Bally Refrigerated Boxes WD-F4, WD-F3, WD-F2, WD-F1, WD-R4 Installating And Operation Manual

Operation, Installation and

Instruction Manual

for

Reach-In and Roll-In

Refrigerators, Freezers and Warmers

BMIL International, Inc.

A Division of BALMAC International, Inc.

61 Broadway, Suite 1900 • New York, NY 10006-2701

212-898-9699 • Fax: [phone] - [e-mail]

Operators Manual

Table of Contents Page

RECEIVING YOUR NEW MODEL........................................................................1

GENERAL INFORMATION AND IMPORTANT OPERATING FACTS .................1

UNCRATING YOUR NEW MODEL ......................................................................2

INSTALLATION AND LOCATION.........................................................................2

CLEARANCES..................................................................................................2

VENTILATION...................................................................................................2

FLOOR LOADS.................................................................................................3

INSTALLING LEGS AND LEVELING REACH-IN MODELS .............................4

MOUNTING ROLL-IN MODELS IN PLACE AND LEVELING ...........................4

INSTALLING CASTERS AND LEVELING REACH-IN MODELS ......................5

INSTALLING CONDENSATE EVAPORATOR..................................................6

REMOVAL OF DOORS AND DOOR ADJUSTMENT .......................................7

REMOVAL OF GRILL .......................................................................................8

INITIAL CLEANING PROCEDURE.......................................................................8

START-UP PROCEDURE ....................................................................................9

ELECTRICAL CONNECTIONS.........................................................................9

115 VOLT, 60 HZ, 1 PHASE CONNECTION ....................................................9

208-230 VOLT, 60 HZ, 1 PHASE CONNECTION .............................................9

SPECIAL VOLTAGE CONNECTIONS..............................................................9

START-UP CHECKLIST .................................................................................10

REMOTE APPLICATIONS..............................................................................10

OPERATION.......................................................................................................11

THERMOMETER CALIBRATION ...................................................................11

CALIBRATION CHECK...................................................................................11

DIAL THERMOMETER ...................................................................................11

DIGITAL THERMOMETER .............................................................................11

REFRIGERATOR SYSTEM AND ADJUSTMENT...........................................13

FREEZER SYSTEM AND ADJUSTMENT ......................................................14

DEFROST OPERATION .................................................................................14

WARMER SYSTEM AND ADJUSTMENT.......................................................15

EVAPORATOR ASSEMBLY ...........................................................................16

LOW-PROFILE,CEILING-MOUNT EVAPORATOR ASSEMBLY ................16

PLUG-TYPE,TOP-MOUNT EVAPORATOR ASSEMBLY............................ 17

INTERIOR REACH-IN ACCESSORIES ..........................................................18

SHELVING INSTALLATION ........................................................................18

OPTIONAL INTERIOR ACCESSORIES......................................................19

SAFETY PRECAUTIONS ...............................................................................20

MAINTENANCE..................................................................................................20

PERIODIC CLEANING PROCEDURE............................................................20

SLIDING AND HINGED GLASS......................................................................21

GENERAL PREVENTATIVE MAINTENANCE................................................ 21

PARTS AND SERVICE ...................................................................................22

TROUBLESHOOTING AND SERVICING GUIDE ..............................................23

WIRING DIAGRAMS ..........................................................................................26

RECEIVING YOUR NEW MODEL

Congratulations on your recent purchase of Bally refrigerator superior food
equipment products! When your shipment arrives, please thoroughly examine the
shipping crate for any punctures, dents, or signs of rough handling. It is in your best
interest to partially remove or open the shipping container in order to examine the
model for any concealed damages which may have occurred during shipment. If
the model is damaged, it must be noted on the delivering carrier's delivery slip or bill
of lading (see "filing a damage claim" under warranty section).

GENERAL INFORMATION AND IMPORTANT OPERATING FACTS

This manual has been compiled to aid in the installation, operation and
maintenance of your new equipment. Please take the time to read all of the material
in order to become more familiar with your equipment and its operation, and enjoy
optimum performance.

Important Note: All value and designer line freezers have an energy-saving fan

delay control to prevent the interior fans from operating until the evaporator coil
becomes chilled. Therefore, on initial start-up, the fans will not turn on immediately.
This is a normal mode of operation. Allow sufficient time for the evaporator coil to
reach its operating temperature (approximately 20 minutes).

No floor drains or plumbing connections are required since all models are
completely self-defrosting and use an automatic defrost condensate water
evaporating system (see "condensate evaporator installation" under installation and
location section).

