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1000R
Service Manual
76 pgs1.56 Mb2

Anthony 1000R Service Manual

Model 1000, 1000R & 1200R
Doors
2500/2700/3000)
Service & Installation
November, 2012
99-20439-I001
Model 1000/1000R/1200R Door Service & Installation
TITLE:
99-20439-I001 Model 1000/1000R/1200R Door Service &
Installation
REV.
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Table of Contents
1. Model 1000 Door (Non-Reversible) (Prior to 7/83) ............................................................ 5
1.1. Drawings & Schematics .......................................................................................... 6
1.1.1. Product Prior to 1987................................................................................. 6
1.1.2. Prior to 1984 .............................................................................................. 6
1.1.3. Torque Assembly (Prior to 1983)............................................................... 7
1.1.4. Model 100-100F (Prior to 1983) ................................................................ 7
1.1.5. Joining Two Frame Sections ..................................................................... 8
1.1.6. Brackets .................................................................................................... 8
2. Model 1000 Door (Non-Reversible) (7/83 to 1/87)............................................................. 9
3. Model 1000 Non-Reversible Door Installation (Prior to 1983).......................................... 10
4. Model 1000 Non-Reversible Door Handle Replacement ................................................. 11
5. Model 1000 Non-Reversible Door Handle Replacement ................................................. 11
6. Model 1000R Door (Reversible) (1987 to 1991) .............................................................. 12
7. Model 1200R Door (Reversible) (Start 10/89) ................................................................. 13
8. Model 1000, 1000R, 1200R Frame (Reversible) ............................................................. 14
9. Models 2500, 2700, 3000 – Pass-Thru Doors (Start 1987) ............................................. 15
10. Models 1000R, 1200R (Reversible) Frames – End & Center Sections, Full Flange
Construction .................................................................................................................... 16
10.1. Flange Placements ............................................................................................... 16
10.2. Finished Frame Width Dimensions ....................................................................... 17
10.3. Finished Frame Width Dimensions ....................................................................... 17
11. Frame Installation ............................................................................................................ 17
12. Reversible/Cordless Door & Hold-Open Installation ........................................................ 19
13. Hold-Open Replacement (Prior to 1987) ......................................................................... 21
14. Hold-Open Replacement (1987 to 1990) ......................................................................... 22
15. Hold-Open Replacement (1987 to 1990) ......................................................................... 22
16. Hold-Open Replacement (1987 to 1990) ......................................................................... 23
17. Models 2500, 2700 & 3000 Pass-Thru Door Installation ................................................. 23
18. Pass-Thru Identification ................................................................................................... 24
19. Pass-Thru Wiring Schematics ......................................................................................... 24
20. Reversing Frame Hardware (1987 to Present) ................................................................ 24
21. Door Reversing Instructions (1987 to 1990) .................................................................... 25
22. Door Reversing Instructions (1991 to Present)................................................................ 28
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23. Wiring Instructions (1991 to Present) .............................................................................. 29
24. Frame Sill Plastic Protector Installation ........................................................................... 30
25. Ordering Replacement Doors .......................................................................................... 30
26. Torquemaster and/or Torque Casting Replacement........................................................ 31
