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Bally Installation Manual

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BALLY REFRIGERATED BOXES, LLC
135 LITTLE NINE DRIVE, MOREHEAD CITY, NC 28557 100 MILLARD DRIVE, HENDERSON, TX 75652 1829 COUNTY LINE ROAD, BARTO, PA 19504 800-242-2559 903-657-2377 800-344-9302

INSTALLATION MANUAL
Bally pre-engineered walk-in coolers/freezers

Proven dependable

Instruction Manual IM-268-10 Copyright 2010 Rev. Oct. 2010

INSTALLATION INSTRUCTIONS WALK-IN COOLER/FREEZER Part 1 - Preparation
1. Before attempting to install the Bally Walk-In, review these instructions and any oth
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Page 1: Bally Installation Manual

BBAALLLLYY RREEFFRRIIGGEERRAATTEEDD BBOOXXEESS,, LLLLCC

113355 LLIITTTTLLEE NNIINNEE DDRRIIVVEE,, MMOORREEHHEEAADD CCIITTYY,, NNCC 2288555577 880000--224422--22555599 110000 MMIILLLLAARRDD DDRRIIVVEE,, HHEENNDDEERRSSOONN,, TTXX 7755665522 990033--665577--22337777 11882299 CCOOUUNNTTYY LLIINNEE RROOAADD,, BBAARRTTOO,, PPAA 1199550044 880000--334444--99330022

IINNSSTTAALLLLAATTIIOONN MMAANNUUAALL Bally pre-engineered walk-in coolers/freezers

Proven dependable

Instruction Manual IM-268-10 Copyright 2010 Rev. Oct. 2010

Page 2: Bally Installation Manual

INSTALLATION INSTRUCTIONS WALK-IN COOLER/FREEZER

Part 1 - Preparation 1. Before attempting to install the Bally Walk-In, review these instructions and any others

supplied with the shipment. A plan view showing the proper layout of panels is enclosed with other important documents you will need for the installation. Make sure that you are using the “As-Built” drawings as opposed to any previously supplied “Prosposal” drawings. You will find these documents in Miscellaneous Box #1 with the orange sticker. Open this box and review its important contents.

2. When the building is delivered, make sure you have the appropriate number of personnel necessary to unload the truck. The delivery company is most likely on a schedule and will require your crew to complete the unloading in a reasonable amount of time depending on the size of the Box. In all situations, one person is NOT enough to unload the truck(s).

3. As you are unloading the panels, be on the look out for freight damage. The refrigeration

units and panels left our factory in perfect condition. Once the Bill of Lading was signed by the carrier, the equipment became your property. Safe delivery of this shipment is now the responsibility of the carrier. If any damage is noted or if the number of pieces received does not agree with the Bill of Lading, do not accept shipment without shortage or damage noted on the freight bill by the carrier’s agent. Failure to do so will jeopardize recovery in a freight claim situation. If any damage or shortage is discovered when unpacking, leave material and packing as is and request an inspection by the carrier. Make your claim promptly. The transportation company will not consider a claim unless it is presented within six months from the date of shipment. Support your claim with the original Bill of Lading, freight bill, and original invoice. Carrier’s agent will assist you in preparing a claim.

4. Use extreme caution when unpacking to prevent damage to panels and other equipment.

Door sections are the most difficult to handle; please pay particular attention to the hardware affixed to the door and door-frame. Do not lift the door by its Hardware or the Light Base. Do not drop panels or slide over unfinished surfaces. Keep panels dry and out of direct sunlight if possible.

5. As panels are unloaded, sort them by type—ceiling, floor vertical etc; this will save time in

assembly. Familiarize yourself with the panels and the finishes; often the equipment will have different finishes on ceilings, floors and unexposed surfaces. Double check panel count against the packing list and Plan View supplied in Miscellaneous Box #1 as described above.

6. Consider removing protective plastic coating before installion panels: this could be done at

the end of the install depending on timing of construction schedules. 7. Preparation of Site for Assembly of Cooler or Freezer - The most important factor when

preparing to install a Bally walk-in is to make certain the floor is level. Typically, installing a box on a level floor will result in a very smooth process. If the floor is not level. Use a laser level or transit to identify the high spots on the floor. We recommend using asphalt shingles as the most efficient way to shim. There are many materials that can be used but realize that floor leveling is the most important step in the process. If the floor’s surface is

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new poured concrete, it is important to provide adequate ventilation. Concrete and tile grout release hydrogen while curing which can damage Bally panels.

