Swingline 3 Swingline 2 Swingline 180 XL 400 Magni-Matic
Contents
1. esesessssssssssssseeeeeeee enne nnnnnrnenn nr nnn nnn 24 9 5 Magnetic Gasket 04040044 25 9 6 Door Handle 26 Frame Heater Replacement SL 3 2 and 180 27 Lamp Shield Replacement 51 3 28 Glass Replacement Drop In 5 00 29 12 1 56 29 12 2 Glass 2 MO rta vu UE GUI D ett nun TE UG cui 33 Glass Replacement p ll MT nnen 36 13 1 Removing the Glass 36 13 2 Installing the New Glass Package 36 Wiring Diagrams SL 3 mettre pun re raria bna vun rns eed 37 14 1 Swingline 3 Normal Temperature Door with Door Heat and Normal Humidity High Humidity Switch before EC 05 37 14 2 Swingline 3 Low Temperature Door with Lights and B J Disconnect before EC 05 Hn 38 14 3 Swingline 3 Normal Temperature Door with Door Heat and Normal Humidity High Humidity Switch EC 05 39 14 4 Swingline 3 Low Temperature Door with Lights and B J Disconnect EC 05 or jl 39 Wiring Diagrams2. Anthony Swingline 3 Swingline 2 Swingline 180 XL 400 Magni Matic Service Manual O Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual TABLE OF CONTENTS 1 Door Model Identification Me pc 5 Tite Lateh Door Obsolete tie ch a E 5 1 2 Magni Matic Woodcore nnn 5 Qc EP OO ec TT 6 1 4 Swingline 180 acess tala bern ated eeu bela d 6 1 5 Swingline 2 with Drop In 00222 00 0 7 1 6 SWINgINE T 7 1 6 1 Swingline with Non Adjustable 2 7 1 6 2 Swingline with Adjustable Hinging ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseenees 7 Ei cuu TEE ED 8 MEC MC eee 8 2 1 1 Current Serial Plate Serial Number 8 2 2 ELEC E 1 OU m 8 2 2 1 SL 2 and 180 Door Model Number Description 9 2 2 2 SL 2 and 180 Serial Number 9 2 3 XL and Es 6 o LETT 9 2 3 1 XL and Magni Matic Door Model Number 9 2 3 2 XL and Magni Matic Serial Number Description 10 3 Door Installation SL 3 2 and 180 ues obi emen nor oce oco ocn on E kn e b i car
3. NOTE Using a screwdriver or similar sharp instrument will damage the new heater A roller tool such as those used to assemble aluminum screens in household doors should be used to roll the heater into the grooves NOTE Prior to May 1974 Normal Temperature frames contained no factory installed mullion heaters 11 Lamp Shield Replacement SL 3 1 To remove the lamp shield push the metal clip This will disengage the side of the shield Rotate the entire shield to disengage the opposite side 2 Toreplace the shield place the shield around the lamp and engage the shield into the channel along one side The shield will snap back into place NOTE All shields on mullions and the left ends of frames have clips at the top of the shield Shields on the right end of the frame have clips on the bottoms of the shields TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 28 of 54 O Anthony 12 Glass Replacement Drop In Models Swingline 3 2 180 XL 400 Magni Matic Service Manual Ardco s Swingline Drop In Glass door opens a new dimension in door service Through Ardco s engineering and manufacturing expertise all Swingline door parts are easily accessible and easily changed Only a few ordinary working tools are needed to service if needed any door component to provide extended life and function for Swingline doors With Drop In Glass Ardco adds yet another feature to its list of door e
4. Page 7 of 54 O Anthony 2 Serial Plate 2 1 Current 1 In addition to the model number and to assist in correct parts identification the frame serial number should be referenced Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 The number is located on the door frame above the first door on the right end 2 1 1 Current Serial Plate Serial Number Description 1 January 1 February 2 March 3 etc 2 Subtract this number from 100 to identify the year of manufacture Ex 100 18 1982 3 Identifies product and place of manufacture 4 Identifies engineering changes 2 2 SL 2 amp 180 1 In addition to the model number and to assist in correct parts identification the frame serial number should be referenced 2 The serial plate is located on the side of one of the mullions the posts between the door openings TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 8 of 54 O Anthony 2 2 1 SL 2 and 180 Door Model Number Description 1 R Identifies door as Swingline 180 or Swingline 2 Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 K Identifies door size 3 4 Identifies a 4 door frame 4 SC3 Identifies glass application 2 2 2 SL 2 and 180 Serial Number Description 1 10 January 1 February 2 March 3 etc 2 27 Subtract this number from 100 to identify the year of manufacture Ex 100 27 1973 3 N Identifies p
5. 51 2 amp 180 aes chet eich rts ec uoi et tesa eau teen bini 40 15 1 Swingline 2 and 180 Low Temperature Door with Lights and B J Disconnect 40 15 2 Swingline 2 and 180 Normal Temperature Door with Door Heat and Normal Humidity High Humidity Switch eret es iren ped 41 Troubleshooting 2 amp 180 tone tonc tenes Condor Concerned 41 Door Installation XL and 44 Mullion Heater Replacement 400 45 Perimeter Heater Replacement 400 0 46 Glass Replacement XL and 47 Door Heater Replacement XL 48 Door Spring Replacement XL and 49 Door Handle Repair XL and 50 TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 3 of 54 Anthony 24 Bottom Hinge Pin 51 25 Troubleshooting XL 400 and Magni Matic eceeeceeeceeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeeeaaees 51 Swingline 3 2 180 XL 400 Magni Matic Service Manu
