Ardco OptiMax2 Installation Manual

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OptiMax2 LED Retrofit Instructions (web only)
99-18258-I001_A
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Document Revision History

Revision History
Version Date Revised by Comments
Rev A 18 May 2010 SWatstein New release. Replace individual LED retrofit manual.
Contributors
Name Name Name Name
Sherman Watstein
Frank Carbajal
Harvey Tsui
Copyright © 2010 by
ALL rights reserved. Information in this document is subject to change without notice. Companies, names and data used in examples herein are fictitious unless otherwise noted. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without express permission of Anthony Manufacturing Co., Inc.
12391 Montero Street, Sylmar, CA 91342
800.772.0900 www.anthonyintl.com 99-18258-I001_A
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Table of Contents

Table of Contents

WARNINGS AND IMPORTANT NOTES ........................................................................................................ 1
Safety ..................................................................................................................................................... 1
Tools....................................................................................................................................................... 2
TIPS........................................................................................................................................................ 2
RETROFIT LED COMPONENTS ....................................................................................................................3
ADDITIONAL PARTS REQUIRED FOR Ardco FRAME ............................................................................... 5
ADDITIONAL PARTS REQUIRED FOR MODELS 1001, 401, 1KDR/1KDB, 401D/401B ............................ 5
REMOVING EXISTING LIGHTING SYSTEM ................................................................................................. 6
Removing Existing Lighting System: ...................................................................................................... 6
Locate, Drill and Mount Clip Mounting Fixtures For Center Mullion ....................................................... 7
ORIENTATION OF CENTER FIXTURES ....................................................................................................... 8
Center Mullion LED Fixture Mounting Instructions ................................................................................. 8
Locking LED Fixture to Center Mullion Fixture....................................................................................... 8
END MULLION FIXTURE ............................................................................................................................. 10
Removing Existing Lighting System ..................................................................................................... 10
Locate, Drill and Mount the LED Fixture Mounting Clip For End Mullion ............................................. 10
Orientation Of End Fixtures .................................................................................................................. 11
End Mullion LED Fixture Mounting Instructions.................................................................................... 11
Locking LED Fixture to Right End Mullion Fixture (Wires Connected at Bottom of Frame) ................. 12
Locking LED Fixture to Left End Mullion Fixture (Wires Connected at Top of Frame)......................... 13
OptiMax2 RETROFIT INSTRUCTIONS FOR
ANTHONY MODEL 401D AND 1KDR .......................................................................................................... 14
Removing Existing Lighting System ..................................................................................................... 14
Locate, Drill and Mount the Top and Bottom LED Fixture
Mounting Clips on Center Mullion (Model 401) .................................................................................... 14
Center Mullion LED Fixture Mounting Instructions ............................................................................... 16
Locate, Drill and Mount the Top and Bottom LED Fixture Mounting Clips for End Mullion .................. 17
End Mullion LED Fixture Mounting Instructions.................................................................................... 19
Locking LED Fixture to Center Mullion Fixture..................................................................................... 20
Locate, Drill and Mount the Top and Bottom LED Fixture Mounting Clips for Center Mullion.............. 21
Connecting LED Light Fixture to Wire Plug Assembly ......................................................................... 23
Ardco FRAMES ............................................................................................................................................ 24
Typical Orientations.............................................................................................................................. 24
Parts Removal ...................................................................................................................................... 24
HUSSMANN FRAME .................................................................................................................................... 26
Removing Existing Lighting System ..................................................................................................... 26
Locate, Drill and Mount the LED Fixture Mounting Clips for Hussmann Frame................................... 26
End Mullion Fixture LED Mounting Instructions.................................................................................... 27
CONNECTING THE WIRE PLUG ASSEMBLY TO THE
LED FIXTURE WIRES .................................................................................................................................. 28
Connecting Wires at the Bottom of the Frame ..................................................................................... 28
Connecting Wires at the Top of the Frame........................................................................................... 28
MOUNTING THE LED POWER SUPPLIES ................................................................................................. 30
Low Power (3-in-1 Driver)..................................................................................................................... 30
Low and High Power ............................................................................................................................ 31
Table 1 Fixture Orientation ......................................................................................................................... 32
ORIENTATION OF CENTER FIXTURES ................................................................................................
STANDARD CONFIGURATION ................................................................................................................... 36
TYPICAL INSTALLATION (HALF POWER END FIXTURES WITH SINGLE FIXTURE DRIVERS) ....36
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..... 34
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Table of Contents
STANDARD CONFIGURATION (1-Door) ............................................................................................ 36
STANDARD CONFIGURATION (2-Door) ............................................................................................ 36
STANDARD CONFIGURATION (3-Door) ............................................................................................ 37
Standard Configuration (4-Door) .......................................................................................................... 37
(Standard Configuration (5-Door) ......................................................................................................... 37
STANDARD CONFIGURATION (6-Door) ............................................................................................ 38
OPTIONAL CONFIGURATION (FULL POWER ENDS) ...................................................................... 38
FULL POWER ENDS OPTION ............................................................................................................ 38
FULL POWER End Option (1-Door) .................................................................................................... 39
FULL POWER End & MULL Option (2-Door) ...................................................................................... 39
FULL POWER End & MULL Option (3-Door) ...................................................................................... 39
CONFIGURATION (MULTI-FIXTURE DRIVER) .................................................................................. 40
TYPICAL INSTALLATION (4-Dr Frame Shown, 3-in-1 Driver) ............................................................ 40
HALF POWER End Options (3-in-1, Driver 1-Door) ............................................................................ 40
HALF POWER End & MULL Options (3-in-1 Drive, 2-Door) ................................................................ 40
HALF POWER End & MULL Options (3-in-1 Driver, 4-Door) .............................................................. 41
HALF POWER End & MULL Options (3-in-1 Driver, 5-Door) .............................................................. 41
HALF POWER End & MULL Options (6-Door) .................................................................................... 41
3-Door (Upper Raceway) ..................................................................................................................... 42
MULLION CONFIGURATIONS .....................................................................................................................44
LED CLEANING INSTRUCTIONS ................................................................................................................46
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WARNINGS AND IMPORTANT NOTES

