Bally Refrigerated Boxes BE-Line Installation Manual

Installation and Maintenance

Instructions

for

Air-Cooled, Remote and Water-Cooled

Condensing Units

Bally Refrigerated Boxes Inc.,

General Sales, Manufacturing and Engineering
135 Little Nine Drive, Morehead City, NC 28557

Phone: 800-24BALLY, 252-240-2829 Fax: [phone]

Service and Warranty

Phone: [phone] Fax: [phone]

Visit our web site at www.ballyrefboxes.com

B40-CU-IM-13

1068157

Table of Contents

Pages

General Safety, Inspection & General Warranty Policy 3
Handling, Placement & Installation 4 – 6
Electrical Information & Wiring Diagrams 7 – 14
Refrigerant Piping 15 – 16
Water-Cooled Condensers, Piping & Flow Rates 17 – 18
System Accessories 19
Leak Testing, Evacuation & Dehydration 20
Line Insulation 21
Refrigerant Charging 21 – 23
Compressor Oils 24 – 25
System Start-up Check List 26 – 27
Low Temperature Room Pull-Down 27
Checking Compressor & Evaporator Superheat 28
System Operational Check List 29
System Troubleshooting 30 – 32
Customer Instructions 33
Maintenance Program 33

Service Parts Availability 33

Finished Goods Warranty & Service Log 34
Warranty Activation Certificate 35
Service Parts List Back Cover

2

General Safety

IMPORTANT SAFETY NOTE

Only a qualified refrigeration mechanic who is familiar with refrigeration systems and components, including all
controls should perform the installation and start-up of the system. To avoid potential injury, use care when
working around coil
should be installed in accordance with all applicable codes, ordinances and local by-laws.

surfaces (if applicable) or sharp edges of metal cabinets. All piping and electrical wiring

WARNING

Always disconnect and lock off the main power supply on any system that will be worked on to avoid
accidental start up of the equipment.

Inspection

Inspect all equipment before unpacking for visible signs of damage or loss. Check shipping list against material
received to ensure shipment is complete.

IMPORTANT: Remember, you, the consignee, must make any claim necessary against the transportation
company. Shipping damage or missing parts, when discovered at the outset, will prevent later unnecessary and
costly delays. If damage or loss during transport is evident, make claim to carrier, as this will be their

responsibility, not that of the manufacturer.

Should carton be damaged, but damage to equipment is not obvious, a claim should be filed for “concealed
damage” with the carrier.

IMPORTANT: Check the electrical ratings on the unit to make sure they correspond to those ordered and to
electrical power available at the job site. Save all shipping papers, tags, and instruction sheets for reference by
installer and owner.

General Warranty Policy

Please refer to the “Finished Goods Warranty” on page 34.

3

g

g

Handling, Placement and Installation

IMPORTANT: When selecting a location for the condensing unit, consideration should be given to some of the

following:
(a) Loading capacity of the floor or roof. Check building codes for weight distribution requirements.
(b) Distance to suitable electrical supply.
(c) Distance to the evaporator.
(d) Adequate air circulation and ventilation.
(e) Close proximity to water source and floor drains (water-cooled units)
(f) Accessibility for maintenance.
(g) Local building codes.
(h) Adjacent buildings relative to noise levels.
(i) Wishes of the end user / owner.

When all of the above points have been considered and a specific location chosen, it is advisable to obtain
written approval of this location from the building and/or condensing unit owner. This may be a means of
avoiding disagreement and expense at a later date.

A fully qualified and properly equipped crew with the necessary tackle and rigging should be engaged to
locate the condensing unit in position. When lifting the unit, spreader bars and chafing gear should be used to
prevent damage.

The unit should be placed on a base, which is level and even. Units should be lagged to sleepers or support
base. Place unit where it will not be subject to damage by traffic or flooding. On critical installations where noise
is liable to be transmitted through the floor structure, vibration isolators should be installed. Isolators should be
installed under mounting base and may be rubber or cork or equal.

DO NOT

The condensing unit should be positioned to allow adequate space for performing service work.

Indoor and outdoor air-cooled condensing units should be positioned using the guidelines shown below.

USE THE SHIPPING SKID AS A PERMANENT BASE.

Air Cooled Condensing Unit Minimum Clearance (for Horizontal Air Flow Units)

48" (1.2 m)

Minimum

Air FlowAir Flow

Condensing UnitCondensing Unit

*

Width of

Condensin

Minimum

* No closer than 24" (.62 m)

Unit

*

Width of

Condensin

Minimum

Unit

* Height of

Condensing Unit

Minimum

Walls

4

p

SPECIAL NOTE FOR LARGE AIR COOLED CONDENSING UNITS: Vertical flow air cooled condensing units
are large and heavy pieces of mechanical equipment and must be handled as such. A fully qualified and
properly equipped crew with the necessary tackle and rigging should be engaged to locate the condensing unit
into location. The unit can be lifted by means of lifting holes located in the base frame of the unit. Spreader
bars should be used to prevent damage to the sides of the unit. Do not sling directly around the base of unit.
The unit should be placed on a base which is level and even.

Air Cooled Condensing Unit Minimum Clearance (For Vertical Air Flow Units)

WALLS OR OBSTRUCTIONS

All sides of the unit must be a minimum of 4 feet
(1.25 m) away from the wall or obstruction.
Overhead obstructions are not permitted. If
enclosed by three walls, the unit must be installed as
indicated for units in a

it.