8. Operation of the Bally Speed Lock: before attempting to erect panels, familiarize yourself

with the operation of the locks. On Bally panels, locks will always be on the left turning in clockwise rotation. If for any reason you have to unlock a panel, be sure to reset the cam stop by turning the lock fully back to its original position. We refer to this as resetting the cam. Check speed lock for obstruction, e.g. foam, dirt etc. and clean if necessary. In the event of a broken or stripped hook, Bally provides several replacements in Miscellaneous Parts Box #1 as described above. See illustration:

9. Check that the building walls that the walk-in is to be erected against are square and plumb.

If the walls are not plumb, this fact will have to be taken into account when erecting the sidewalls. Lay out the exact dimension of the walk-in with chalk line. Re-check dimensions and check layout. If refrigeration and coil drain tubing is to be run between walk-in and building wall allow sufficient space for ease of installation. If this is not the case, the walk-in may be set up no closer than 2” from the building wall, provided the wall is plumb and square. Look up; make sure there is not any steel or overhead device hanging down below the height of the new walk-in’s location that will become a problem.

PART II ERECTING BALLY WALK IN PANELS

Enclosed you will find a floor plan view of the walk-in you have purchased. Locate and tag all special panels (marked with blue stickers). Become familiar with the

Bally nomenclature and labeling system (see page 12).

Walk-Ins erected near building walls must be positioned with a minimum 2” clearance to allow for air flow circulation and prevent possible condensation on the exterior surface of the walk-in. Depending on temperature and humidity, air circulation may be needed to equalize the air temperature and the panel surface temperature above the dew point. This is usually required in a dead air space and a high humidity environment.

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1. Installing Less-Floor Walk-ins – Make sure building floor is leveled. Using a transit or builders level, locate the highest point on the perimeter. Position the first 12 X12 corner to be level with the high point. Begin at a corner and align panels at the top Shim below panels to match the high panel. Use a plumb bob to keep verticals plumb. See illustration:

Incorrect Correct

Prior to engaging vertical panel to full locking position, check metal to metal alignment at points indicated. This will assure you of a neat installation and maintain all panels on a true horizontal plane

2. Position a vertical panel to the left and right of the corner panel per plan view. Once these

panels have been positioned and aligned properly, fully engage all vertical to vertical locks. Lock panels from the top vertical speedlok hole down to the bottom speedlok hole. See illustration below, left. Shim panels to the high point of the floor. Use a level or plumb bob to determine vertical squareness. See right illustration below, right.

3. If Bally Foam Screeds are provided, lock them to panels before placing verticals. Vinyl floor

screeds are anchored to concrete in less-floor walk-ins via drive pins with sleeve anchors provided by Bally. Drill into the concrete or other surface with a masonry bit. When using vinyl screeds, make sure panels are level inside the screed. Leveling can be accomplished with Masonite shims or shingles. If being installed on quarry tile, floor holes may be drilled to hit tile seams. Check all dimensions before proceeding.

4. When enough vertical panels are set to accept the installation of the first ceiling end panel,

begin assembly of ceiling panels.

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5. When erecting a door panel for installation on a concrete floor, it is necessary to provide a cutout in the concrete floor for all freezer applications. This is because the heater channel must be below grade to prevent icing at the sill. Cooler doors are set directly on top of the concrete surface.

6. If your door sticks out at the top, your frame is not plumb; you’ll need to move the bottom of

frame in or out to correct this problem. If the gap at the top of the door is inconsistent, your frame is not level and the door latch may not work properly. Shim one side of the frame to raise the low side of the door frame.

7. Caulk and seal any gaps under panels or door to floor. Apply base trim as per plan view. For

outdoor installation it is recommended that all exterior panel joints be caulked during installation.

8. Anchor panels to floor using either Continuous Angle provided or, for outdoor boxes,

L-bracket attachments known as WA-1’s and WA-2. See illustration:

9. Installing With-Floor Walk-ins – Make sure the building floor is level. The entire area

beneath walk-in floor should be covered with a heavy polyethylene vapor barrier to prevent possible damage by moisture.

10. Check drawings for any special panel configuration, then place a 23.5” wide floor end panel

along the most logical starting point, usually the furthest corner. Be sure the panel is a floor panel; all floor panels have extra heavy gauge metal on the interior. It is best to start the install next to a building wall, if possible. Set the first floor panel section in place, then install the next floor section and align with the panel next to it. Leveling needs to take place as each panel is installed. Make sure panels are leveled to the high point of the concrete slab. Continue installing floor panels until the last floor panel is in place.

