SERVICE MANUAL WALK-IN COOLERS AND FREEZER IM-268S-11 Routine maintenance 2 Safety Walk Strips 2 Gaskets Replacing magnetic gasket on hinged Walk-In doors Replacing wiper gasket at bottom of hinged Walk-In door 3 3 Hinged Walk-In Doors Replacing the D-1000 touch latch on Walk-In doors Replacing D-1250 spring loaded hinges on Walk-In door panels Shimming Walk-In door hinges 4 5 5 Anti-Condensate Heaters Replacing anti-condensate heater element around door frame of hinged Walk-In doors 6 Reach-In Doors Replacing magnetic gasket on hinged Reach-In doors Adjusting self-closing hinges on Reach-In doors 7 7 Replacing hinges on Reach-In door panels 8 Replacing anti-condensate heater element around frame of hinged Reach-In doors 8 Pressure Relief Port Replacing klixon on Pressure Relief Port Replacing anti-condensate heaters on Pressure Relief Ports Replacing magnetic gasket on Pressure Relief Ports Door Closer Replacing Door Closer REV: 5/2013 9 9 9 10 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. 1 ROUTINE MAINTENANCE A. Keep all walkway surfaces clean and free of spilled liquids and food particles. B. Walk-In panels and magnetic door gasketing should be periodically wiped clean with a damp cloth. Use only mild soap to clean the panels: never abrasive pads or powders that could mar the finish. Remove all soap film and thoroughly dry with a clean cloth. Protect Digital and Electronic Alarms from moisture, or warranty is null and void. C. Never flush the inside of the Walk-In with water. Use a clean damp mop or rag when cleaning spills on the floor. D. Heater wires should be checked for proper function. Feel for warmth around the door frames on hinged entrance doors and pressure relief port doors, if applicable. Note: Condensation or Ice buildup around doors may indicate leakage or heater failure. Contact a serviceman immediately. E. Keep door gaskets clean with a solution of water and mild soap. F. Inspect refrigeration units frequently for proper function of evaporator & condenser fan motors, drain pan heaters, defrost controls, and drain line heaters. Condensate water must never be permitted to drip on the Walk-In floor. Drain pan or drain line heater failure will result in ice buildup and Evaporator damage. Refer to the Refrigeration System Instructions for proper drain pan and condensate drain line instructions. G. Don’t overload the Walk-In with product. Maintain orderly storage to permit good airflow within the unit. H. Inspect the condition of abrasive anti-skid strips monthly. Replace or add additional strips when necessary. REPLACING SAFETY WALK STRIPS A. Remove old worn Safety Walk Strips from Walk-In floor, ramps, or a stepplate. See figure 1. B. Clean and completely dry areas where new strips are to be placed. C. Install new strips on to the Walk-In floor pressing them firmly in place. Figure 1 2 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. GASKETS Replacing magnetic door gasket on Hinged Walk-In doors A. Remove the old gasket and clean the surface where the new gasket will be placed. B. Position the new gasket, starting at the top corners. Tap it into place with a wood block and hammer. Do not stretch the gasket to make it fit. Be sure the gasket lies flat. See Figure 2. C. Check door for proper operation and seal. Figure 2 Part Numbers: #016543 – 24” x 78” #017402 – 30” x 78” #017403 – 30” x 84” #016546 – 34” x 78” #016547 34” x 84” #054117 – 36” x 78” #054119 – 36” x 84” #032999 – 42” x 78” #032999 – 42” x 84” #016548 – 48” x 84” #016549 – 60” x 84” A. Open the door 90 degrees. B. Grasp the old gasket and pull it away from the interior skin of the door. Clean the surface where the new gasket is to be placed. C. Position the new gasket; tap it into place with a wood block and hammer. Do not force the gasket into place; excessive force may damage the door cap. D. If the gasket binds when the door is closed, the gasket is too wide. Be sure the gasket is properly centered, and trim the ends as needed. See Figure. 3. Figure 3 Part Numbers: #016614 – 30” Door #016611 – 34” Door #054028 – 36” Door #016612 – 42” & 48” Doors #016613 – 60” Door REV: 5/2013 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. 3 HINGED WALK-IN DOORS Replacing the D-1000 touch latch on Walk-Ins A. Remove the defective latch assembly. First remove the handle spring clip from under the handle at the back of the latch base, using a pair of needle-nose pliers. See Figure 4. B. Using a hammer and punch, drive out and remove the latch handle pin from the handle. Remove the three ¼-20 oval-head machine screws from the latch base and remove the base. C. From the inside of the Walk-In, drill out the roll pin from the safety release handle and remove the handle. (Doors prior to 1995) Current production doors are provided with an interior mounted safety knob which is threaded directly onto the strike bolt. Loosen the allen screw located in the side of the knob using a 5/32 allen key and turn counter clockwise until disengaged from the strike bolt. Pull the strike bolt from the outside away from the Walk-In wall. The strike plate will fall away. D. Secure the new D-1000 latch base to the Walk-In door with three ¼-20 oval-head machine screws. E. Insert the new strike bolt with attached strike plate into the holes on the door jamb panel. F. Screw the new inside knob onto the strike bolt until adequate tension is applied to the rod to hold the assembly firmly in place. Tighten the set screw on the side of the knob using a 5/32 allen key to allow for ¼ turn safety