Remcor DB275-BCP Installation Manual

Page 1

ICE/BEVERAGE DISPENSER

Operator’s Manual

Model DB275--BCP

Part No. 620906904 December, 1997 Revision D Revised February, 1998

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment

IMI CORNELIUS INC; 1997Ó

PRINTED IN U.S.A

Page 2

TABLE OF CONTENTS

GENERAL DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ICEMAKER ADAPTER KITS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLA TION INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START-UP AND OPERA TING INSTRUCTIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ICE PORTIONING SYSTEM OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NORMAL OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAN MODE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NORMAL ICE PORTION ADJUSTMENT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATION REFILL TIME ADJUSTMENT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL ICE DISPENSING OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTRA ICE PORTION ADJUSTMENT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING INSTRUCTIONS 8............................................

DISPENSER 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COLD PLATE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGE SYSTEM CLEANING AND SANITIZING 9. . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

DAILY (OR AS REQUIRED) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEEKLY (OR AS REQUIRED) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MONTHLY 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLOWN FUSE OR CIRCUIT BREAKER. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SLUSHY ICE. WATER IN HOPPER 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGES DO NOT DISPENSE. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGES TO SWEET. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGES NOT SWEET ENOUGH. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE). 12. . . . . . . . . .

NO ICE DISPENSED FROM ICE PORTION CONTROLLER 13. . . . . . . . . . . . . . . .

NO ICE DISPENSED FROM MANUAL ICE DISPENSE

PUSHBUTTON SWITCH 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

620906904

Page 3

TABLE OF CONTENTS (cont’d)

LIST OF FIGURES

FIGURE 1. PARTS IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. DRIP-TRAY DRAIN ASSEMBLY FOR BOTTOM HOOK-UP 3. . . . . . .

FIGURE 3. DISPENSER DIMENSIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. MOUNTING TEMPLATE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. BEVERAGE SYSTEM SCHEMATIC 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. PLUMBING SCHEMATIC 5.....................................

FIGURE 7. CUP SIZE LABEL 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. WIRING DIAGRAM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. ICE/SOFT DRINK POST-MIX DISPENSER EXPLODED VIEW

AND PART LIST 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. CABINET/ICE BIN ASSEMBLY EXPLODED VIEW

AND PART LIST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 11. ICE CHUTE ASSEMBLY EXPLODED VIEW AND PARTS LIST 16. . . FIGURE 12. ELECTRICAL CONTROL BOX ASSEMBLY -- EXPLODED VIEW

AND PARTS LIST 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 13. MOTOR ASSEMBLY DETAIL -- EXPLODED VIEW

AND PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

620906904

Page 4

RETAINER

ICE PORTION

CONTROL MODULE

ICE CHUTE

2851828518

2851828518 2851828518

2851728517

2851928519

28519285192851928519

2851928519

REMOVABLE STRAW

HOLDER PANEL

LID/STRAW

HOLDER

ICE BIN COVER

2851928519

28519285192851928519

2851928519

2851928519 2851928519

28519285192851928519

2851928519

2851828518

BEVERAGE FAUCET

ON/OFF SWITCH

MANUAL AIR VALVE

MANUAL ICE DISPENSE PUSH BUTTON SWITCH

ICE

AGITATOR

5218952189

7092470924

5218952189

7092470924

5218952189

7092470924

5218952189

7092470924

5218952189

7092470924

70924709247092470924709247092470924709247092470924

7092470924

5218952189

7092470924

5218952189 5218952189

5218952189

CUP REST

BEVERAGE

FAUCETS (8)

LOWER ACCESS

PANEL

DRIP TRAY

FIGURE 1. PARTS IDENTIFICATION

620906904

Page 5

GENERAL DESCRIPTION

This section gives the Unit description, theory of operation, and design data for Ice/Beverage Dispenser, Model number DB275--BCP

IMPORTANT: To the user of this manual -- This manual is a guide for installing, operating, and main- taining this equipment. Refer to the Table of Contents for page location for detailed information pertaining to questions that arise during installation, operation, service, or maintenance of this equipment.

SAFETY PRECAUTIONS

Always: disconnect power to the dispenser before servicing or cleaning. Never: place hands inside of hopper or gate area without disconnecting power to the dispenser. Agitator

rotation occurs automatically when dispenser is energized! This ice dispenser has been specifically designed to provide protection against personal injury and eliminates

contamination of ice. To insure continued protection and sanitation, observe the following. Always: be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior

and possible contamination of the ice.

Always: be sure the upper and lower front panels are securely fastened. Always: keep area around the dispenser clean of ice cubes.

CAUTION: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has frozen into large chunks can void warranty. The dispenser agitation is not designed to

be an ice crusher. Use of large chunks of ice which “jam up” inside the hopper will cause failure of the agitator motor and damage to the hopper. If bagged ice is used, it must be carefully and completely broken into small, cube-sized pieces before filling into the dispenser hopper.