6. Tighten the screws if loose or unscrew them if replacing the handle Swingline 3 2 180 XL 400 Magni Matic Service Manual 3 Replace the aluminum strip 10 Frame Heater Replacement SL 3 2 and 180 1 Disconnect the frame from the power source 2 Remove the necessary doors to expose the stainless coverplates that cover the defective heaters 3 Remove all door hold open slides from the frame 4 Remove all stainless coverplates to expose the defective heater Use a flat blade to remove the stainless coverplates if necessary 5 Cut out the defective heater at the cold leads and remove the defective heater 6 Install the new heater in the appropriate grooves Check the routing of the heater as per the appropriate wiring diagram Check the heater for continuity Splice new heater to cold leads using line to line connectors Mullion Heater Channels Frame Heater Channels NOTE Use extreme care to prevent the heater from touching itself It may be necessary to physically keep the heater from touching by using foil tape or permagum in the area of the egress point TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 27 of 54 Anthony 7 Replace all stainless coverplates screws and hold open slides Swingline 3 2 180 XL 400 Magni Matic Service Manual 8 Re install all doors and Lok Clips or Lok Plates and reset the door tension 9 Reconnect the frame to the power source
7. side this screw is six inches from the top of the door 1 4 Swingline 180 1 Manufactured from December 1970 to January 1976 2 Magnetic gasket is about 34 wide and goes around the back refrigerated side of the door 3 Can be identified by a recess in the center of the door on the hinge side This is the point of spring tension adjustment and the point from which the door heater power cord exits TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 6 of 54 O Anthony 1 5 Swingline 2 with Drop In Glass Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Manufactured from January 1976 to June 1980 2 Can be identified by the wide magnetic gasket about 1 3 8 wide that covers the entire back frame refrigerated side of the door 3 Arecess in the center of the door on the hinge side contains the spring adjustment and is the point from which the door heater power cord exits 1 6 Swingline 3 1 6 1 Swingline 3 with Non Adjustable Hinging 1 Manufactured from July 1980 to March 1983 2 A new door extrusion is the only difference between this door and the Swingline 2 1 6 2 Swingline 3 with Adjustable Hinging 1 Manufactured from March 1983 to present 2 The only difference between this door and the original SL 3 is the door stop plate 3 This model is not covered in this manual TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual
8. Check with lamp manufacturer 5 Defective lamps 6 Improper ballast application 7 Defective ballast c Lamp Flicker Spiraling or Swirling Effect 1 New lamps should be operated 100 hours for proper seasoning 2 Defective lamps 3 Improper voltage 4 Improper ballast application 5 Defective ballast d Audible Ballast Hum 1 Loose fixture louvers panels or other parts 2 Insecure ballast mounting TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 43 of 54 O Anthony 3 Defective ballast Swingline 3 2 180 XL 400 Magni Matic Service Manual e Very Slow Starting 1 Improper voltage too low Poor lamp to lampholder contact Defective lamp Improper circuit wiring Inproper ballast application D Bulb wall temperature too low or too high f Blinking High voltage Improper wiring or installation Defective ballast N gt Wrong type lamps 5 Wrong number of lamps 17 Door Installation XL and Magni Matic 1 Be sure that the locknut B is on the upper hinge pin A but not tight against the frame 2 Insert the top of the door over the top hinge pin A 3 Lift the door up and set the door bottom onto the bottom hinge pin C 4 Plug in the power cord and secure it with a screw if available TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual 44 54 Anthony 5 To set door tension Swin
9. Lok Plate from the top of the door Swingline 3 2 180 XL 400 Magni Matic Service Manual 4 Lift the door up and out to disengage the bottom door pin Remove the door and place it face down on soft cloth to protect the finish and glass 5 Remove the gasket by peeling it away from the back of the door 6 Using a stiff putty knife remove the narrow aluminum outer moulding This is best done by beginning at a corner Insert the knife between the moulding and the door frame at the outer edge and push down on the knife prying along the entire length Remove the outer moulding as required for repair hinge side Pa Outer moulding 7 Remove the wide aluminum inner moulding from the hinge side by squeezing it toward the outer edge of the door frame until it is disengaged Lift the inside edge straight up Inner moulding Cuter moulding TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 16 of 54 Anthony 8 Remove the center coverplate Swingline 3 2 180 XL 400 Magni Matic Service Manual Coverplate 9 At this point the door tension adjustment assembly springs etc or disconnect switch can be repaired or changed without further teardown 5 1 Door spring replacement Remove retaining clip A Remove hinge pin spring assembly B Insert new spring assembly into proper position C Replace retaining clip Replace aluminum strips R