All cabinets must be given sufficient time to reach normal operating temperature
before placing any food inside. For refrigerators, approximately 2 hours of operation
are required to lower the cabinet temperature to 40 degrees f. Freezers require
approximately 4 hours of operation to lower the cabinet temperature to 0 degrees f
(see "operation" section for further information).

Never overload top shelf with product so as to block or restrict cabinet airflow.
Doing so will result in poor performance, decrease in efficiency and possible need
for service to de-ice evaporator.

Prior to factory shipping, all models are performance run tested for a minimum of 12
hours providing a highly sophisticated temperature analysis recording exclusive to
each individual cabinet. This recording is supplied within this manual packet. A final
leak check, vibration, noise level and visual examination is made by a qualified
quality control team to assure a quality product. The carrier signs to this effect when
he accepts the product for shipping. To insure the maximum in safety and
sanitation, all models are listed under the reexamination service of underwriter's
laboratories and with the national sanitation foundation.

- 1 -

UNCRATING YOUR NEW MODEL

The shipping container should remain on your model as protection against dents or
scratches while transporting it to the actual set-up location. Remove the shipping
container only at the last possible moment by following these simple steps:

1. Using a pry bar, pry off and remove crate end bottom staples.

2. Pry off and remove crate front and rear bottom staples.

3. Slide crate upward and remove it, being careful not to rub against cabinet.
There are up to four (4) bolts securing the cabinet to the wooden skid. The bolts are
located at each end on the underside of the skid. In order to remove these bolts it is
advisable to tilt the cabinet backwards and place wooden blocks at each end in
order to hold it in its tilted position. Using a 3/4" socket or open end wrench, remove
the bolts and carefully slide the model off of the skid. After skid removal, the cabinet
should never be moved without dollies or rollers to avoid damage to the cabinet
bottom or floor.

Important Note: Do not under any circumstances lay your new model on its

front or sides. Only for a brief period, may you lay the model on its back and only
then, when its properly blocked so as not to crush the condensate drain tubing and
also to allow provision for your hands in order to set it in its upright position without
inflicting damage to the cabinet. Do not plug in and operate model for at least

three (3) hours after cabinet is set upright from being on its back as damage
could result to the compressor.

INSTALLATION AND LOCATION
CLEARANCES

Before moving the cabinet to its final point of installation, accurately measure all
doorways or passages to assure clearance. If additional clearance is needed,
cabinet doors and grill can be easily removed (see instructions outlined in "removal
of doors" and "removal of grill" sections).

VENTILATION

The final location site of your air cooled refrigerator or freezer must be able to
provide a large quantity of cool, clean air. The refrigeration system operates most
efficiently and trouble-free with cool, dry air circulation. Avoid locations near heat
and moisture generating equipment such as stoves, ovens, cooking ranges, fryers,
dish washers, steam kettles, etc., and also direct sunlight where temperatures can
be in excess of 100 degrees f. Also, do not select a location in an unheated room or
area where temperatures may drop below 55 degrees f. Air supply to the
condensing unit is equally important. Restricting the air supply will place an
excessive heat load on the condensing unit and adversely effect its operating
efficiency.

- 2 -

Important Note: To assure sufficient air supply and circulation to the

condensing unit, a minimum clearance of 12" above the grill and 3" on each
side and back of the cabinet must be provided (see figure 1). If necessary,
special venting or air supply ducts must be installed by the installer for this purpose.
Do not at any time obstruct the grill area in front of the cabinet in any way, and
never place or store anything on top of the cabinet machine compartment. These
rules are essential for maximum cooling capacity and long life of refrigeration parts.

FIGURE 1

MINIMUM CLEARANCE DIMENSIONS

FLOOR LOADS

The floor at the final location site must be level, free of vibration and strong enough
to support the total combined weights of your new model plus the maximum
product load which might be placed into it. A fully loaded reach-in or roll-in model
may reach 2,000 - 3,000 pounds. To estimate the possible product load weight,
assume that each cubic foot of storage space weighs approximately 35 pounds.
Multiply 35 pounds by the amount of cubic feet in the cabinet and obtain the
product load weight. For example, a 20 cubic foot refrigerator can hold
approximately 700 pounds of product (35 x 20) and assuming the refrigerator itself
weighs 300 pounds, the total combined weight of cabinet and product is
approximately 1000 pounds. Therefore, the floor in this example must be capable of
supporting up to 1000 pounds.