WARNINGS AND IMPORTANT NOTES
BEFORE YOU BEGIN
Read these instructions completely and carefully.
WARNING: TO REDUCE THE RISK OF FIRE, ELECTRICAL SHOCK OR INJURY,
OBSERVE THE FOLLOWING:
1. INSTALLATION OF THIS RETROFIT ASSEMBLY REQUIRES A PERSON FAMILIAR WITH THE CONSTRUC­TION AND OPERATION OF ELECTRICAL SYSTEMS AND THE HAZARD INVOLVED.
2. Use this unit in the manner intended by the manufacturer.
3. Before servicing or cleaning, switch power off.
4. Turn power off before removing existing lighting system and follow appropriate lock out/tag out safety procedures.
5. For use in a commercial refrigeration case with packaged foods only.
6. When drilling for installation hardware, be careful not to nick wires or electrical components which may result in risk of fire or electrical shock.
7. Only those open holes indicated in the photographs and/or drawings may be made or altered as a result of kit installation. Do not leave any other open holes in an enclosure of wiring or electrical components
8. Risk of fire or electrical shock. Install this kit only in the luminaries that has the construction features shown in the photographs and/or drawings.
9. To prevent wiring damage or abrasion, do not expose wiring to edges of sheet metal or other sharp objects.
NOTE: Remove and dispose of existing ballasts per any local or Federal guidelines.

Safety

Proper safety equipment includes:
safety glasses
TURN OFF ALL ELECTRICAL POWER PRIOR TO BEGINNING WORK ON THE DOOR OR ON ANY ELECTRICAL. USE EXTRA CAUTION WHEN WORKING WITH OR AROUND THE DOOR GLASS PACKAGE.
work gloves
work shoes
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WARNINGS AND IMPORTANT NOTES

Tools

Tools required for this procedure include:
#2 Phillips-head screwdriver Rubber or plastic mallet
Cordless drill w/attachments Flat-head screwdriver
Needle-nose pliers Wire stripper and cutter
Razor Knife Tape measure

TIPS

• Always use the correct tool for the job to be performed. This ensures proper installation and minimizes safety risks.
• If there is any doubt about the work to be performed, consult with a certified technician or Anthony representative.
• Preventative maintenance is recommended to ensure product longevity.
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LED Power Supply Part No.

RETROFIT LED COMPONENTS

RETROFIT LED COMPONENTS
1
2
1
60-16979-0002
1
or 60-16851-0002
1
60-17544-0001
2
60-16979-0002 - 500 ma, Low Power
60-16851-0002 - 700 ma, High Power
60-17544-0001 - 500 ma, Multi-Fixture
Center Fixture Part No. Description Color Temp (K)
60-17447-0001 60” Light Fixture 4100
60-17447-0002 72” Light Fixture 4100
60-17447-0003 48” Light Fixture 4100
60-17447-1001 60” Light Fixture 5000
60-17447-1002 72” Light Fixture 5000
60-17447-1003 48” Light Fixture 5000
60-17447-2001 60” Light Fixture 3500
60-17447-2002 72” Light Fixture 3500
60-17447-2003 48” Light Fixture 3500
HALF POWER END
Right End Fixture Part No. Description Color Temp (K)
60-17445-0001 60” Light Fixture 4100
60-17445-0002 72” Light Fixture 4100
60-17445-0003 48” Light Fixture 4100
60-17445-1001 60” Light Fixture 5000
60-17445-1002 72” Light Fixture 5000
60-17445-1003 48” Light Fixture 5000
60-17445-2001 60” Light Fixture 3500
60-17445-2002 72” Light Fixture 3500
60-17445-2003 48” Light Fixture 3500
HALF POWER END
Left End Fixture Part No. Description Color Temp (K)
60-17446-0001 60” Light Fixture 4100
60-17446-0002 72” Light Fixture 4100
60-17446-0003 48” Light Fixture 4100
60-17446-1001 60” Light Fixture 5000
60-17446-1002 72” Light Fixture 5000
60-17446-1003 48” Light Fixture 5000
60-17446-2001 60” Light Fixture 3500
60-17446-2002 72” Light Fixture 3500
60-17446-2003 48” Light Fixture 3500
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LED Power Supply Part No.
RETROFIT LED COMPONENTS
1
2
60-16979-0002
1
or 60-16851-0002
1
60-17544-0001
2
60-16979-0002 - 500 ma, Low Power160-16851-0002 - 700 ma, High Power
60-17544-0001 - 500 ma, Multi-Fixture
Full POWER END
Right End Fixture Part
No.
60-17554-0001 60” Light Fixture 4100 x x
60-17554-0002 72” Light Fixture 4100 x x
60-17554-0003 48” Light Fixture 4100 x x
60-17554-1001 60” Light Fixture 5000 x x
60-17554-1002 72” Light Fixture 5000 x x
60-17554-1003 48” Light Fixture 5000 x x
60-17554-2001 60” Light Fixture 3500 x x
60-17554-2002 72” Light Fixture 3500 x x
60-17554-2003 48” Light Fixture 3500 x x
Mounting Kit Part No.
04-18201-0001 OptiMax2 Mounting Kit
Description Color Temp (K)
x
x
x
x
x
x
x
x
x
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ADDITIONAL PARTS REQUIRED FOR Ardco FRAME