10. Service Manual 1 Lamp bees used in assembles with odd Assembly shown typical 2 door with 2 malbon and 2 and High Humidime Cen Deor Loduied inside Back of Door Plugifiscaptacia Door Hager Frame 4 Mullion Heater Located inside Fret of Frame Heater naide Front Fra 16 Troubleshooting SL 3 2 amp 180 1 Condensation NOTE Low voltage supply i e less than 108V results in significantly lower wattage Lower wattage will decrease the efficiency of heaters a Glass 1 Check relative humidity in case area 2 Check power supply at receptacle Low Temperature only 3 Check disconnect switch Low Temperature only 4 f Scan X equipped check Scan X control and sensor Low Temperature only TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 41 of 54 O Anthony b Door Extrusion Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Check relative humidity in case area 2 Check power supply at receptacle 3 Check continuity of heater 4 If Scan X equipped check Scan X control and sensor c Frame Check relative humidity in case area Check power supply to frame heaters Check continuity of frame heaters N gt If Scan X equipped check Scan X control and sensor 5 Check to ensure back of frame perimeter is caulked properly 2 Mechanical a Door Will Not
11. after installation remove the top and side frame screws and wedge the frame from the rear with a screwdriver until the tops of the doors are parallel with the frame Reset the top and side frame screws 7 Re install the screw in each electrical plug 8 Caulk the perimeter of the frame on the refrigerator side and adjoiners 9 Remove the protective tape from the door and the frame before energizing the unit for any extended period of operation 10 90 Door Stop Hold Open The door stop keeps the door from opening past 90 Slide the hold open sideways to hold the door fully open for fast stock loading Slide the hold open back out and the door again closes automatically 4 Swing Hinge Conversion SL 3 2 and 180 Ardco Swingline is a reversible hinge door Should remodeling or changes in store traffic make it desirable to change right hinge doors to left hinge or vice versa Swingline can be converted in approximately 5 minutes or less per door Both door and frame hardware must be changed as described NOTE Doors cannot be hinged back to back within a frame TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 12 of 54 O Anthony 4 1 Doors 1 Remove the door To remove open the door to approximately 45 Remove the Lok Clip or Lok Plate from the top of the door Remove the screw that retains the power cord Lift the door up and out to disengage the bottom door pin Door closing tensions need no
12. corner points Swingline 3 2 180 XL 400 Magni Matic Service Manual 4 Install the provided glazing tape paper side up around the glass The tape should be pressed onto the edge of the glass flush against the side of the door frame After installation remove the protective paper 5 For re wiring the glass package disconnect the switch and heater as shown in the wiring diagram TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual 34 54 O Anthony 6 Replace the metal moldings a Place the wide inner molding into the groove in the channel at the outer edge of the door frame and rest the molding on the glazing tape Swingline 3 2 180 XL 400 Magni Matic Service Manual b Place the narrow outer molding into the groove of the inner molding c Starting at a corner push inward and down on the outer molding until the moldings snap into place Be certain that the inner molding enagaes into the channel Continue pushing along the full length of the molding gt 7 Re install the black vinyl gasket a Beginning at a corner pull the inner edge of the gasket into the channel of the wide inner molding that faces the glass Repeat at each corner b Work the gasket into the outer molding channel while prtessing the gasket into the channel of the narrow outer molding Complete installing the gasket at the center door opening TITLE Swingline 3 2 180 XL 400 Ma
13. illinois 60658 Serial Number 1 7 2 32 3 N 4 02 3 Door Installation SL 3 2 and 180 1 Lift the door into the frame to engage the top door hinge pin A into the top door hinge pin bushing B Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 10 of 54 Anthony 2 Rest the door on the hold open and slide the mounting plate to allow finger clearance to plug in the electrical cord C Swingline 3 2 180 XL 400 Magni Matic Service Manual 3 Open the door approximately 45 to align the bottom door pin D with the door mounting socket in the hold open slide mounting plate E Swing the door open or closed to drop it into the proper position 4 Adjust the door closing tension using the furnished hex key tool The tool is a standard 5 16 allen wrench If the tool is lost another can be obtained locally Insert the tool into the adjusting nut the center of door recessed location is always opposite the electrical plug Rotate the tool only in the direction the door opens toward the glass Three to four ratchet clicks gives approximately the proper tension Increase tension until positive closing occurs with the door open approximately one inch Adjusiment TITLE f Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 11 of 54 O Anthony 5 Install Lok Clip or Lok Plate Swingline 3 2 180 XL 400 Magni Matic Service Manual 6 If the door appears to sag
