults (such as broken thermocouple circuits).

11. The Red Light: When there is a critical failure a red operational error light and an alarm turns on. Possible triggers are:

Error displayed on screen Meaning

Air temperature above 100° This is most likely due to a refrigeration failure. The unit will shut down so that the fans

will not draw out even more heat from the food, perhaps triggering the re suppression system. The food must be cooled some other way, and the refrigeration system must be serviced.

Fan contactor failure This is a self-diagnosis by the controller. The fans will not come on if the fan contactor

fails. Any food must be cooled elsewhere, and replace the contactor.

Defrost contactor failure This is self-diagnosis by the controller. The unit will not defrost. This may not prevent

acceptable performance, since it only eects defrost. Replace the contactor.

Air probe open The air temperature input probe is not working correctly, and the unit cannot operate.

12. Item Maintenance Locations for Bally Northwinds Blast Chillers

Item Part# Location/Means of Access

Fan Motor 016915 Inside Fan Frame/Remove entire Fan Cover (not the wire fan guards).

Refrigeration Valve 005424 Part of the Liquid Line, left side of Coil Frame. Unscrew the 6 black topped screws, and

remove coil lter and side cover.

Solenoid Valve 061514 Attached to the Refrigeration Valve. Part of the Liquid Line. (See above).

TXV 000388 Part of the Liquid Line (See above).

Power Head 099644 Attached to TXV, above (Special 60” bulb tube).

Defrost Switch 088779 In the top bend of coil frame, usually on the Liquid Line side. (Wired closely to the coil

junction box.)

Air Probe 046759 Behind the upper fan motor. Remove the Fan Cover (not the Wire guard).

Auxiliary Probe 089226 In plain sight. Plugged into top of coil frame.

Light Bulb none In plenum. Unscrew 4 at head screws with a 2.5mm hex key (not a common size). Hex

key is taped to the light at the time of shipment.

Probe plugs: The temperature probes are low voltage circuits that are routed through plugs located at the top of the coil frame and behind the fan frame.

Problem Solution

Erroneous probe readings Use a light abrasive pad (like Scotch-Brite) to clean the plugs, and a Q-tip to clean the

receptacles.

Defrost Switch: The defrost switch sends a signal back to the controller indicating the temperature of the coil. The switch is designed to handle high amperages and has a life span of about 100,000 cycles.

Problem Symptom

Fails Closed The Defrost Cycle cannot be initiated. Even when the coil is frozen solid

Fails Open The full 20 minute Defrost Cycle will occur after every Chilling cycle. Even when the blast chiller interior

is at room temperature.

A Northwind 500 Model is shown. A Northwind 1000 Model is twice as deep.

FAN SEAL STRIP

INTERIOR REAR PLENUM SUPPORT 013163

HARNESS COVERS 026803

CEILING DEFLECTOR 012993

GREEN

CEILING PLENUM

CONTROLLER

YELLOW

BROWN

WHITE

CABLE

CONNECTIONS

(8)

RED

BLUE

LIQUID & SUCTION LINES

COIL TRIM

ANGLE

012905

(2 EACH SIDE)

COIL TOP TRIM 013121

FAN FRAME 012911

COIL

FRAME

012737

DRAIN LINE