ADDITIONAL PARTS REQUIRED FOR Ardco FRAME
Part Number Description
15-12314-0001 UL approved enclosure
40-12348-1002 #8/32 zinc nuts
40-10997-1005 #8-32 X 3/8” screws
40-11012-1007 #10X 1/2” hex screw with washers
70-13705-0001 #1/32” thick foam sealant tape
77-12036P018 #10-32 hex nuts
NOTE:1 The OptiMax2 lamp assemblies are available from Anthony Inc. Specify the lamp length and color temperature required when ordering LED lamp assemblies.
Items listed must be ordered before retrofiting the Ardco frame.
ADDITIONAL PARTS REQUIRED FOR MODELS 1001, 401, 1KDR/1KDB,
401D/401B
Part Number Description
40-12348-1002 #8/32 zinc nuts
40-10997-1005 #8-32 X 3/8” screws
70-13705-0001 #1/32” thick foam sealant tape
NOTE:1 The OptiMax2 lamp assemblies are available from Anthony Inc. Specify the lamp length and color temperature required when ordering LED lamp assemblies.
Items listed must be ordered before retrofiting the model 1001, 401, 1KDR/1KDB or 401D/401B.
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REMOVING EXISTING LIGHTING SYSTEM

REMOVING EXISTING LIGHTING SYSTEM

Removing Existing Lighting System:

1. Remove the following items:
a. Lens
b. Fluorescent lamps
c. Lamp holder
d. Mounting clips
e. Ballasts from existing lighting system
2. For Anthony 401D and 1KDR with ELS option only:
a. Remove Mullion cover using a flat screwdriver.
b. Remove the raceway cover by inserting a flat screwdriver into the seam between the metal raceway and the
plastic cover and pry open.
NOTE: Refer to case manufactures instructions for any questions on removing the fluorescent system and ballast.
3. Seal any open holes on Mullion using neutral cure silicone sealant (not provided).
4. Make sure you save the two #8 tapping screws used to hold the ballast.
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Locate, Drill and Mount Clip Mounting Fixtures For Center Mullion

1. Using a ruller measure the total width of the Mullion and mark a vertical line half the total width near the top and bottom of the Mullion.
2. Mark a vertical line from the top of the Mullion to the bottom of the Mullion thru the lines mea­surement in step 1.
3. Divide the vertical line distance in half and mark as a Center Line.
4. Mark a horizontal line 7/16” (0.438”) below the center line.
5. Mark two horizontal lines, one from the center as follows:
a. For 72” fixture-- 30.125” (
and (
B) to Center line.
REMOVING EXISTING LIGHTING SYSTEM
A) to Center Line
b. For 60” fixture-- 25.475” (
and (
B) to Center Line.
c. For 48” fixture-- 20.825” (
and (
B) to Center Line.
6. Mark one horizontal line 7/16” (0.438”) below the line (
7. Mark one horizontal line 7/16” (0.438”) above the line (
8. Position the center punch directly over at the intersection of the horizontal lines (6 total) and the vertical line (top, center and bottom) and establish a dimple.
9. Use a power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Using a Phillips screw driver, tread the the two #8 tapping screws (supplied) to hold each mounting clip. A total of (6) screws and (3) mounting clips should be installed.
11. Go to ORIENTATION OF CENTER FIXTURES
on page 8.
A).
B).
A) to Center Line
A) to Center Line
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ORIENTATION OF CENTER FIXTURES

Light

Center Mullion LED Fixture Mounting Instructions

1. Align the LED light with the mounting clips so that the LEDs are facing the display case interior. Snap the LED light into the mount­ing clips:
a. By placing one edge of the LED light into the groove.
b. Gently rotate until the opposite edge firmly locks into the
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
c. Adjust the lamp position until it is centered on the Mullion.
2. Go to Locking LED Fixture to Center Mullion Fixture on page 8.
mounting clip
ORIENTATION OF CENTER FIXTURES

Locking LED Fixture to Center Mullion Fixture

1. Using a (#29) 0.136 dia. drill bit, drill a hole through the LED Lighting fixture end cap and through the Center Mullion Fixture.
2. Using a Phillips screw driver to start threading the #8 X 1” long self-tapping screw to hold the end cap to the Center Mullion.
3. Continue to “CONNECTING THE WIRE PLUG ASSEMBLY TO
THE LED FIXTURE WIRES" on page 28.
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ORIENTATION OF CENTER FIXTURES
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Page 14

END MULLION FIXTURE

Removing Existing Lighting System

Refer to "Removing Existing Lighting System:" on page 6.

Locate, Drill and Mount the LED Fixture Mounting Clip For End Mullion

1. Using a ruller measure 1” min. from the inside of the end Mullion exclusion at the top and bottom.
2. Mark a vertical line from the top of the Mullion to the bottom of the Mullion thru the lines measurement in step 1.
3. Divide the vertical line distance in half and mark as a center line.
4. Mark a horizontal line 7/16” (0.438”) below the Center Line (
5. Mark two horizontal lines, one from the cen­ter (
A) as follows:
a. For 72” fixture-- 30.125” (
and (
A).
B) to Center Line.
END MULLION FIXTURE
A) to Center Line
b. For 60” fixture-- 25.475” (
Line and (
c. For 48” fixture-- 20.825” (
Line and (
6. Mark one horizontal line 7/16” (0.438”) below the line (
7. Mark one horizontal line (H) 7/16” (0.438”) above the line (
8. Position the center punch directly over at the intersection of the horizontal lines (6 total) and the vertical line (top, center and bottom) and establish a dimple.
9. Use A power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Repeat step 1. thru step 9.for the opposite side end Mullion.
11. Using a Phillips screw driver, tread the two #8 tapping screws (supplied) to hold each mounting clip. A total of (6) screws and (3) mounting clips should be installed per Mullion.
12. Go to Orientation Of End Fixtures on page
11.
B) to Center Line.
B) to Center Line.
A).
B).
A) to Center
A) to Center
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Orientation Of End Fixtures

Light
Refer to Orientation Of End Fixtures.