14. 10 Swing Hinge Conversion 51 3 2 and 180 12 SNB T 13 14 5 JDoorDis Assembly 51 3 2 15 5 1 Door spring 17 5 2 Tension adjustment assembly 18 5 3 Lektroni gard or disconnect switch depending upon the glass package wiring 18 5 4 Replace metal mouldings eeessssssssessssssessseeeeeennennnennnn nnne 19 5 5 Re install the black vinyl 19 6 Door Handle Replacement SL 3 and 2 20 7 Door Heater Replacement SL 3 2 20 B Door Dis Assembly 51 180 Eon er oe ripe Rer ieu 21 TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 2 of 54 O Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 9 10 11 12 15 16 17 18 19 20 21 22 23 Door SU i 22 9 1 Door Spring Replacement 22 9 2 Tension Adjustment Assembly 0 23 9 3 Lektroni gard or Lektra Gard 23 9 4 Door Heater Replacement
15. Close 1 Door requires tension adjustment Damaged torque rod Ratchet assembly inoperative Torque rod not engaged Door stop pin screw loose binding 2 C Door stop pin stripped or missing Mounting hardware should be replaced with welded plate which has stop pin and hinge socket welded to the mounting plate 7 Hold open slide screw loose binding 8 Lok Plate or Lok Clip is binding 9 Foreign object restricting closing b Door Not Sealing 1 Magnetic gasket damaged 2 Door not closing completely see Door Will Not Close c Door Saw toothed 1 Door out of square Diagonal dimensions should be within 1 16 2 Frame out of square Diagonal dimensions should be within 1 8 3 Glass package shifted 4 Worn hinge pin and bushing TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 42 of 54 Anthony 5 Worn mounting hardware Swingline 3 2 180 XL 400 Magni Matic Service Manual 6 Case not level on floor 3 Ballasts a Lamps Won t Start 1 Lamp failure Poor lamp to lampholder contact Incorrect wiring Low voltage supply Dirty lamps or lamp pins Low or high lamp bulb wall temperature High humidity Fixture not grounded NOOR wD 9 Improper ballast application 10 Ballast failure b Short Lamp Life 1 Improper voltage 2 Improper wiring 3 Poor lamp to lampholder contact 4 Extremely short duty cycles Greater than average number of lamp starts per day
16. al TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 4 of 54 Anthony 1 Door Model Identification 1 1 Latch Door Obsolete Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Manufactured from 1958 to December 1961 2 This door has a latch type handle 3 The door gasket is a compression type 1 2 Magni Matic Woodcore Manufactured from December 1961 to March 1966 The power cord exits the door seven inches from the top on the hinge side Spring tension adjustment is performed at the top hinge side of the door The magnetic gasket is held in place by aluminum strips attached with Phillips head screws 5 There is a screw head visible on the outside edge of the door on the hinge side this screw is one inch from the top of the door 6 Woodcore means there is wood inside of the door extrusion TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 5 of 54 O Anthony 1 3 XL 400 Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Manufactured from March 1966 to December 1970 The power cord exits the door seven inches from the top on the hinge side Spring tension adjustment is performed at the top hinge side of the door Ron The magnetic gasket is held in place by aluminum strips attached with Phillips head screws 5 There is a screw head visible on the outside edge of the door on the hinge
17. and Magni Matic 1 Disconnect the power cord loosen the locknut and lift the door up and out 2 Remove all the outer moldings A remove the gasket and remove all the inner moldings B 3 Remove the spring retainer screw C XL door and slide the spring and block down and out On Magni Matic doors the screw holding the block will need to be removed There may also be a screw on the inner side of the block The glass package must be removed to get to this screw Page 48 of 54 Swingline 3 2 180 XL 400 Magni Matic Service Manual Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 4 Disconnect the defective heater from the power cord and remove it from the door frame On Magni Matic doors it will be necessary to remove the wood inserts to remove and replace the heater 6 Replace the block and spring wood inserts if Magni Matic inner molding gasket and outer molding 7 Re install the door and connect power 22 Door Spring Replacement XL and Magni Matic NOTE First determine which door is to be repaired The springs are not interchangeable 1 Disconnect the power cord loosen the locknut and lift the door up and out 2 Remove the outer molding A on the hinge side of the door TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 49 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 3 Lift the gasket out of the w
18. ature applications made a double loop around the frame the replacement will make only one Cooler NT Frame Heaters Freezer LT Frame Heaters TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 46 of 54 Anthony 6 Connect the new heater at the cold leads Swingline 3 2 180 XL 400 Magni Matic Service Manual 7 Replace the stainless coverplates and doors 8 Reset tension on the doors and connect power to the frame 20 Glass Replacement XL and Magni Matic 1 Disconnect the power cord loosen the locknut and lift the door up and out 2 Lay the door flat with the handle side down 3 Remove the outer molding A gasket and inner molding B from the entire door perimeter 4 Turn the door over carefully 5 It may be necessary to use a putty knife to free the glass from the door frame 6 Carefully push the glass package from the door frame 7 Clean any old glazing tape from the inner lip of the front door flange and add new tape 8 Turn the door over TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 47 of 54 Anthony m Swingline 3 2 180 XL 400 Magni Matic Service Manual 9 Center the new glass package into the frame and insert wooden wedges at the corners to secure the glass 10 Re install the inner molding B gasket and outer molding A 11 Re install the door and connect the power 21 Door Heater Replacement XL