27. Door Plastic (Cover) Replacement .................................................................................. 31
28. Door Handle Replacement .............................................................................................. 32
29. Side Access Plate Replacement...................................................................................... 33
30. Door Heater and/or Door Plug Replacement (Prior to 1987) ........................................... 33
31. Door Heater Replacement (1987 to 1991)....................................................................... 34
32. Door Heater Replacement (1987 to 1991)....................................................................... 35
33. Frame Single Station Socket Replacement ..................................................................... 35
34. Hinge Pin Replacement (1987 to 1991)........................................................................... 36
35. Torque Rod Replacement (1987 to 1991) ....................................................................... 37
36. Torque Rod Replacement (1991 to Present) ................................................................... 38
37. Front Bumper Bar Field Installation ................................................................................. 38
38. Flush Mount Lock Field Installation ................................................................................. 39
39. Door Cylinder Lock Replacement or Repair .................................................................... 39
40. P.O.M. Lock Installation................................................................................................... 40
41. P.O.M. Lock Retrofit Installation ...................................................................................... 41
42. Ordering Replacement Frames ....................................................................................... 42
43. Glass Replacement (Reglazing) ...................................................................................... 44
44. Frame Gasket Replacement – Models 1000, 2500, 3000 (Before 1981)......................... 46
45. Frame Gasket Replacement – Models 1000R, 1200R, 2500, 2700 (1981 to Present).... 47
46. Frame Junction Box Wiring (Standard Production).......................................................... 47
47. Heater Wire Diagram: Models 1000, 1000R, 1200R, 2500, 2700, 3000.......................... 48
48. “Boost & Buck” Transformer Wiring Diagram................................................................... 48
49. Pre-Wired Ballast Replacement (8G-4039W-02) (1984 to Present) ................................ 49
50. Raceway Clip Installation or Replacement (Start 1/1/93) ................................................ 50
51. Ballast, Lamp & Heater Wiring Diagram Models 1000R, 1200R (120 Volt) (1984 to
Present) ........................................................................................................................... 51
52. Ballast Wiring Diagram Models (Prior to 1984)................................................................ 52
52.1. Model 1000 Coolmaster™ Normal Temp (Also Model 100 Normal Temp) ........... 52
52.2. Model 1000 Coolmaster™ Normal Temp (Also Model 100 Normal Temp) ........... 52
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53. Ballast Wiring Diagram for One- and Two-Light Ballasts (Prior to 1984) ......................... 53
53.1. Model 1000 Frame and Door Wiring Diagram ...................................................... 53
53.2. Model 1000 Light Wiring Diagram for One- and Two-Light Ballast ....................... 53
54. Light Bulb Replacement................................................................................................... 54
55. Light Channel Replacement ............................................................................................ 54
56. Light Socket Replacement............................................................................................... 55
57. Lamp Location: Reversible Models 1000R, 1200R (Prior to 1986).................................. 55
58. Lamp Locations: Cooler Door Lighting (1986 to Present) Models 1000R, 1200R ........... 56
59. Lamp Locations: Cooler Door Lighting (1986 to Present) Models 1000R, 1200R ........... 57
60. Model 1000R, 1200R Shelf Assembly ............................................................................. 58
61. Model 4000 Shelf Assembly ............................................................................................ 59
62. Shelving Installation and/or Replacement (Prior to 1984)................................................ 59