11. Install shims under corners and across panel joints as needed to ensure proper support and

levelness of panel. Be sure the shims are not more than 23” apart at any given point under the panel. Shimming done properly will eliminate any potential sagging. Follow Plan View.

12. Check bottom section of door to be used to insure the proper door is being used in the proper

location. A freezer door may have a different stepplate condition than a cooler door. Doors are specifically located by the floor plan drawing which is enclosed with the installation instructions. Follow the suffix 01 – 02 that corresponds to the drawing.

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13. VERY IMPORTANT: If structural steel is required, it should be located and installed before going further.

14. Start at a convenient corner and assemble wall and corner sections. If walk-in is to be

erected in a corner or against a building wall, it is advisable to start in that corner. Start by setting a corner section in place and fastening an adjoining panel to hold the panels in place. Refer to the floor plan for proper location of each section. Line up the top edges and the surfaces of each panel before locking. Check each lock to ensure it is engaged in the pin box properly. Check to be sure that the proper metal finish is exposed where specified on the plan view.

15. When enough vertical panels have been set to allow installation of the first ceiling panel,

install the panel walls in an order that will allow a ceiling section to be installed before proceeding with more panel walls. The ceilings should-be fastened to each other. When two or three ceiling panels are in place, lock the first ceiling end panel to verticals to prevent the others from shifting. A quick and accurate way to check for correct alignment is to measure the distance from the edge of the ceiling or floor to the nearest vertical panel joint. This measurement must be 11.5 inches; it must be maintained at every joint to assure proper assembly of the walk in (see illustration below left). Use an alternate locking sequence on the vertical panels (see illustration below right). This will help keep panels plumb and square. Always plan for a corner panel to be the last wall section installed. Lock vertical panels to ceiling and floor panels after aligning verticals to each other.

16. When all walls and ceiling panels are in place, lock all vertical panels to floor panels (if

applicable). Door sections are held down through the threshold plate. Drill through

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threshold's pre-drilled holes into floor. Secure to floor with screws provided (see illustrations below).

17. For a walk-in requiring anchors on the outside of the walls, begin by centering anchors WA-3

to vertical panel joints and WA-4 to corners (see illustration below).

18. Installing Multi-compartment Walk-ins: the most common arrangement for a walk-in is a

two compartment Cooler/Freezer combination. Installation of panels in this situation is the same as described above. The use of a “Breaker” or “Tee” panel is used to separate the

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different compartments. These panels will be either 23” or 46”; typically the verticals are the opposite of the ceilings and floors.

19. The Partition Wall will have at least two special panels referred to a “P-1” and a “P-2”. The

panel widths are either 7.6” or 19.1” and are marked with a special blue sticker that corresponds to the drawing. The P-2 panels are a double tongue panels (has hook pockets on both sides) which allows for final locking of the partition wall

20. In large multi-compartment walk-ins, (three compartments or more) it is very important to

control the alignment of the panels and make sure if there is any growth in the vertical panels that they are growing at the same rate as the ceiling and floors. A quick and accurate way to check for correct alignment is to measure the distance from the edge of the ceiling to the nearest vertical panel joint. This measurement must be 11.5 inches; it must be maintained at every joint to assure proper assembly of the walk in. In these instances we recommend that after the floors are placed and leveled that the center most partition be the starting point and to work toward either end of the box.

21. Look at the plan view and take special note of which side of the panels the wrench holes are

on. If there is not a door in the partition wall the panels will lock to ceiling and floors in either orientation. An error on the partition wall could cost many man hours to correct. The entire box will most likely have to be taken down to correct this error because of condensation that will occur. As a general rule of thumb, the wrench holes should always be on the colder compartment side, usually the freezer.

22. Completing the Bally Install: Trim door wiper gaskets (if necessary) from the inside bottom

of door. The wiper gasket should gently touch the threshold when the door is in the closed position. Adjust hinges and latch if necessary (shims provided in Misc. Box).

23. After all locks are engaged, it is very important to secure the plug buttons over the speed-lok

holes. These buttons are located in the Miscellaneous Box #1. 24. Make sure all of the protective plastic is removed from the panels and the job site debris is

cleaned up. 25. Inform the electrician that he is now able to complete connections to door light and Pressure

Relief Port (if on a separate circuit). Please note that it is not recommended to hook up door heaters until the mechanical refrigeration is fully operational. The heat will melt the door gasket.

26. After the installation is complete, use a silicone caulk between the outside vertical panels and

the concrete floor. If large gaps exist, make certain to first fill the voids with expanding foam prior to sealing with caulk. Apply sealant to building floor for water-tight seal.