19. ay and remove the inner molding B a 4 Reove the spring retainer screw C This screw will not be present on Magni Matic doors 5 Slide the spring down and out The block may be removed at this time if necessary If the door is a Magni Matic the block will be held in place by a screw RH LH Magni Matic 6 After replacing the spring and or block replace the moldings and gasket and re hang the door 23 Door Handle Repair XL and Magni Matic NOTE Magni Matic doors and early XL doors were supplied with a handle that had a 9 center between the mounting posts These handles are no longer available If it becomes necessary to replace this handle new holes may be drilled and the old holes plugged 1 To tighten or replace the door handle remove the outer molding A on the handle side only TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 50 of 54 Anthony 2 Move the gasket aside There will be holes in the inner molding to allow access to the handle screws Swingline 3 2 180 XL 400 Magni Matic Service Manual 24 Bottom Hinge Pin Replacement The bottom hinge pin and roller bearing assembly is threaded and screws into the bottom frame member If these threads have become damaged Ardco can supply bottom hinge pins with oversized threads The original threads were 1 2 20 The larger parts have 9 16 18 and 3 4 16 threads The frame can be re drilled and re tapped to ac
20. cept these parts It is advisable to replace the bottom door bushing when replacing the bottom hinge pin assembly Bottom hinge pin e and roller osaring e Bottom door bushing 25 Troubleshooting XL 400 and Magni Matic 1 Condensation NOTE Low voltage supply i e less than 108V results in significantly lower wattage Lower wattage will decrease the efficiency of heaters a Glass 1 Check relative humidity in case area 2 Check power supply at receptacle Low Temperature only 3 Check lektroni gard Low Temperature only b Door Extrusion 1 Check relative humidity in case area 2 Check power supply at receptacle 3 Check continuity of heater TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 51 of 54 O Anthony c Frame Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Check relative humidity in case area 2 Check power supply to frame heaters 3 Check continuity of frame heaters 4 Check to ensure back of frame perimeter is caulked properly 2 Mechanical a Door Will Not Close 1 Door requires tension adjustment 2 Damaged spring 3 Damaged hinge block assembly 4 Door stop pin loose binding 5 Hinge pin w roller bearing loose binding or stripped Oversized hinge pin w roller bearing available for replacement 6 Hold open slide loose or binding 7 Foreign object restricting closing b Door Not Sealing 1 Magnetic gasket damaged 2 Door not closing complet
21. ding TET RE TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 30 of 54 O Anthony 5 Remove the wide aluminum inner moulding from around the door by squeezing it toward the outer edge of the door frame until it is disengaged Lift the inside edge straight up Swingline 3 2 180 XL 400 Magni Matic Service Manual 6 For doors equipped with heated glass cut the balck and white wires extending from the glass near the glass frame 7 Remove the insulated glass unit from the door frame To do so raise the end of the door and place a block under an unbroken end of glass or a corner and pull down on the door frame Grasp the raised end of the glass unit by its outer edge remove the glass unit from the door and discard it CAUTION Use gloves or other protection and take care to prevent broken pieces of glass from falling on your person TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 31 of 54 O Anthony 8 When the glass has been removed scrape away any wax like wedges remaining on the inside of the door frame at each corner Also clean away any dirt or particles remaining on the front gasket or other mounting surfaces Swingline 3 2 180 XL 400 Magni Matic Service Manual 9 A new disconnect switch is provided with a replacement heated glass package The wiring on the glass package may vary from the original glass package therefore the new di
22. e the door as required Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 Remove the center coverplate 3 Remove the door torque adjuster assembly A 4 Disconnect the defective heater and connect the new heater per the wiring diagram 5 Pull out the defective heater and insert the new heater completely into the channel B in the extrusion 6 Re assemble and re install door NOTE cooler doors built from June 1974 to June 1975 did not have door heat or power cords 9 5 Magnetic Gasket Replacement TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 25 of 54 O Anthony 1 Remove all snap in aluminum strips Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 Beginning in the center of the door remove the gasket from the outer edge working toward the corners Magnetic Gasket 3 Replace the outer edge of the new gasket starting at the corners of the door working toward the center Tuck in the corners Snap the inner edge of the gasket into place all around 4 Replace the aluminum strips 9 6 Door Handle Replacement Simple tightening or complete replacement can be performed without removing the door 1 Remove the snap in aluminum strip on the handle side only sk UE M EN GET AT ERES D ERE A i PUN 52 TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 26 of 54 Anthony 2