End Mullion LED Fixture Mounting Instructions

END MULLION FIXTURE
1. Align the LED light with the mounting clips so that the LEDs are facing the display case interior. Snap the LED light into the mounting clips:
a. By placing one edge of the LED light into the groove.
b. Gently rotate until the opposite edge firmly locks into
the mounting clip.
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
c. Adjust the LED lamp assembly until it is centered on
the Mullion.
2. Go to Locking LED Fixture to Right End Mullion Fixture
(Wires Connected at Bottom of Frame) on page 12 or go
to “Locking LED Fixture to Left End Mullion Fixture
(Wires Connected at Top of Frame) on page 13.
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Locking LED Fixture to Right End Mullion Fixture (Wires Connected at Bottom of Frame)

1. Using a (#29) 0.136 dia. drill bit, drill a hole through the LED Lighting fixture end cap and through the End Mullion Fixture.
2. Using a Phillips screw driver to start threading the #8 X 1” long self-tapping screw to hold the clip to the End Mullion fixture.
3. Continue to “CONNECTING THE WIRE PLUG
ASSEMBLY TO THE LED FIXTURE WIRES" on page
28.
END MULLION FIXTURE
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Locking LED Fixture to Left End Mullion Fixture (Wires Connected at Top of Frame)

1. Using a (#29) 0.136 dia. drill bit, drill a hole through the LED Lighting fixture through the end cap and End Mullion Fixture.
2. Using a Phillips screw driver to start threading the #8 X 1” long self-tapping screw to hold the end cap to the End Mullion.
3. Continue to “CONNECTING THE WIRE PLUG ASSEMBLY
TO THE LED FIXTURE WIRES" on page 28
END MULLION FIXTURE
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OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR

OptiMax2 RETROFIT INSTRUCTIONS FOR
ANTHONY MODEL 401D AND 1KDR

Removing Existing Lighting System

Refer to "Removing Existing Lighting System:" on page 6.

Locate, Drill and Mount the Top and Bottom LED Fixture Mounting Clips on Center Mullion (Model 401)

NOTE: Refer to
"Fixture Orientation" on page 32 for
the following procedures:
1. Using a ruller measure the total width of the Mul­lion and mark a vertical line half the total width near the top and bottom of the Mullion.
2. Mark a vertical line from the top of the Mullion to the bottom of the Mullion thru the lines measure­ment in step 1.
3. Divide the vertical line distance in half and mark as a Center Line.
4. Mark a horizontal line 7/16” (0.438”) below the center line.
5. Mark two horizontal lines, one from the center as follows:
a. For 72” fixture-- 30.125” (
and (
B) to Center line.
b. For 60” fixture-- 25.475” (
and (
B) to Center Line.
c. For 48” fixture-- 20.825” (
and (
B) to Center Line.
6. Mark one horizontal line 7/16” (0.438”) below the line (
A).
7. Mark one horizontal line 7/16” (0.438”) above the line (
B).
8. Position the center punch directly over at the intersection of the horizontal lines (6 total) and the vertical line (top, center and bottom) and establish a dimple.
A) to Center Line
A) to Center Line
A) to Center Line
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With ELS Option
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
9. Use a power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Insert two #8-32 X 3/8” screws thru each clip and Mullion cover and secure with two #8-32 captive nuts. A total of (6) screws, (3) nuts, and (3) mounting clips should be installed.
11. Drill a 3/8” hole about 1/2” from the top of the installed LED mounting clip.
NOTE: 3/8” hole will be used for bring the leads from the wire plug assembly to the LED fixture.
12. Go to Center Mullion LED Fixture Mounting
Instructions on page 16.
With T-10 Option
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Page 20

Center Mullion LED Fixture Mounting Instructions

Light
1. Align the LED light with the mounting clips so that the LEDs are facing the display case interior. Snap the LED light into the mount­ing clips:
a. By placing one edge of the LED light into the groove.
b. Gently rotate until the opposite edge firmly locks into the
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
c. Adjust the lamp position until it is centered on the Mullion.
2. Continue to “Locking LED Fixture to Center Mullion Fixture" on
page 8.
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
mounting clip
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OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR

Locate, Drill and Mount the Top and Bottom LED Fixture Mounting Clips for End Mullion

NOTE: Refer to
"Fixture Orientation" on page 32 for
the following procedures:
1. Using a ruller measure 1 1/8” min. from the inside of the end Mullion exclusion at the top and bottom.
2. Mark a vertical line from the top of the Mullion to the bottom of the Mullion thru the lines measurement in
step 1.
3. Divide the vertical line distance in half and mark as a center line.
4. Mark a horizontal line 7/16” (0.438”) below the Cen­ter Line (
5. Mark two horizontal lines, one from the center ( as follows:
a. For 72” fixture-- 30.125” (
b. For 60” fixture-- 25.475” (
c. For 48” fixture-- 20.825” (
6. Mark one horizontal line 7/16” (0.438”) below the line (
7. Mark one horizontal line (H) 7/16” (0.438”) above the line (
8. Position the center punch directly over at the inter­section of the horizontal lines (6 total) and the verti­cal line (top, center and bottom) and establish a dimple.
9. Use as power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Repeat step 1. thru step 9. for the opposite side end Mullion.
A).
(
B) to Center Line.
(
B) to Center Line.
(
B) to Center Line.
A).
B).
A)
A) to Center Line and
A) to Center Line and
A) to Center Line and
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With ELS Option
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
11. Insert two #8-32 X 3/8” screws thru each clip and Mullion cover and secure with two #8-32 captive nuts. A total of (6) screws, (3) nuts, and (3) mount­ing clips should be installed.
12. Drill a 3/8” hole about 1/2” from the top of the installed LED mounting clip.
NOTE: 3/8” hole will be used for bring the leads from the wire plug assembly to the LED fixture.
13. Continue to “End Mullion LED Fixture Mounting
Instructions" on page 19.
With T10 Option
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Page 23