- 3 -

INSTALLING LEGS AND LEVELING REACH-IN MODELS

Your new reach-in model is supplied with adjustable type legs for leveling
purposes. Each single and two section model has four leg mounting holes on its
case bottom, and three section models have six leg mounting holes. Legs are
packed in the accessory carton from which they must be removed and installed on
the cabinet case bottom (see figure 2). In order to install the legs, carefully tip the
cabinet rearward adding four (4) 2" wood blocks underneath and simply screw the
threaded leg studs into the case bottom front leg holes. Repeat this procedure by
tilting the cabinet in the opposite direction and install the remaining legs. Make sure
the legs are tightened extremely well or the entire model will sway or rock with each
opening or closing of the doors, possibly causing damage to the case bottom. This
procedure should be performed close to the final installation site and allow access
to the rear of the cabinet for condensate evaporator installation (see "condensate
evaporator installation" under installation and location section).

To assure your cabinet is level, all legs are equipped with bullet-type leveling bolts.
These bolts can be turned by hand or by wrench, clockwise or counterclockwise to
level the cabinet.

FIGURE 2

LEG INSTALLATION

MOUNTING ROLL-IN MODELS IN PLACE AND LEVELING

Your new roll-in model is designed and constructed to be mounted directly on the
floor without legs or casters. The floor must be level and the base of the cabinet
should be sealed to the floor around its entire perimeter. If the floor is not level, it
must be made level prior to mounting your roll-in model.

Your roll-in model comes with one cart ramp per door opening. To install the
ramp(s), simply open the cabinet door and position the ramp slots onto the screws
located along the cabinet bottom front. If the door wiper rubs along the ramp to the
extreme where the door will not self-close, you will need to adjust the door (see
"door adjustment" section) or level the cabinet as explained above.

- 4 -

Important Note: It is extremely important that your new reach-in or roll-in

model is perfectly level for proper operation. If it is not level, the following
adverse conditions will become apparent:

1. The door(s) will not be properly aligned and consequently will not provide a
good seal. Roll-in door wiper(s) may bind.

2. Your model will run excessively due to improper door seal(s).

3. An excessive amount of ice will accumulate inside the cabinet, around the door
opening(s) and especially on the finned evaporator coil. If allowed to continue,
ice will eventually block the coil and the model will fail. This will result in the
loss of all food stored within the cabinet.

4. Defrost water will fail to drain properly and will overflow the evaporator coil drain
pan and into the cabinet of both refrigerator and freezer models.

INSTALLING CASTERS AND LEVELING REACH-IN MODELS

If you wish to install casters on your new reach-in model, follow the steps above for
"installing legs" to install the casters, making sure again that the casters are
tightened extremely well (see figure 3). If the casters are not installed tightly, the
cabinet will sway or rock with each opening or closing of the doors, possibly
causing damage to the case bottom.

To assure that your cabinet is level, caster cups must be installed under the casters
which need leveling. Caster cups are not provided with your new model but can be
purchased at most hardware or furniture stores. Do not attempt to level casters

by unscrewing them from the case bottom as this will cause damage to the
cabinet bottom and leg hole threads, voiding all warranties.

FIGURE 3

CASTERS MUST BE TIGHT TO CABINET BOTTOM

- 5 -

INSTALLING CONDENSATE EVAPORATOR

No floor drains or plumbing connections are required since all models use an
automatic condensate water evaporating system. All designer line models utilize a
unique hot gas condensate water evaporating system which is completely self­contained and no further assembly or maintenance is required (these models are
recognized by their evaporator coil which is located out of the food zone in an
insulated plug-box housing next to the condensing unit). All value line models are
supplied with an electric condensate evaporator pan and mounting bracket packed
in the accessory carton. To install the condensate pan on value line models only,
remove both mounting screws located on the bottom of the cabinet back and install
the mounting bracket on the case bottom as shown in figure 4. Slide the
condensate pan onto the bracket, install the drain tube into the pan making sure it
is not blocked or kinked, and plug the ten foot power cord into the receptacle
labeled "vaporizer" located on the case top electrical box.

IMPORTANT NOTE: It is extremely important to be sure that the

condensate pan is plugged into its correct receptacle labeled "vaporizer" and
that the condensing unit is plugged into its correct receptacle labeled
"condensing unit".

FIGURE 4

CONDENSATE EVAPORATOR INSTALLATION

- 6 -

REMOVAL OF DOORS AND DOOR ADJUSTMENT

During installation, it may become necessary to remove the cabinet doors to
facilitate passage through narrow doorways or hallways. To remove a door, pry off
all hinge covers using a sharp tool or knife (see figure 5). Swing the door to the
open-door position (90 degrees) and carefully lift the door upward, removing the
door from the hinge bodies. If it is necessary to remove the hinge bodies from the
cabinet face, be extremely careful not to lose the light switch pin located inside all
top hinge bodies. To reinstall the door, reverse the above procedure.