23. ely see Door Will Not Close c Door Saw toothed 1 Door out of square Diagonal dimensions should be within 1 16 2 Frame out of square Diagonal dimensions should be within 1 8 3 Glass package shifted 4 Worn hinge block assembly 5 Worn bottom hinge pin w roller bearing 6 Case not level on floor 3 Ballasts a Lamps Won t Start 1 Lamp failure 2 Poor lamp to lampholder contact 3 Incorrect wiring 4 Low voltage supply 5 Dirty lamps or lamp pins TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 52 of 54 Anthony Low or high lamp bulb wall temperature High humidity Fixture not grounded Swingline 3 2 180 XL 400 Magni Matic Service Manual ND 9 Improper ballast application 10 Ballast failure b Short Lamp Life 1 Improper voltage 2 Improper wiring 3 Poor lamp to lampholder contact 4 Extremely short duty cycles Greater than average number of lamp starts per day Check with lamp manufacturer 5 Defective lamps 6 Improper ballast application 7 Defective ballast c Lamp Flicker Spiraling or Swirling Effect 1 New lamps should be operated 100 hours for proper seasoning 2 Defective lamps 3 Improper voltage 4 Improper ballast application 5 Defective ballast d Audible Ballast Hum 1 Loose fixture louvers panels or other parts 2 Insecure ballast mounting 3 Defective ballast e Very Slow Starting 1 Improper voltage too low Poor
24. eplace gasket TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 17 of 54 O Anthony 5 2 Tension adjustment assembly Swingline 3 2 180 XL 400 Magni Matic Service Manual Tension Assembly a Slide out tension assembly Install new assembly to engage torque spring b Replace coverplate and aluminum strips c Replace gasket 5 3 Lektroni gard or disconnect switch depending upon the glass package wiring 2 wires lektroni gard 3 wires disconnect switch Diaconnaect Switch a Remove the power cord ground screw located in the channel b Disconnect wires connecting lektroni gard or disconnect switch to the gray power cord Remove the power cord from the channel d Remove the defective device e Rewire the new device using the appropriate wiring diagram Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 18 of 54 O Anthony f Re install snap out aluminum strips Swingline 3 2 180 XL 400 Magni Matic Service Manual g Re install gasket 5 4 Replace metal mouldings a Place the wide inner moulding into the groovein the channel at the outer edge of the door frame and reset the moulding on the glazing tape Outer Moulding Inner Moulding view shows outer moulding removed b Place the narrow outer moulding into the groove of the inner moulding c Starting at a corner tap the outer moulding until the mouldings snap into place Be certain
25. gline 3 2 180 XL 400 Magni Matic Service Manual a Close the door b Be sure that the locknut B is loose c Turn the hinge pin A in the same direction as the door closes d While keeping the tension on the hinge pin A tighten the locknut B e Adjust as needed 18 Mullion Heater Replacement XL 400 NOTE These instructions do not pertain to Magni Matic frames as the stainless coverplates were glued in place on those models 1 Disconnect the frame from the power source 2 Remove the doors that cover the mullion with the defective heater from the frame 3 Remove the stainless coverplate covering the defective heater Freezer LT Frame amp Mullion Heaters 5 Replace the stainless coverplate and doors 6 Reset tension on the doors and connect power to the frame TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 45 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 19 Perimeter Heater Replacement XL 400 NOTE These instructions do not pertain to Magni Matic frames as the stainless coverplates were glued in place on those models Disconnect the frame from the power source 2 Remove the doors from the frame Remove the stainless coverplates to expose the defective perimeter heater the original heater was encased in aluminum foil the replacement will not be 5 Install the new heater in the channel the original heater for low temper
26. gni Matic Service Manual Page 35 of 54 Anthony 13 Glass Replacement SL 180 13 1 Removing the Glass Package Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Dis assemble the door as required 2 Remove the door gasket heater and tension assembly 3 Remove the corner block screw 4 Remove the door members 5 Remove the glass package with the vinyl molding and discard 13 2 Installing the New Glass Package 1 Starting at the bottom center of the glass fit the new vinyl molding around the glass notching it at each corner for a proper fit using the old vinyl molding as a pattern Heated glass units require that a hole be cut for glass leads 2 Re assemble the door frame ensuring that the glass package and the vinyl molding are fully inserted in the door extrusion channel If a tight fit occurs it may be necessary to use furniture clamps or a similar device to insert the new unit TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 36 of 54 o Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 3 Re install the corner block screws 4 Measure diagonally from corner to corner to ensure that the door frame is square 5 Re install all removed parts For heated glass units see the wiring diagram for proper connections 6 Completely re assemble and install the door 9 Re install the door handle 14 Wiring Diagrams SL 3 14 1 Swingline 3 Nor