UNIT DESCRIPTION

The Remcor “DB” series of ice dispensers solve your ice and beverage service needs in the sanitary , space saving, economical way. Designed to be manually filled with ice from any remote ice making source, these dispensers will dispense cubes (up to 1-1/4” in size), cubelets and hard-chipped or cracked ice, and in addition, several flavors of post-mix beverages.

The unit includes beverage faucets and a cold plate and is designed to be supplied direct from syrup tanks and carbonator, with no addition cooling required.

SPECIFICATIONS

Model: DB275S-BCP Ice Storage: 275 lbs. Maximum Number of Faucets Available 8 Built-in Cold Plate Yes Electrical: 115/1/60 Dimensions: 30”W x 30”D x 41½”H

Drain Connection 7/8 ID Hose

ICEMAKER ADAPTER KITS

Remcor model Ice/Beverage Dispensers are designed to be used with one of several different types of topmounted icemakers. The icemaker must be obtained from the appropriate manufacturer.

Check with a Remcor Sales Coordinator for a list of icemaker kits available for this dispenser model. The kit will contain parts and instructions necessary to mount the selected icemaker to the dispenser.

620906904

Page 6

INSTALLATION INSTRUCTIONS

IMPORTANT: TO THE INSTALLER. It is the responsibility of the installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI/ASME A1 12. 1.2-1979; or an approved vacuum breaker or other such method as proved effective by test.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to Federal, State, and Local laws.

1. Locate the dispenser indoors on a level counter top. The ice dispenser must be sealed to the counter. The template drawing (Figure 4) indicates openings

which must be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in the counter.

Apply a continuous bead of National Sanitation Foundation (NSF) listed silastic sealant (Dow 732 or equal) approximately 1/4” inside of the unit outline dimensions and around all openings. Then position the unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately.

2. UTILITIES: The unit has provisions for routing the beverage tubing, air/CO2line, drain line, and power cord either out the bottom or out the rear of the cabinet (see Figure 3). For routing the utilities out the bottom of the unit, refer to the mounting template (Figure 4) for locating the required clearance holes in the counter.

3. DRAIN CONNECTION: Use the insulated tubing and clamp provided with the unit to assemble to the driptray drain. To insure proper drainage, do not allow a “trap” to form in the drain line. Check that the drain line runs flat with the bottom of the dispenser. See (Figure 2) for bottom hook-up of the unit drain line.

NOTE: This equipment must be installed with adequate backflow protection to comply with Federal, State, and Local Codes.

DRIP TRAY DRAIN LINE

ELBOW

CLAMP INSULATED TUBING TO ELBOW

DISPENSER BOTTOM

FIGURE 2. DRIP-TRAY DRAIN ASSEMBLY FOR BOTTOM HOOK-UP

4. BEVERAGE SYSTEM: Connect the beverage system product lines as indicated in the beverage system schematics shown in Figures 5 & 6. This work should be done by a qualified serviceman.

5. ICE PORTION CONTROLLER: Regulated and filtered CO2gas pressure or compressed air is required to operate the ice portion control dispensing system. Proceed as follows to connect the CO2gas pressure source line to the dispenser.

A. Connect and route the Air/CO2line from outlet side of the source regulator assembly up to the dis-

penser. NOTE: That the minimum source -- regulated pressure is 40 psig. B. Connect the Air/CO2source line to dispenser inlet line labeled “AIR/CO2” . C. The dispenser regulator outlet pressure is factory preset to 34 psig ± 2 psig. DO NOT ADJUST.

IMPORTANT: Maximum Air/CO2operating pressure is 35 psig.

6. Clean the hopper interior (see cleaning Instructions). 3

620906904

Page 7

7. Connect the power cord to 115 volt, 60 cycle, 3-wire grounded receptacle.

BEVERAGE VALVE

ON/OFF SWITCH

LID AND

STRAW HOLDER

ICE PORTION

CONTROL (4) SIZES

UF-1 OPTIFILL

DISPENSE SWITCH

VALVES

MANUAL AIR VALVE

MANUAL

35 1/2

35/8

1 11/16

4 1/2

14 6

1 3/16

REMOVABLE PANEL FOR REAR HOOKUP OF BEVERAGE TUBING

41 1/2

AND AIR CO2 LINES

ELECTRICAL

10 1/8

POWER CORD

REMOVABLE HOLE PLUGS (2) FOR REAR

HOOKUP OF DRIP TRAY DRAIN

FIGURE 3. DISPENSER DIMENSIONS

BACK

1 1/8

3/8

27 3/4

7 7/16

1 1/8

620906904

6 1/2

FRONT

NOTE SHADED AREA INDICATES OPENING IN CABINET BOTTOM NEEDED FOR UTILITIES AND BEVERAGE TUBING.

FIGURE 4. MOUNTING TEMPLATE

20 3/4

14 1/2

Page 8

FAUCETS

FAUCETS VIEWED FROM THIS SIDE

COLD PLATE

ICE/SOFT DRINK POST MIX

DISPENSER. ITEMS OUTSIDE

BROKEN LINES ARE NOT INCLUDED.

S1 S2 S3

FAUCET NO.