All doors have been aligned at the factory, however vibration during transportation
may cause doors to shift and realignment may be necessary. If the door(s)
require realignment, proceed as follows:

1. Pry off all hinge covers using a sharp tool or knife.

2. For each door, loosen the screws which secure the hinge bodies to the cabinet
face and slide the door into alignment. Hold the door firmly in place and tighten
all screws securely.

If the door gasket(s) do not seal properly to the cabinet face and there are
gaps between the gasket and the face on the hinge edge, proceed as follows:

1. For each door, loosen all screws which are directed into the edge of the door
and push the door towards the cabinet eliminating the gap. Hold the door firmly
in place and tighten all screws securely.

2. Replace all snap-on hinge covers.

FIGURE 5

DOOR ADJUSTMENT AND REMOVAL

- 7 -

REMOVAL OF GRILL

To remove the grill, loosen all four (4) grill mounting screws located on the backside
of the grill one or two turns. Simply lift grill up off of its mounting screws and out. To
replace the grill, line up the grill mounting screws with the keyhole slots located on
the cabinet body, push in on the grill and down.

Important note: If the model is provided with a digital or dial thermometer, the

front grill cannot be completely removed from the cabinet without first removing the
thermometer bulb from inside the cabinet. However, enough capillary tubing and/or
wiring cable has been provided to allow the grill to be laid across the top of the
cabinet after it has been removed. Take care not to damage the capillary tubing
when handling the grill.

If it is necessary to remove the thermometer bulb from inside of the cabinet, first
locate the thermometer bulb cover and remove the thumbscrews securing it in
place. On value line models, the thermometer bulb cover is located on the interior
top left corner towards the front of the cabinet. On designer line models, the
thermometer bulb is located on the interior top under the air duct. Once the cover is
removed, carefully grasp the bulb and push it back through the cabinet hole. The
thermometer bulb and grill can now be removed from the cabinet. When reinstalling
the thermometer bulb, be sure to replace the permagum sealant around the hole
after inserting the bulb.

INITIAL CLEANING PROCEDURE

Prior to start-up and before placing any food inside of your new reach-in or roll-in
model, the interior of the cabinet should be thoroughly cleaned. Washing with a
mild soap and warm water solution is recommended for cleaning the aluminum and
stainless steel surfaces of your cabinet. This should be followed by cleaning with a
baking soda solution (three (3) tablespoons of baking soda to each quart of warm
water). Rinse thoroughly with clear water and dry with a clean, soft cloth.

Important Note: Never use harsh detergents, cleaners, scouring powders or

chemicals when cleaning your model. Failure to dry the interior surfaces after
cleaning may result in a streaking or staining of the metal.

Complete cleaning procedures and precautions are listed in the "periodic cleaning
procedure" under the maintenance section.

- 8 -

START-UP PROCEDURE
ELECTRICAL CONNECTIONS

To insure proper operation, your new model must be connected to an individual
circuit that can supply the full voltage as stated on the cabinet serial data plate. For
correct voltage, power draw, and wire accommodations, check the data on the
serial data plate located on the inner right wall of your new model. Verify that this
information exactly matches the electrical characteristics at the installation location.
An electrical wiring diagram, located on the upper cabinet end panel next to the
electrical console box, should also be consulted during connection.

Important Note: The condensing unit supplied with all self-contained models is

designed to operate with a voltage fluctuation of +
the cabinet serial data plate. Full voltage of the correct service, on an individual line
not affected by the operation of other electrical appliances, must be available to the
condensing unit at all times. Burnout of the compressor due to exceeding the

high or low voltage limits is easily detected and will automatically void the
factory warranty.

10 % of the voltage indicated on

115 VOLT, 60 HZ, 1 PHASE CONNECTION

All 115 volt models are provided with a U.L. approved power cord and polarized
plug which is factory installed.

Warning: Any alterations to this cord and plug could cause an electrical

hazard and will void the factory warranty.
To insure proper operation, this equipment must be plugged into a NEMA 5-15R
compatible, grounded receptacle that can supply the full voltage as stated on the
serial data plate.

208-230 VOLT, 60 HZ, 1 PHASE CONNECTION

All 208-230 volt models are to be permanently connected and are provided with
four (4) field wiring leads which exit the electrical console box located in the
machine compartment behind the front grill. The cabinet circuitry is 115 volts and
the condensing unit is 208-230 volts in which the wiring includes a neutral and a
mechanical ground. This wiring should be connected to the appropriate power
source by a qualified electrician and must conform to all local electrical codes.

SPECIAL VOLTAGE CONNECTIONS

When models are ordered from the factory with special, optional voltages,
connections should be made as required on the electrical wiring diagram provided
on the upper cabinet end panel next to the electrical console box.

- 9 -