release operation Check to be certain that the “T” rod rotates freely when turning the inside knob. G. Insert the latch handle spring into the indicated hole on the latch base. Slip the latch handle over the latch base and align all holes. Be sure the latch handle spring engages the latch handle tab on the underside of the handle. Insert the latch handle pin through the handle and base. Using needle-nose pliers, insert the spring clip through the slot in the latch base assembly. Make certain to align the slot in the latch handle pin with the slot in the base before inserting the clip. This will firmly secure the latch handle in place for use. H. Open and close the door several times to assure proper operation of the latch. Figure 4 4 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. Replacing D-1250 spring-loaded hinges on Walk-In door panels A. Close the door. Securely hold the door in place by shimming between the outside doorcap and the door frame. Remove the slotted machine screws from the hinge base and blade. If tamperproof screws are used See Figure 5. Remove the defective hinge assembly. Secure the new hinge assembly with a screwdriver by tightening the machine screws in the same holes. B. Remove the shims from around the perimeter of the door frame. C. Open the door and check for proper operation and seal. Figure 5 Shimming Walk-In door hinges A. If the Walk-In door is installed properly, no shimming is required. Shim only where misapplication or poor installation of the door panel have caused the door cap to seal improperly. If the door cap toes outward at the top or bottom of the latch side of the panel, shim the diagonally opposite hinge base outward, forcing the corner of the door cap back into alignment with the door frame for a positive seal. See Figure 6. B. To shim hinges on Walk-In doors, loosen the machine screws on the base of the hinge enough to slip the required number of shims into place behind the base. See Figure 7. Where tamper-proof screws are used, loosen them by tapping the screw head counterclockwise with a center-punch and hammer as shown in Figure 5. C. Retighten machine screws and check door cap for proper seal. Bally also offers a screw remover tool. Call the factory for details. Figure 6 Figure 7 REV: 5/2013 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. 5 ANTI-CONDENSATE HEATER Replacing anti-condensate heater element around door frame of hinged Walk-In doors A. Disconnect the outside power source leading to the door frame light junction box. Open the door 180 degrees. A large piece of cardboard can be used to close off the open doorway until the heater is replaced. B. Remove the light switch on the exterior of the door panel. Disconnect the heater wire leads by unscrewing the wire nuts. Remember how the wires are connected so you can attach the proper leads on the new wire. C. Remove the screws from the door strikes around the door frame. Remove the strikes. See Figure 8. D. Remove the screws which secure the stepplate. Remove the stepplate. E. Remove the defective heater element from the door frame and the grooved hardboard at the base of the frame. Take note of the position of the heater element in the grooved hardboard before removing it. (For replacement or updated heaters, a new hardboard will be supplied with an installation diagram.) F. Apply a small bead of silicone caulking around the perimeter of the door frame to retain the new heater element until the door strikes can be reinstalled. G. Guide the leads of the new heater element into the switch box containing the light switch. Note: Only heater wire leads are to protrude into the switch box-- this will prevent premature heater burnout. Press the heater element firmly into the corner around the perimeter of the door frame. Locate and press the heater element back into the grooved hardboard exactly the same way it was removed. When the heaters are first energized, they will contract. If the wire is not pressed into the corners, it could short out by pulling too tight against the edges of the strikes and sillplate. H. Replace and secure the stepplate to the Walk-In floor. Replace the door strikes. Be careful not to pinch the wires when remounting the hardware. I. Reconnect the new heater element to the heater wire leads. Recaulk the opening in the door frame where the heater wire passes through into the junction box. This is very important. J. Re-energize the outside power source to the door frame light junction box. Check for proper operation. Figure 8 6 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. REACH-IN DOORS Replacing magnetic gasket on Reach-In doors A. To replace the magnetic door gasket, it may be necessary to remove the door from the Walk-In. Simply open the door and lift it off the hinge bases. Lay the door facedown on a flat working surface. B. Remove the defective gasket and clean the surface where the new gasket will be placed. C. Position the new gasket and tap firmly into place with a wood block and hammer. Be sure the gasket lies flat. See Figure 2. D. Place the door back on the hinges. Check the door for proper operation and seal. Part Numbers: #016582 – 18½” x 30” #016584 – 20” x 30” #016583 – 30” x 30” Adjusting self-closing hinges on Reach-In doors A. Do not oil door hinges. If dirt accumulates on the Delrin cams and causes them to bind, apply dry silicone spray lubricant. B. Begin by determining whether the hinge is correctly adjusted. When the strap of the hinge is flush with the flange, there must be clearance as shown in Figure 9. Without clearance, the door may not close. Adjust the hinge by following these steps: 1. Open the door 90 degrees and lift the door from its hinge bases. 