63. Four-Post Stabilizer Bar Installation ................................................................................ 61
64. Four-Post Shelving System Installation (After 1984) ....................................................... 62
65. Plastic Tag Molding Installation ....................................................................................... 63
66. Humastat Installation Procedure...................................................................................... 64
67. Electrical Information for Model 1000R Normal Temp Doors, Frames & Light Fixtures
(Heater Amperages @ 120 Volts).................................................................................... 66
68. Heat Load in BTU/Hr for Glass, Door Rail, Frame Heaters and Lights (Per Door, with
Doors Closed @ 75°F Store Ambient)............................................................................. 69
69. Electrical Information for Model 1200 Normal Temp Doors, Frames & Light
Fixtures (Amperages @ 120 Volts).................................................................................. 71
70. Heat Load in BTU/Hr for Glass, Door Rail, Frame Heaters and Lights (Per Door, with
Doors Closed @ 75°F Store Ambient)............................................................................. 72
71. Troubleshooting............................................................................................................... 73
72. Safety Precautions .......................................................................................................... 74
73. Tips.................................................................................................................................. 75
74. Dew Point Chart .............................................................................................................. 75
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1. Model 1000 Door (Non-Reversible) (Prior to 7/83)
Description
Description
Description
1. Heater Wire 10. Safety Clip 19. Torque Casting
2. Plastic 11. Camel Back Hinge Pin 20. Female Plug
3. Door Rail 12. S.J. Cord 21. Door Stop Assembly
4. Contact Plate 13. Camel Back Hinge 22. Door Stop Sliding Block
5. Handle 14. Camel Back Hinge Pin Holder 23. Door Stop Nut & Bolt
6. Handle Screw 15. Camel Back Washer 24. Slide Stop Bumper
7. Corner Screw 16. Adjustment Pin 25. Hold-Open
8. Top Hinge Pin 17. Torque Rod 26. Door Stop Sliding Block Screw
9. Top Hinge Pin Holder 18. Set Pin 27. 10” Door Stop Arm
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1.1. Drawings & Schematics
1.1.1. Product Prior to 1987
1.1.2. Prior to 1984
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1.1.3. Torque Assembly (Prior to 1983)
1.1.4. Model 100-100F (Prior to 1983)
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1.1.5. Joining Two Frame Sections
1.1.6. Brackets
Model 1000/1000R/1200R Door Service & Installation
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2. Model 1000 Door (Non-Reversible) (7/83 to 1/87)
Description
Description
Description
1. Door Rail 10. Safety Clip 19. Female Plug
2. Plastic 11. Male Plug 20. Door Stop Assembly
3. Heater Wire 12. Camel Back Hinge Pin 21. Door Sliding Block
4. Contact Plate 13. Camel Back Hinge 22. Door Stop Nut & Bolt
5. Handle 14. Nylon Washer 23. Bumper
6. Handle Screw 15. Camel Back Hinge Pin Holder 24. Torque Rod
7. Corner Screw 16. 10” Door Arm 25. Torquemaster
8. Hinge Pin 17. Block Screw
9. Pin Holder 18. Hold-Open
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3. Model 1000 Non-Reversible Door Installation (Prior to 1983)
1. Insert top of door into top hinge pin “A”.
Safety Precaution: Snap ring must be used on every door. Place snap ring on top hinge pin after installation of every door.
2. Lift up door and insert torque shaft “B” into socket “C”. Using two (2) long pins,
adjust torque to desired tension and set with one (1) short pin. Both long and short pins are provided.
Note: Do not over-adjust door as this will cause door to slam.
3. Connect 90° door stop arm “D” to slide block on frame. Secure with screw
provided.
4. Reverse instructions to remove door.
Caution: Before removing door, extract torque set pin and safety snap ring
with a pair of pliers.
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4. Model 1000 Non-Reversible Door Handle Replacement
1. To remove handle, insert 5/32” Allen wrench through back side of door frame. Handle
screws are contained in door frame.
5. Model 1000 Non-Reversible Door Handle Replacement
1. Door does not have to be disassembled to replace torque rod. Drive tapered shaft of
torque rod as shown below.
2. To replace new torque rod, align torque shaft with key way in door. Tapered shaft
must be driven flush with bottom of door.