End Mullion LED Fixture Mounting Instructions

1. Align the LED light with the mounting clips so that the LEDs are
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
2. Continue to “Locking LED Fixture to Center Mullion Fixture" on
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
facing the display case interior. Snap the LED light into the mount­ing clips:
a. By placing one edge of the LED light into the groove.
b. Gently rotate until the opposite edge firmly locks into the
mounting clip
c. Adjust the lamp position until it is centered on the Mullion.
page 20.
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Page 24

Locking LED Fixture to Center Mullion Fixture

OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
1. Using a (#29) 0.136 dia. drill bit, drill a hole through the LED Lighting fixture end cap and through the Center Mullion Fixture.
2. Using a Phillips screw driver to start threading the #8 X 1” long self-tapping screw to hold the end cap to the Center Mullion.
3. Continue to “CONNECTING THE WIRE PLUG ASSEMBLY TO
THE LED FIXTURE WIRES" on page 28.
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OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR

Locate, Drill and Mount the Top and Bottom LED Fixture Mounting Clips for Center Mullion

NOTE: Refer to
"Fixture Orientation" on page 32 for
the following procedures:
1. Using a ruller measure the total width of the Mul­lion and mark a vertical line half the total width near the top and bottom of the Mullion.
2. Mark a vertical line from the top of the Mullion to the bottom of the Mullion thru the lines measure­ment in step 1.
3. Divide the vertical line distance in half and mark as a Center Line.
4. Mark a horizontal line 7/16” (0.438”) below the center line.
5. Mark two horizontal lines, one from the center as follows:
a. For 72” fixture-- 30.125” (
and (
B) to Center line.
b. For 60” fixture-- 25.475” (
and (
B) to Center Line.
c. For 48” fixture-- 20.825” (
and (
B) to Center Line.
6. Mark one horizontal line 7/16” (0.438”) below the line (
A).
7. Mark one horizontal line 7/16” (0.438”) above the line (
B).
8. Position the center punch directly over at the intersection of the horizontal lines (6 total) and the vertical line (top, center and bottom) and establish a dimple.
A) to Center Line
A) to Center Line
A) to Center Line
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Page 26
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
9. Use a power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Insert two #8-32 X 1” screws thru each clip and Mullion cover and secure with two #8-32 captive nuts. A total of (6) screws, (3) nuts, and (3) mounting clips should be installed.
11. Drill a 3/8” hole about 1/2” from the top of the installed LED mounting clip.
NOTE: 3/8” hole will be used for bring the leads from the wire plug assembly to the LED fixture.
12. Go to Center Mullion LED Fixture Mounting
Instructions on page 16.
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Page 27

Connecting LED Light Fixture to Wire Plug Assembly

1. Bring the wires from the LED fixture thru the 3/8” DIA. hole.
2. Connect wires from the LED light fixture to the black and red wires from the 2-conductor harness (Refer to "RETROFIT LED COMPO-
NENTS" on page 3) using Wago Wall-NUT connector part number
773-162 or other approved connectors.
3. Snap the end cap onto LED light fixture making sure the wire cover is locked into the end cap.
4. Remove the protective film from the lens.
5. Seal off the cutouts in the Mullions using insulating material.
a. For wiring diagram Refer to "Fixture Orientation" on page 32.
b. Continue to “MOUNTING THE LED POWER SUPPLIES" on page
30.
OptiMax2 RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND 1KDR
5/18/2010 23 99-18258-I001_A
Page 28

Ardco FRAMES

ACORN NUT
MULLION
MOUNTING CLIP
HEX NUT AND LOCKWASHER
FOAM TAPE

Typical Orientations

Refer to "STANDARD CONFIGURATION" on page 36.