2. Adjust the hinges as shown in Figure 10 a. Put a pencil mark on cam and on hinge; this enables you to see how much the cam is being turned. b. Loosen bottom nut and turn half way off. c. Tap against bottom of nut with a hammer until pin and cam are loose. The reason for this is the pin has a tapered shaft. d. Turn cam in direction of the arrow in increase clearance; opposite direction to decrease. e. Hold cam in position and tighten bottom nut securely. 3. Replace the door on its hinge bases. Check to make sure door operates properly. Figure 9 REV: 5/2013 Figure10 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. 7 Replacing hinges on Reach-In door panels Figure 11 A. Close the door and shim the cap securely around the perimeter of the frame. Remove the slotted machine screws from the hinge base and blade. If tamperproof screws are used Refer to Figure. 5. Remove the defective hinge assembly. See Figure 11. B. Secure the new hinge assembly using a screwdriver to tighten the slotted machine screws in the same holes. C. Remove the shims around the perimeter of the door frame. D. Open the door and check for proper Replacing anti-condensate heater element around door frame of Reach-In doors A. De-energize the outside power source leading to the door frame junction box. Open the door a full 180 degrees and lift it from the hinge bases. B. Remove the screws from the stainless steel door strikes around the door frame. Remove the strikes. See Figure 12. C. Remove the cover plate from the junction box on the inside of the door frame. Locate and disconnect the defective heater element from the door frame. D. Remove the defective heater element from the door frame. E. Apply a small bead of silicone sealant around the perimeter of the door frame to retain the new heater element. Press the new heater element firmly into the corner around the perimeter of the door frame. The heater element may also be taped into position with UL-approved electrical tape.(Remove) See Figure 12. Run the heater leads into the junction box. F. Reconnect the heater element to the outside power source. Recaulk the opening in the door where the heater wire passes into the junction box. G. Replace the door strikes and junction box cover plate. (Be careful not to break or pinch the heater element.) Replace the door on the hinge bases. H. Re-energize the power source to the door frame junction box. Check the door for proper operation and seal. 8 Figure 12 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. Pressure Relief Ports (PRP) Figure 13 Replacing magnetic gasket on PRP A. Remove the port door by removing the screws from the poly-hinge at the top of the port door. See Figure 14. B. Remove the interior plastic panel from the door by removing the screws around its perimeter beneath the magnetic gasket. C. Remove and discard the defective gasket. D. Position the new gasket (#016597) and the interior plastic panel on the door; secure with screws. E. Reinstall the port door. Replacing anti-condensate heaters on PRP A. Disconnect the power supply at its source, and remove the port door by removing the two screws from the polyhinge at the top of the door. See Figure 14. B. Remove the stainless steel door strikes by removing the two screws in the top and bottom flanges. C. Disconnect the defective anti-condensate heater in the junction box at the top of the door. Discard the old heater. D. Insert the new heater (#015628) and reassemble the door strikes. Exercise care not to pinch the heater wire beneath the door strikes. E. Replace the port door and refasten the screws. F. Reconnect the electrical power. Figure 14 Replacing klixon on PRP A. Disconnect power at its source, and remove the electrical junction box cover above the port. B. Remove the screws located in flanges on the exterior of the port, and lift the unit from the panel. C. Disconnect the appropriate wire nuts in the junction box. Remove and replace the defective klixon (#017083). See Figure 15. D. Caulk around the perimeter of the opening, and replace the port. Rewire and replace the junction box cover. Reconnect electrical power. See Figure 16. Figure 15 Figure 16 REV: 5/2013 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc. 9 Replacing Door Closer A. Position a putty knife against the base of the bottom of the closer cover to protect the door surface as shown. See figure 17. Pry open the cover using a small flat bladed screw driver. The closer cover is friction fit onto its base and will pry out and upward away from the door. B. Remove all mounting screws from the closer base on the door and from the “J” hook mounted on the door frame. C. Install new closer and “J” hook onto door and frame using the existing holes. If for any reason the existing holes do not line up with the holes in the new closer you will be required to drill and tap the door at the location of the holes for the new closer mounting base. Once firmly secured, rotate the cover back down over the base and snap into place. D. Adjust the “J” hook, if required, to align the rubber wheel of the closer with the tip of the hook. When properly aligned the tip of the hook should touch the top of the rubber wheel as the wheel passed into the hook. Figure 17 Part Number: #031349 – Dictator Hydraulic Door Closer V1600B 10 IM-268S-11 2013 © Bally Refrigerated Boxes, Inc.