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6. Model 1000R Door (Reversible) (1987 to 1991)
Description
Description
Description
1. Corner Piece 7. Door Plastic 13. Torque Rod
2. Corner Screw 8. Receptacle 14. Handle Screw
3. Glazing Channel 9. Camel Back 15. Handle
4. Heater Wire 10. Hinge Pin 16. Torque Rod (1987-1991)
5. Door Rail 11. Door Plastic 17. Hinge Pin (1991 to Present)
6. Contact Plate 12. Access Cover 18. Torque Rod (1991 to Present)
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7. Model 1200R Door (Reversible) (Start 10/89)
Description
Description
Description
1. Hinge Pin 8. New Hold-Open 15. Access Hole Cover
2. Molded Hinge Pin 9. Door Foam 16. Contact Retainer
3. Corner Screw 10. Handle 17. Glazing Channel
4. Corner Piece 11. Female Receptacle 18. Torque Rod
5. Door Extrusion 12. Door Foam 19. Corner Piece
6. Camel Back 13. Contact Plate 20. Door Cover (Hinge Side)
7. Old Hold-Open 14. Torque Rod
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8. Model 1000, 1000R, 1200R Frame (Reversible)
Description
Description
Description
1. Safety Cover 8. End Bracket 15. Hole Plug
2. Socket 9. Ballast 16. End Caps
3. Light Socket 10. Raceway Cover 17. Socket
4. Hold-Open 11. Bulb 18. Torquemaster
5. Gasket 12. Center Bracket 19. Heater
6. Frame Cover 13. Screw 20. Center Fixture
7. End Light 14. Installation Screw
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9. Models 2500, 2700, 3000 – Pass-Thru Doors (Start 1987)
Description
Description
Description
1. Hinge Pin 9. Corner Piece 17. Screw
2. Door Rail 10. Handle Screw 18. Heater
3. Camel Back Hinge 11. Handle 19. Mullion
4. Door Plastic 12. Rubber Flap 20. Frame Gasket
5. Contact Plate 13. Retainer 21. Torquemaster
6. Glazing Channel 14. Single Station Socket 22. Torque Rod
7. Door Heater 15. Hold Open 23. Female Receptacle
8. Corner Screw 16. Access Hole Cover
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10. Models 1000R, 1200R (Reversible) Frames – End & Center Sections, Full Flange Construction
10.1. Flange Placements
a. Left End Section from customer side has no flange on right end of frame. b. Center Section from customer side has flanges on neither side. c. Right End Section from customer side has no flanges on left end of frame. d. Full Flange Frames have flanges on all four (4) sides.
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Actual Door Width
Catalog Size
A B C D E
21-5/8” 23”
C-C
46-1/2”
69-1/2”
92-1/2”
23” 46” 25-3/8”
26-3/4” C-C
54”
80-3/4”
107-1/2”
26-3/4”
53-1/2”
27-3/8”
28-3/4” C-C
58”
86-3/4”
115-1/2”
28-3/4”
57-1/2”
28-7/8”
30-1/4” C-C
61”
91-1/4”
121-1/2”
30-1/4”
60-1/2”
NOTE: C-C: Center-To-Center Dimension
F G H I J
69” 92” 115”
24” 47”
80-1/4””
107”
133-3/4”
27-3/4”
54-1/2”
86-1/4”
115”
143-3/4”
29-3/4”
58-1/2”
90-3/4”
121”
151-1/4”
31-1/4”
61-1/2”
K L M N O
70” 93” 116”
24” 47”
81-1/4””
108”
N/A
27-3/4”
54-1/2”
87-1/4”
116”
N/A
29-3/4”
58-1/2”
91-3/4”
122”
N/A
31-1/4”
61-1/2”
P Q
70” 93”
81-1/4””
108”
87-1/4”
116”
91-3/4”
122”
Actual Door Height
Catalog Size
R
51” 54”
53-13/16”
64” 67”
66-13/16”
70” 73”
72-13/16”
72” 75”
74-13/16”
76” 79”
78-13/16”
10.2. Finished Frame Width Dimensions
10.3. Finished Frame Height Dimensions
Notes: 1. Features A Thru Q denote actual finished frame dimensions.
2. For outside to outside frame flange width or height, add 1-1/8” total
11. Frame Installation
1. Read instructions completely before installing frames.
2. Openings must conform to net openings listed in Price Book or other.
3. Check size of finished frame to net opening.
for Decorator (Flat) Rail. Add 1-7/8” total for Serrated Rail.
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4. Do not force frame into tight opening.
5. Check cooler opening for plumb and square as shown below. Sill must be level left
to right and front to back. a. Jambs, header and sill should be wood for a secure installation. b. Anthony door frame needs a sill of at least 1-1/2” for proper installation.
Frame
Installation
6. Set frame in opening. For safety, partially install wood screws in top of frame. Do
not tighten. Torquemaster (silver rectangular box) goes at bottom of frame. Hinge
pin to top of frame.