27. l Page 22 of 54 Anthony 5 Insert the new spring assembly into the proper position Swingline 3 2 180 XL 400 Magni Matic Service Manual 6 Replace the retaining clip aluminum strip and door stop plate if left hinge door and re install door 9 2 Tension Adjustment Assembly 1 Dis assemble the door as required 2 Remove the center coverplate Slide out the tension adjustment assembly Install the new assembly to engage the torque spring 3 Replace the coverplate and aluminum strip and re install the door 9 3 Lektroni gard or Lektra Gard Replacement Lektra Gard 2 wire open contact unit is replaced by Lektroni Gard 4 wire sealed assembly 1 Dis assemble the door as required 2 Remove the center coverplate Carefully withdraw the defective assembly Coverplate TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 23 of 54 O Anthony 3 Disconnect the old and insert the new Lektroni Gard assembly into the extrusion channel Swingline 3 2 180 XL 400 Magni Matic Service Manual Lektra Gard No Longer Available Door Heater Ground Screw Lektroni Gard Orange Black 2 Lektroni Gard 5 Re install the snap in aluminum strip Re install the door and Lok Plate and reset the closing tension 9 4 Door Heater Replacement TITLE 2 Swingline 3 2 180 400 Magni Matic Service Manual Page 24 of 54 O Anthony 1 Dis assembl
28. lamp to lampholder contact Defective lamp Improper circuit wiring Inproper ballast application dme Bulb wall temperature too low or too high TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 53 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual f Blinking 1 Qu ge oq High voltage Improper wiring or installation Defective ballast Wrong type lamps Wrong number of lamps TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 54 of 54
29. mal Temperature Door with Door Heat and Normal Humidity High Humidity Switch before EC 05 Larme balas used wit pgd number o in pi TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 37 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual r mm mm NUM Gm umm m m 14 2 Swingline 3 Low Temperature Door with Lights and B J Disconnect before EC TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 38 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 14 3 Swingline 3 Normal Temperature Door with Door Heat and Normal Humidity High Humidity Switch EC 05 or later 1 Lama AMAT Hi wo 22 ef lenior 1 ere p p Xo i later iis im l 1 3 donr unir with alish and ight em E TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 39 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 15 Wiring Diagrams SL 2 amp 180 15 1 Swingline 2 and 180 Low Temperature Door with Lights and B J Disconnect Bi ERE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 40 of 54 O Anthony 15 2 Swingline 2 and 180 Normal Temperature Door with Door Heat and Normal Humidity High Humidity Switch Swingline 3 2 180 XL 400 Magni Matic
30. roduct and place of manufacture 4 07 Identifies engineering changes Door Model R Door Model Heater Amps Serial No _ Factory No Bere 1027N07 TF 522 60 Hertz 1 Light Amps Listed gt Patent EL Qr wars E ardeo 9 Ardco Inc Chicago Illinois 80658 Serial Number 1 10 2 27 3 N 4 07 2 3 XL and Magni Matic 1 In addition to the model number and to assist in correct parts identification the frame serial number should be referenced 2 The serial plate is located on the side of one of the mullions the posts between the door openings 2 3 1 XL and Magni Matic Door Model Number Description 1 XL doors are identified as shown or with the letter prefix H such as HK 2 K Identifies door size 3 4 Identifies a 4 door frame TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 9 of 54 O Anthony 4 SC3 Identifies glass application Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 3 2 XL and Magni Matic Serial Number Description 5 January 1 February 2 March 3 etc 6 Subtract this number from 100 to identify the year of manufacture Ex 100 27 1973 7 Identifies product and place of manufacture 8 Identifies engineering changes Door Model K 4 SC3 Diar Factory Hertz 118 Vole Light Amps E Patanbsc has Ardea Inc Chicago
31. sconnect switch must be used even if the old device has not failed a To remove the original Lektroni Gard 1 Remove the door center coverplate by unscrewing and prying it out of the channel pulling the power cord with it 2 Pull the white frame heater out of the channel to a point past the door center coverplate 3 Slide the Lektroni Gard down the channel and out of the cover plate opening TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 32 of 54 O Anthony 4 Discard the Lektroni Gard Swingline 3 2 180 XL 400 Magni Matic Service Manual NOTE Removal of the disconnect switch does not require coverplate removal as it can be lifted from the channel 12 2 Glass Replacement 1 Place blocks at each end within the door frame Place the replacement glass unit on the blocks At one end lift the frame up to the glass Holding the glass within the frame remove the block and rest the glass within the frame on the working surface Repeat at the other end 2 Diagonal measurement of the door frame must be equal If measurements are not equal tap the appropriate end of the frame with a rubber mallet and recheck measurements TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 33 of 54 O Anthony 3 Center the glass in the frame Using the supplied wood wedges install two of them between the glass unit and the inside of the door frame at each end of eight