Parts Removal

1. Turn the power switch to the frame off.
2. Disconnect the frame from the main power.
3. Remove all of the old lamps and light fixtures from the frame.
NOTE: All hardware should be taken off, this includes lamp guards, clips and fasteners.
4. Remove all acorn nuts along the Mullion.
5. Close any holes along the Mullion with a 1/32” thick foam sealant. Refer to "ADDITIONAL PARTS REQUIRED FOR Ardco FRAME" on
page 5 and Refer to Figure 1 and Figure 2 .
Figure 1
6. Install three LED mounting clips onto the lamp side of the Mullion using #10-32 hex nuts and lock washers. Refer to "ADDITIONAL PARTS
REQUIRED FOR Ardco FRAME" on page 5.
7. Clip should be installed near the top, the bottom and at the midpoint of the Mullion.
Ardco FRAMES
Figure 2
NOTE: Do not use the acorn nuts previously removed to fasten the clips. Refer to
8. Install the LED power supply(s) into a UL approved enclosure. Refer to "ADDITIONAL PARTS REQUIRED FOR Ardco FRAME" on page 5.
Figure 3
Figure 2 .
5/18/2010 24 99-18258-I001_A
Page 29
Ardco FRAMES
9. Route the LED connector as shown in Figure 3 . The LED cable assembly must pass through an appropriate UL approved strain relief or an approved cover cap not shown in Figure 3 .
NOTE: Additional hardware to install the power supply and remote enclosures can be supplied by A.I. Refer to
Orientation" on page 32
10. The Red and Black main input power must pass through an appropri­ate UL approved strain relief secured to the enclosure to prevent wire damage.Refer to Figure 3 .
11. LED power transformer:
a. Cut off the of the 3-position plug on the LED power supply and strip
the Blue (Hot), Green/yellow (GND) and White/Blue wires.
b. Connect the Red main input power wire to Blue LED power supply
wire using a Wago Wall-NUT connectors or approved connector.
c. Connect the Black main input power wire to Black LED power
supply wire using a Wago Wall-NUT connector or approved connector.
12. Plug all unused holes on the enclosure with an approved cover cap.
13. Mount the remote enclosure(s) to the top header above the frame.
.
"Fixture
NOTE: Before installing the OptiMax2 lamp assembly into the clips verify the following (Refer to
a. The wire leads exiting the lamps are oriented correctly for connec-
tion to the LED power supplies.
b. The right and left Mullions will use a lamp fixture marked with “RT”
and “LT” respectively.
c. The center Mullions will use the fixture labeled with “CTR”.
14. Install the OptiMax2 LED lamp assembly to the clips on the Mullion by:
a. Align the LED light with the mounting clips so that the LEDs are
facing the displace case interior.
b. Snap the LED light into the mounting clips:
c. By placing one end of the LED light into the groove.
d. Gently rotate until the opposite edge firmly locks into the mounting
clip.
"Fixture Orientation" on page 32):
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
e. Adjust the lamp position until it is centered on the Mullion.
15. Continue to “Locking LED Fixture to Center Mullion Fixture" on page 8.
5/18/2010 25 99-18258-I001_A
Page 30

HUSSMANN FRAME

Removing Existing Lighting System

Refer to "Removing Existing Lighting System:" on page 6.

Locate, Drill and Mount the LED Fixture Mounting Clips for Hussmann Frame

1. Place a mounting clip at the top of the Mullion against the outer edge away from the wall and mark one hole at (
1. Place the same mounting clip at the bottom of the Mullion against the other edge away from the wall and mark one hole at (
2. Mark a vertical line from (
3. Divide the vertical line ( center line
4. Mark a horizontal line ( line (
5. Mark two horizontal lines, one from the center ( lows:
a. For 72” fixture-- 30.125” (
B).
D) to (B).
D) and (B) in half and mark as a
(A).
G) 7/16” (0.438”) below the center
A).
HUSSMANN FRAME
A) as fol-
A) to (C) and (A) to (E).
D).
b. For 60” fixture-- 25.475” (
c. For 48” fixture-- 20.825”
6. Mark one horizontal mark ( (
C).
7. Mark one horizontal line (
A) to (C) and (A) to (E).
(A) to (C) and (A) to (E).
F) 7/16” (0.438”) below the line
H) 7/16” (0.438”) above the line
(E).
8. Center the center punch directly over at the intersection of the horizontal lines (6 total) and the vertical line (top, cen­ter and bottom) and establish a dimple.
9. Use a power drill and (#29) 0.136” dia. drill bit, drill (6) holes at the intersection of the vertical center line and the horizontal lines.
10. Repeat step1. thru step 9. for the opposite side end Mul- lion.
11. Using a Phillips screw driver, tread the two #8 tapping screws (supplied) to hold each mounting clip. A total of (6) screws and (3) mounting clips should be installed per Mullion.
12. Refer to "Fixture Orientation" on page 32.
13. Continue to “Orientation Of End Fixtures" on page 11.
5/18/2010 26 99-18258-I001_A
Page 31

End Mullion Fixture LED Mounting Instructions

1. Align the LED light with the mounting clips so that the LEDs are fac­ing the displace case interior. Snap the LED light into the mounting clips:
a. By placing one end of the LED light into the groove.
b. Gently rotate until the opposite edge firmly locks into the mounting
NOTE: Ensure that the mounting clips lock into the outer edge of the LED light aluminum extrusion.
c. Adjust the LED lamp assembly until it is centered on the Mullion.
2. To lock LED fixture to Mullion:
a. Right end Mullion, refer to “Connecting Wires at the Bottom of the
b. Left end Mullion, refer to “Connecting Wires at the Top of the
3. To lock LED Fixture:
a. Locking LED fixture to right end Mullion (wires connected at bottom
HUSSMANN FRAME
clip.
Frame on page 28.
Frame on page 28.
of frame) Continue to “Locking LED Fixture to Right End Mullion
Fixture (Wires Connected at Bottom of Frame)" on page 12.
b. Locking LED fixture to left end Mullion fixture (wires connected at
top of frame) Continue to “Locking LED Fixture to Left End Mullion
Fixture (Wires Connected at Top of Frame)" on page 13.
5/18/2010 27 99-18258-I001_A
Page 32
CONNECTING THE WIRE PLUG ASSEMBLY TO THE
LED FIXTURE WIRES

Connecting Wires at the Bottom of the Frame

1. Connect wires from the fixture to the black and red wires from the 2-conductor harness using Wago Wall-NUT connector part number 773-162 or other approved connectors.
NOTE: End fixtures need to be connected together. Refer to "Center Mullion
LED Fixture Mounting Instructions" on page 8
2. Tuck the wire connectors underneath the wire cover before snapping it to the end cap.
3. Make sure the wire cover is locked into the end cap.
4. Remove the protective film from the lens.
5. Seal off the cutouts in the Mullions using insulating material.
6. Continue to “MOUNTING THE LED POWER SUPPLIES" on page 30.

CONNECTING THE WIRE PLUG ASSEMBLY TO THE LED FIXTURE WIRES

.