Pass-Thru Cross-Section (with/without
Threshold)
7. Check frame for square as shown. Shim as necessary. Ensure that shims are
placed as close to installation holes as possible. When shimming is necessary, shim top to bottom and/or left end of frame and right end of frame to maintain square of frame in net opening.
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8. From the inside of case, caulk all four sides of frame between frame and case
opening, as shown above.
9. Starting with frame sill, install mounting screws and tighten; first sides, then top.
(Do not over-tighten top screws as this will bow frame.)
10. From inside the case, re-check caulking.
11. For joining frame sections without flanges on center section, or one end of left
end and one of right end of frame, align top and bottom with end sections and join together with sex bolts provided.
12. Reversible/Cordless Door & Hold-Open Installation
1. Align door with torque rod and insert into the Torquemaster socket at base of door.
2. Engage door with hinge pin plug inserted into hinge pin plug receptacle at top of
frame.
3. Push door into top frame with thumb until hinge pin plug snaps into place.
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4. Hold-Open Instructions: (1987 to 1990)
a. Hold door stop and hold-open device into camel back side of door.
Note: Change is for hook to be installed coming up from the underside of the
camel back hinge.
b. Slide hold-open bar with spring clip through box on frame until clip snaps into
place.
5. Hold-Open Instructions: (1990 to Present)
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a. Insert rectangular nut provided into hold-open hinge on frame as shown below.
Note: On hold-opens starting March, 1990, the nut is affixed to hold-open arm.
b. With shoulder screws provided, mount new hold-open as shown. Tighten
screws.
c. Install thin metal slide toward top of frame.
d. Do not use power tools for installation or removal.
6. Adjust closing force by turning the screw on the front of the Torquemaster with a
flat-head screwdriver. Turn counterclockwise to tighten, clockwise to loosen. Do not over-adjust as this will cause door to slam.
7. If necessary to square door in frame opening, turn end screw on Torquemaster
13. Hold-Open Replacement (Prior to 1987)
(marked SAG ADJ) with flat-head screwdriver.
1. To remove, insert flat-head screwdriver into shoulder screw on frame white slide
block and remove. Go to back of door and remove locking washer and solid rivet. This will remove 10” door stop arm.
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2. To remove white block inside slide channel, remove end Phillips-head screw and
slide block outside of channel.
3. To remove fork, remove two (2) Phillips-head screws. To remove complete hold-
open assembly, remove back of frame raceway for access to screws that hold hold-open channel to frame. Remove screws.
4. Reverse instructions to replace.
14. Hold-Open Replacement (1987 to 1990)
1. Open the door and lock into hold-open position. Using a flat-head screwdriver,
release the door stop and hold-open frame attachment from slide channel as shown below.
2. Remove door stop and hold-open device from door as shown.
3. Reverse instructions to replace.
15. Hold-Open Replacement (1987 to 1990)
1. Remove shoulder screws from both ends of slide stop arm.
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2. With a flat-head screwdriver, turn screws counter-clockwise.
3. Reverse instructions to replace.
16. H
ld-Open Replacement (1987 to 1990)
1. Remove existing hold-open (see 15. & 16.).
2. Using a 1/4” drill, enlarge hole for hold-open on hinge side of door.
3. Insert rectangular nut provided into hold-open hinge on frame.
4. Mount new hold-open with shoulder screws provided.
5. Thin metal slide goes toward top of frame.
6. Do not over-tighten screws. (Hand tighten with hand driver only.)
17. Models 2500, 2700 & 3000 Pass-Thru Door Installation
Note: If Roll-A-Way cart is included in order, it must be behind the door before
installing frame.
1. When threshold is desired, drill and lag on pre-drilled mounting holes only.
2. For door and hold-open installation instructions, see previous pages.
3. When door is in closed position, adjust floor wiper seal to fit flush with door slab
and screw into place.
4. For additional bottom support, Anthony Pass-Thru doors are equipped with a base
plate and two special floor anchor bolts.
Base Plate Torquemaster
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