MULTIPLE UNITS

A minimum of 8 feet (2.5 m) is required between
multiple units placed side by side. If placed end to
end, the minimum distance between units is 4 feet
(1.25 m)

4 ft

(1.25 m)

min.

8 ft

(2.5 m)

min.

UNITS IN PITS:

The top of the unit must be level

the top of the pit. In addition, a

above

with, or

minimum of 8 feet (2.5 m) is required between
the unit and the pit walls.

LOUVERS / FENCES:

Louvers/fences must have a minimum of 80% free
area and 4 feet (1.25 m) minimum clearance
between the unit and the louver/fence. Height of
louver/fence must not exceed

top of unit.

8 ft

(2.5 m)

min.

8 ft

(2.5 m)

min.

4 ft

(1.25 m)

min.

4 ft

(1.25 m)

min.

Units equipped with spring-mounted compressors have shipping spacers that are designed to hold the
compressor rigidly during transit to prevent possible damage. Before operating the unit, it is necessary to
remove these spacers. To remove the shipping spacers, follow these steps:

(a) Remove the upper nuts / washers.
(b) Discard the shipping spacers.
(c) Install the rubber cone washers (located in the electrical box).
(d) Replace the upper mounting nuts / washers.
(e) Allow 1/16 inch space between the mounting nuts / washers and the compressor foot.

On units equipped with rigid mounted compressors, check the compressor mounting bolts to insure they have
not vibrated loose during shipping.

5

Ventilation

If the compressors or condensing units are to be located in machine rooms, adequate ventilation air must be
provided in order to avoid an excessive temperature rise in the room. Air requirements vary with ambient air
temperatures and the refrigeration load, however the following rule of thumb may be used to approximate
ventilating air quantities:

Model Type Air Quantity

Air-cooled condensing units (for horizontal air flow units) 1,000 cfm (472 L/s) per Hp

Air-cooled compressors (with remote condensers) 250 cfm (118 L/s) per Hp

Suction cooled or water-cooled compressors 200 cfm (94 L/s) per Hp
(with remote or water cooled condensers)

All of the above mentioned air quantities are based on relatively short discharge line runs within the machine
rooms. If using long uninsulated discharge line runs are unavoidable in the machine room, additional ventilation
air is required to offset the heat added to the room by the discharge gas.

6

Electrical Information

WARNING

All wiring and connections to the unit must be made in accordance with national as well as local electrical codes
and by-laws.

Electrical wiring should be sized in accordance with the minimum circuit ampacities shown on the unit
nameplate and applicable electrical codes. The unit power connections are approved for copper wire only.

Connect the field power supply through a fused branch circuit disconnect switch. The entering service fuse must
not exceed the maximum overcurrent protection (MOP) value on the unit data plate.

Field connected control circuit wires are terminated directly at the control circuit terminal block in accordance
with the appropriate wiring diagram.

Voltage at the unit terminals must not vary more than the allowable variation during start-up and while under full
load. If the voltage is normal at the supply with the compressor not running and drops considerably when the
switch is closed and the motor is trying to start, there is a high resistance due to undersized wires or faulty
connections. Voltage drop between inoperative and full load must not exceed 3% of line voltage. In addition, the
phase imbalance at the motor terminals should be within 2% on three phase units.

60 Hz Supply 50 Hz Supply

Power Allowable Variation Power Allowable Variation

115-1-60 103-127 V 100-1-50 90-110 V

208/230-1-60 197-254 V 200/220-1-50 190-242 V

208/230-3-60 187-254 V 200/220-3-50 180-242 V
460-3-60 414-506 V 380/400-3-50 342-440 V
575-3-60 518-632 V

All systems should use a liquid line solenoid valve (installed at the evaporator) and should be energized by the
room or fixture thermostat. For systems with a defrost time clock, the liquid line solenoid and thermostat should
be energized by the time clock. Initially set the defrost time clock (model 8145) as follows:

Air defrost evaporators; 3 per day (every 8 hours) with the time termination at 45 minutes.

Electric defrost evaporators; 4 per day (every 6 hours) with time termination set (Fail Safe) at 30 minutes.

Check that the wiring from the defrost termination thermostat is wired to terminal “X” on the clock and terminates
the defrost cycle when the evaporator coil reaches approximately 55
also be checked for proper operation. This ensures that all water droplets have been refrozen to the coil before
the evaporator fan starts back up.

Note: The above settings are guidelines only and must be re-adjusted to suit local field conditions and actual
evaporator equipment specifications.

Refer to the evaporator installation manual for further information.

An evaporator airflow interlock is recommended on some installations so that the compressor will pump down
and shut off in the event that the evaporator fan is off for any reason. This is wired into the control circuit in
series with the thermostat and solenoid valve.

Refer to the following wiring diagrams for typical air defrost and electric defrost wiring arrangements.

o

F. The fan delay thermostat wiring should

WARNING

Any deviation or change to the electrical components or wiring as supplied on the original equipment, or
noncompliance with the voltage and phase balance requirements without written authorization will void the
warranty.

7

Electrical Wiring Diagram – Horizontal Air Flow Condensing Units (RP-Line)

8

Electrical Wiring Diagram – Horizontal Air Flow Condensing Units (RP-Line)

9

Electrical Wiring Diagram – Horizontal Air Flow Condensing Units (BE-Line)

10

Electrical Wiring Diagram – Horizontal Air Flow Condensing Units (BE-Line)

11