Connecting Wires at the Top of the Frame

1. Connect wires from the fixture to the black and red wires from the 2-conductor harness ( Refer to "RETROFIT LED COMPONENTS" on page 3) using Wago Wall-NUT connector part number 773-162 or other approved connectors.
NOTE: End fixtures need to be connected together. Refer to "Center Mullion
LED Fixture Mounting Instructions" on page 8
2. Tuck the wire connectors underneath the wire cover before snapping it to the end cap.
3. Make sure the wire cover is locked into the end cap.
4. Remove the protective film from the lens.
5. Seal off the cutouts in the Mullions using insulating material.
6. Continue to “MOUNTING THE LED POWER SUPPLIES" on page 30.
.
5/18/2010 28 99-18258-I001_A
Page 33
CONNECTING THE WIRE PLUG ASSEMBLY TO THE LED FIXTURE WIRES
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Page 34

MOUNTING THE LED POWER SUPPLIES

Low Power (3-in-1 Driver)

MOUNTING THE LED POWER SUPPLIES
1. Install the LED power supply in the same location where the ballast was fitted or in the general location for ease of wire connection.
2. Mount the LED power supply using two #8 tapping screws saved when the ballast was removed.
NOTE: Installer may have to drill two holes in raceway to accommodate LED power supply.
NOTE: The LED power supply case is grounded. Attach the LED power supply to a ground point in the refrigerated case either directly with a screw or by using the green wire to attach to a remote point.
3. Connect LED Light fixture wire connectors to LED power supply using plug assembly provided. Refer to "RETROFIT
LED COMPONENTS" on page 3 .
4. Connect the 3-position plug on the primary side of the LED power supply as follows:
a. If a 3-position plug is present on the load wire harness go
to step 5.
b. If no 3-position plug is present on the load wire harness
go step 6.
5. Connect the primary LED power supply input 3-position plug (blue, green and white/blue wires) to the harness 120­240 VAC electrical 3-position plug (blue/white and white/ blue wires). Go to step 7.
6. If no 3-position plug is present on the load wire harness:
a. Cut off the 3-position plug on LED power supply.
b. Connect the blue (+) on LED power supply to the original
load blue/white wire on the frame using a Wago Wall­NUT connector part number 773-162 or approved connector.
a. Connect the white/blue (-) on the LED power supply to
the original load white/blue wire from the frame using a Wago Wall-NUT connector part number 773-162 or approved connector.
7. Reinstall raceway cover(s).
8. Turn power on and verify LED fixture(s) are working.
5/18/2010 30 99-18258-I001_A
Page 35

Low and High Power

MOUNTING THE LED POWER SUPPLIES
1. Install the LED power supply in the same location where the ballast was fitted or in the general location for ease of wire connection.
2. Mount the LED power supply using two #8 tapping screws saved when the ballast was removed.
NOTE: Installer may have to drill two holes in raceway to accommodate LED power supply.
NOTE: The LED power supply case is grounded. Attach the LED power supply to a ground point in the refrigerated case either directly with a screw or by using the green wire to attach to a remote point.
3. Connect LED Light fixture wire connectors to LED power supply using plug assembly provided. Refer to "RETROFIT
LED COMPONENTS" on page 3.
4. Connect the 3-position plug on the primary side of the LED power supply as follows:
a. If a 3-position plug is present on the load wire harness go
to step 5.
b. If no 3-position plug is present on the load wire harness
go step 6.
5. Connect the primary LED power supply input 3-position plug (blue, green and white/blue wires) to the harness 120-240 VAC electrical 3-position plug (blue/white and white/blue wires). Go to step 7.
6. If no 3-position plug is present on the load wire harness:
a. Cut off the 3-position plug on LED power supply.
b. Connect the blue (+) on LED power supply to the original
load blue/white wire on the frame using a Wago Wall­NUT connector part number 773-162 or approved connector.
a. Connect the white/blue (-) on the LED power supply to the
original load white/blue wire from the frame using a Wago Wall-NUT connector part number 773-162 or approved connector.
7. Reinstall raceway cover(s).
8. Turn power on and verify LED fixture(s) are working.
5/18/2010 31 99-18258-I001_A
Page 36