27. If installing an outdoor Bally Box with a membrane roof, make sure all the termination bars

are securely fastened and that all exterior joints have been caulked to prevent water leaks in driving rain events. All outdoor walk-ins require some form of roof protection. Please see “Installation Instructions for Membrane Roof”. We also can supply a standing seam aluminum roof where specified. Bally will provide separate installation instructions as needed for these products.

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28. You are now ready to hang evaporators and connect refrigeration. See separate installation instructions supplied by the manufacturer of the refrigeration’s mechanical equipment.

PART III OTHER IMPORTANT INFORMATION 1. Vapor Leaks Because they are molded in massive steel fixtures, modular panels are

square and dimensionally accurate. In most installations they will seal effectively against vapor leaks. However, in some unusual cooler applications, minor vapor leaks may occur.

a. The leaks can occur if the panels follow slab variations or if the building in which the walk-in is installed settles. If the internal temperature is cycled periodically, the expansion and contraction of building materials will cause enough movement to allow some vapor penetration.

b. Unfortunately, internal dripping does not always occur directly across from the vapor leak. Locating a leak can therefore be troublesome. In order to avoid time-consuming search procedures, caulk the exterior junction of three or more ceiling panel joints (see illustration below left). Most leaks caused by settlement will be at these points.

c. All penetrations should be sealed. This includes any protruding clips or hangers installed in panel joints (see illustration below right). Use either industrial-grade or silicone caulking. When silicone is used, sealed areas must be cut open whenever the panels are to be disassembled for relocation or enlargement.

2. Making holes for refrigeration tubing and electrical lines

A. When a remote refrigeration system is used, it will be necessary at the job site to make holes for refrigeration and electrical lines. After installation, use permagum to caulk around the electrical and refrigeration lines. Caulk both the interior and exterior gaps.

B. Condensation in electrical junction boxes and lights is caused by warm vapor passing from the exterior to the interior of the walk-in through electrical conduit lines. This problem can be eliminated by installing a seal-off fitting in the conduit line where it

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passes through the wall. Install the fitting as shown in illustration below and fill it with sealant.

3. Making electrical connections to entrance doors and installing vapor-proof light

a. Electrical connections to the walk-in doors are made at the top interior of each door panel. Remove the socket plate to expose the wire connections in the junction box.

b. Remove the short wire “pigtails” and connect the service at the wire nuts, through the hole provided in the junction box.

c. Refer to serial tag for proper electrical characteristics. Insure that the electrical service is properly grounded.

d. Note: Do not turn on power to door section until after the refrigeration system has been started.

e. Remount the vapor-proof light assembly after all connections have been made. f. See electrical diagram next page.

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Typical Bally Door Wiring Diagram

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4. Understanding Bally Nomenclature

Bally identifies panels with barcode labels that specify: a. Panel type

• FLR floor • CLG ceiling • V vertical • VC vertical corner • BKR breaker

b. Panel dimensions c. Panel interior and exteriors finishes

• Finishes always listed as “exterior/interior” • EW embossed white galvanized • GM galvalume • SM smooth aluminum • SS stainless steel • ST stucco aluminum

d. Bally part number and serial number e. Listed below are some typical panel descriptions:

46V106 5O IPH EP GM/EW = 46” wide vertical, 106” long, 5” thick, interior plain with holes, exterior plain, galvalume exterior, embossed white galvanized interior

12VC82 4H IPH EP ST/SM = 12” vertical corner, 82” long, 4” thick, interior plain with holes, exterior plain, stucco aluminum exterior, smooth aluminum interior

FLR 4 ENH 23.5 X 8 EW/SS = floor, 4” thick, end no holes, 23.5” wide, 8’ long, embossed white galvanized exterior and stainless steel interior

CLG 4 BKR 46 X 8 GM/GM = ceiling, 4” thick, breaker, 46” wide, 8’ long, galvalume exterior and interior

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113355 LLIITTTTLLEE NNIINNEE DDRRIIVVEE,, MMOORREEHHEEAADD CCIITTYY,, NNCC 2288555577 880000--224422--22555599 110000 MMIILLLLAARRDD DDRRIIVVEE,, HHEENNDDEERRSSOONN,, TTXX 7755665522 990033--665577--22337777 11882299 CCOOUUNNTTYY LLIINNEE RROOAADD,, BBAARRTTOO,, PPAA 1199550044 880000--334444--99330022

Bally Installation Help (800) 344-9302 BALLY INSTALLATION/WALK-IN: 13