32. t be relieved Rest the door on the mounting plate and unplug the lelectrical cord Lift the door out Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 Remove the door stop plate A from the bottom of the door Attach the door stop plate to the top of the door with the screw provided NOTE The straight edge of the door stop plate faces the front of the door Turn the door upside down and the door is ready to install 3 After frame conversion re install the door and Lok Clip or Lok Plate and reset the closing tension TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 13 of 54 O Anthony 4 2 Frame Swingline 3 2 180 XL 400 Magni Matic Service Manual 1 Remove the hold open slide A and hold open slide mounting plate B and door mounting socket C TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 14 of 54 O Anthony 3 For end doors transfer the electrical output cap F For a mullion hinged door remove screws rotate the stainless electrical cover plate H to maintain polarity and replace screws G Swingline 3 2 180 XL 400 Magni Matic Service Manual 4 Re install doors and reset closing tension 5 Door Dis Assembly SL 3 and 2 1 To remove the door remove the screw and unplug the electrical cord TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 15 of 54 O Anthony 3 Remove the Lok Clip or
33. that the inner moulding engages into the channel Continue doing so along the full length of the molding 5 5 Re install the black vinyl gasket a Beginning at a corner pull the inner edge of the gasket into the channel that faces the glass of the wide outer moulding Repeat at each corner b Work the gasket into the outer moulding channel while pressing the gasket into the channel of the narrow inner moulding Complete installing the gasket at the center door opening TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 19 of 54 Anthony 6 Door Handle Replacement SL 3 and 2 Swingline 3 2 180 XL 400 Magni Matic Service Manual Simple tightening or complete replacing can be done without removing the door 1 Peel the gasket away from the handle area 2 Tighten the screws if they are loose or unscrew them if replacing the handle NOTE If the handle is mounted with allen screws a 5 32 allen wrench is required 7 Door Heater Replacement SL 3 and 2 Steps 1 thru 6 on Dis Assembly should be followed to remove the entire gasket and all snap in moulding 1 After removing the snap in moulding disconnect the defective heater and connect the new heater TITLE Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 20 of 54 O Anthony 2 Pull out the defective heater removing plastic retainers and insert the new heater wire into the channel extrusion A Make s
34. ure that the heater is pushed all the way into the channel Swingline 3 2 180 XL 400 Magni Matic Service Manual 3 Position the plastic heater retainers in the same area they were in originally 4 Re install the coverplate aluminum strips and gasket 8 Door Dis Assembly SL 180 1 To remove the door open the door to approximately 45 2 Remove the Lok Plate 3 Unplug the electrical cord Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 21 of 54 Anthony 4 Lift the door up and out to disengage the bottom door pin Remove the door and place it face down on soft cloth to protect the finish and glass Swingline 3 2 180 XL 400 Magni Matic Service Manual 5 Using a stiff putty knife remove the snap in aluminum strips Beginning at a corner insert the blade of the knife between the strip and the door frame at the outer edge and push down on the knife prying along the entire length Remove as many of the aluminum strips as required for repair NOTE During re installation of aluminum strips a plastic hammer should be used to prevent distortion 9 Door Repair SL 180 9 1 Door Spring Replacement 1 Dis assemble the door as required 2 Remove the door stop plate for left hinge doors only 3 Remove the retaining clip r 1 4 Remove the hinge pin spring assembly Swingline 3 2 180 XL 400 Magni Matic Service Manua
35. xclusives which include the only reversible swing door concealed power cord door tension adjustment narrow crowned extrusions substantially increased glass area and more This manual provides complete information for installation of replacement glass units and field service of other Swingline Drop In Glass door components To assure correct installation or service with minimum time and effort read the entire instructions before performing each procedure Vinyl Gasket Cuter Molding 225757 Wide Inner Molding 12 1 Glass Removal 1 Remove the door from its frame Peel the black vinyl gasket away from the back of the door behind the handle until the handle screw access holes are exposed TITLE f Swingline 3 2 180 XL 400 Magni Matic Service Manual Page 29 of 54 Anthony Swingline 3 2 180 XL 400 Magni Matic Service Manual 2 Using a Phillips screwdriver remove the door handle Handle screws stay in the door channel 3 Lay the door on a flat surface backside up Starting at a corner peel away and remove the black vinyl gasket from around the door 4 Using a stiff putty knife remove the narrow aluminum outer moulding This is best done by beginning at a corner Insert the blade of the knife between the moulding and the door frame at the outer edge and push down on the knife prying along the entire length Remove the entire outer moulding from around the door Take care not to deform the moul
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