Table 1: Fixture Orientation

MOUNTING THE LED POWER SUPPLIES
Orientation Center Mullion End Mullion 401D, 1KDR,
ELS
“(Standard Configuration (5-Door)”
on page 37
“3-Door (Upper Raceway)”
on
page 42
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“END MULLION FIXTURE”
on
page 10
“OptiMax2
RETROFIT INSTRUCTIONS FOR ANTHONY MODEL 401D AND
1KDR”
page 14
“FULL POWER End & MULL Option (2-Door)”
on page 39
“FULL POWER End & MULL Option (3-Door)”
on page 39
“FULL POWER End Option (1-Door)”
on
page 39
“HALF POWER End & MULL Options (3-in-1 Drive, 2-Door)” on
page 40
“HALF POWER End & MULL Options (3-in-1 Driver, 4-Door)” on
page 41
“HALF POWER End & MULL Options (3-in-1 Driver, 5-Door)” on
page 41
“HALF POWER End & MULL Options (6-Door)”
on page 41
“HALF POWER End Options (3-in-1, Driver 1­Door)” on page 40
“ORIENTATION OF CENTER FIXTURES”
on
page 34
“STANDARD CONFIGURATION (1-
on page 36
Door)”
“STANDARD CONFIGURATION (2­Door)”
on page 36
“STANDARD CONFIGURATION (3­Door)” on page 37
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
on
ARDCO Frame HUSSMANN
Frame
“Ardco FRAMES”
on page 24
“Ardco FRAMES”
on page 24
“HUSSMANN FRAME”
on
page 26
“Ardco FRAMES”
on page 24
“HUSSMANN FRAME”
on
page 26
“Ardco FRAMES”
on page 24
“HUSSMANN FRAME”
on
page 26
“Ardco FRAMES”
on page 24
“Ardco FRAMES”
on page 24
“HUSSMANN FRAME”
on
page 26
“HUSSMANN FRAME”
on
page 26
“Ardco FRAMES”
on page 24
“Ardco FRAMES”
on page 24
“Ardco FRAMES”
on page 24
5/18/2010 32 99-18258-I001_A
Page 37
Table 1: Fixture Orientation (Continued)
MOUNTING THE LED POWER SUPPLIES
“Standard Configuration (4-Door)”
“STANDARD CONFIGURATION (6­Door)”
“TYPICAL INSTALLATION (4-Dr Frame Shown, 3-in-1 Driver)”
“TYPICAL INSTALLATION (HALF POWER END FIXTURES WITH SINGLE FIXTURE DRIVERS)” on
on page 37
on page 38
on page 40
page 36
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“Center Mullion LED Fixture Mounting
Instructions”
on
page 8
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“END MULLION FIXTURE”
on
page 10
“Ardco FRAMES”
on page 24
“Ardco FRAMES”
on page 24
“HUSSMANN FRAME”
on
page 26
5/18/2010 33 99-18258-I001_A
Page 38
Typical input
wires
x Side 2 end fixture will remain the same orientation as
the center light fixtures. Side 1
end fixture must be flipped over for the correct orientation as shown. Therefore, the installer must connect the wires at the top of the frame instead of the bottom as Side 2
.
Viewed from the inside of the case.
SIDE 1
SIDE 2

ORIENTATION OF CENTER FIXTURES

ORIENTATION OF CENTER FIXTURES
5/18/2010 34 99-18258-I001_A
Page 39
ORIENTATION OF CENTER FIXTURES
5/18/2010 35 99-18258-I001_A
Page 40
View from the inside of the case.
View from the inside of the case.
View from the inside of the case.

STANDARD CONFIGURATION

STANDARD CONFIGURATION

TYPICAL INSTALLATION (HALF POWER END FIXTURES WITH SINGLE FIXTURE DRIVERS)

STANDARD CONFIGURATION (1-Door)

STANDARD CONFIGURATION (2-Door)

5/18/2010 36 99-18258-I001_A
Page 41

STANDARD CONFIGURATION (3-Door)

View from the inside of the case.
View from the inside of the case.
View from the inside of the case.

Standard Configuration (4-Door)

STANDARD CONFIGURATION

(Standard Configuration (5-Door)

5/18/2010 37 99-18258-I001_A
Page 42

STANDARD CONFIGURATION (6-Door)

View from the inside of the case.
View from the inside of the case.

OPTIONAL CONFIGURATION (FULL POWER ENDS)

FULL POWER ENDS OPTION

STANDARD CONFIGURATION
5/18/2010 38 99-18258-I001_A
Page 43

FULL POWER End Option (1-Door)

View from the inside of the case.
View from the inside of the case.
View from the inside of the case.

FULL POWER End & MULL Option (2-Door)

STANDARD CONFIGURATION

FULL POWER End & MULL Option (3-Door)

5/18/2010 39 99-18258-I001_A
Page 44

CONFIGURATION (MULTI-FIXTURE DRIVER)

Viewed from the inside of the case.
Viewed from the inside of the case.
Viewed from the inside of the case.

TYPICAL INSTALLATION (4-Dr Frame Shown, 3-in-1 Driver)

HALF POWER End Options (3-in-1, Driver 1-Door)

STANDARD CONFIGURATION

HALF POWER End & MULL Options (3-in-1 Drive, 2-Door)

5/18/2010 40 99-18258-I001_A
Page 45

HALF POWER End & MULL Options (3-in-1 Driver, 4-Door)

Viewed from the inside of the case.
Viewed from the inside of the case.
Viewed from the inside of the case.

HALF POWER End & MULL Options (3-in-1 Driver, 5-Door)

STANDARD CONFIGURATION

HALF POWER End & MULL Options (6-Door)

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Page 46

3-Door (Upper Raceway)

View from the inside of the case.
STANDARD CONFIGURATION
5/18/2010 42 99-18258-I001_A
Page 47
STANDARD CONFIGURATION
5/18/2010 43 99-18258-I001_A
Page 48

MULLION CONFIGURATIONS

MULLION CONFIGURATIONS
1001 w/ELS System
1001 T10-12 1001 T10-T123
401D/401B 401 D/401B 401D/401B
1001 T10-T12 1001 w/E:S System
401 (old) 401 (old) 401 (old)
1KDR/1KDB 1KDR/1KDB 1KDB/1KDR
1KDR/1KDB Standard T12
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Page 49
MULLION CONFIGURATIONS
5/18/2010 45 99-18258-I001_A
Page 50

LED CLEANING INSTRUCTIONS

LED CLEANING INSTRUCTIONS
• The LED light may be dusted as needed with a dry, clean, soft cloth.
• The outer lens should be cleaned periodically with a mild dish detergent.
• Do not use chemical cleaners to clean the system.
• Keep the outside clean. Wipe with a clean cloth lightly damped with mild dish washer detergent. Dry with a clean, soft cloth
• Do not wipe the lens with a soiled dish cloth or wet towel. These may leave a residue that can damage the fin­ish.
• Do not use scouring pads, powered cleaners, bleach or cleaners containing bleach because these products can scratch and damage the finish.
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Page 51
LED CLEANING INSTRUCTIONS
5/18/2010 47 99-18258-I001_A
Page 52
12391 Montero Street, Sylmar, CA 91342
800.772.0900 www.anthonyintl.com
99-18258-I001_A
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