1,5,6,7,8

4 3 2

S5 S6 S7 S8

OPTIONAL FOR

DIET OR

ROOT BEER

PSIG

5--15

WATER HOOK UPS -- MAYBE

CARBONATED

OR PLAIN WATER AS REQUIRED

15--50PSIG

S3S2

CARBONATOR

NON--CARB. WATER

FILTER

S6S5

OPTIONAL

PRESSURE

REGULATOR

REGULATORS

CO TANK

SYRUP TANKS

60--100 PSIG

WATER SUPPLY

BC MODELS 19 X 28 COLD PLATE

BEVERAGE SYSTEM SCHEMATIC

WITH FRONT INLET FITTINGS

8 VALVE HOOK UP

NOTES:

1) FORREFERENCE ONLYNOT FOR CONSTRUCTION.

2) SEEPLUMBING SCHEMATICLABEL UNDER LOWERPANEL FORAPPROPRIATE

HOOK UP. (SEE MANUAL)

FIGURE 5. BEVERAGE SYSTEM SCHEMA TIC

PLUMBING SCHEMATIC

3 4

SYRUP

INLETS

MAY BE CARBONATED

OR NON--CARBONATED

NOTE:

1. TO SERVICE COLDPLATE INLET FITTINGS, SINK

HAS TO BE REMOVED. TO REMOVE, DISCONNECT SINK DRAIN CONNECTIONS, THEN LIFT TWO (2) SIDE MOUNTING PINS AND PULL SINK FORWARD. REVERSE TO RECONNECT.

FAUCETS

COLDPLATE

1,5, 6,7,

WATER INLETS

7 86

621 5

SYRUP

INLETS

2. MAKE SURE ALL DRAIN CONNECTIONS ARE PROPERL YPOSITIONED FOR DRAINING AFTER SERVICE, BEFORE PANELS ARE INSTALLED

FIGURE 6. PLUMBING SCHEMATIC

620906904

Page 9

START-UP AND OPERATING INSTRUCTIONS

Fill the hopper with ice and replace the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this procedure whenever the dispenser has been standing overnight or other long periods without ice use. Start up the beverage system and adjust faucets to the proper brix. Contact your local syrup distributor for complete information on the beverage system.

To dispense ice, hold cup under ice chute and press the appropriate size button on the ice portion control located above the ice chute. An extra ice portion may be obtained by pressing the increase key (Y) before pressing the button.

For beverage dispensing, place a cup on the cup rest against the faucet lever of the desired flavor. Beverage will be dispensed automatically filling the cup and shutting off. A delay feature is provided in the faucet controller to “top-off” the drink after shut off.

CAUTION: Use caution to avoid spilling ice when filling dispenser. Clean up immediately any spilled ice from filling or operating the unit. To prevent contamination of ice, the lid must be installed at the unit at all times.

ICE PORTIONING SYSTEM OPERATION

INDICAT ORLIGHT

DECREASE SMALL LARGEMEDIUM X-LARGE INCREASE

FIGURE 7. CUP SIZE LABEL

The ice portioning system consists of three main components:

1. Ice Portion Control

2. Ice Gate Mechanism

3. Solenoid Operated Air Valve

When a size button on the ice portion control is pressed, the control supplies a voltage to the air valve for a brief period of time. The air cylinder attached to the ice gate will then open the ice gate for a short time allowing ice to be dispensed from the ice chute.

The ice portion control has five modes to allow adjustment of the ice portions and for normal operation. They are as follows: (Refer to Figure 7)

MODE INDICATOR STATUS Normal operation Green Cleaning mode Red/Amber flashing Normal ice portion adjustment Amber Extra ice portion adjustment Red

Agitation refill time adjustment Amber flashing The control will return to Normal Operation Mode (green indicator) automatically if a button has not been operated for a period of one minute whenever one of the three adjustment modes have been accessed.

620906904

Page 10

NORMAL OPERATION

To dispense ice, hold a cup directly under the ice chute, then press the appropriate size button on the ice portion control. To obtain a full cup of ice, press the increase button followed by the appropriate size button. The ice portion control will not dispense ice and will display a flashing green indicator light if sufficient ice is not available in the ice chute to dispense the selected size. The indicator light will return to solid green and ice dispensing will resume after the ice chute has been filled.

The amount of ice dispensed for each size is changed in the Normal and Extra Ice Adjustment Modes. To access the adjustment modes, press the decrease and increase button at the same time. The control will advance to the next mode in the sequence as shown in the table on page 6 and the indicator light will change to identify which mode is currently active.

CLEAN MODE

Access this mode when cleaning the ice chute. Refer to Cleaning Instructions on pages 7 thru 9.

NORMAL ICE PORTION ADJUSTMENT

From the Normal Operation Mode (green indicator), press both the decrease and increase buttons at the same time twice. The amber indicator verifies that the normal portion adjustment mode has ben accessed.

To change the amount of ice dispensed, press and hold down the size button for the desired size to be changed. While holding the size button, press the decrease or increase button to decrease/increase the ice portion size. When the minimum ice portion adjustment has been reached, the indicator will flash at a slow rate; at the maximum adjustment, the indicator will flash at a fast rate. After releasing the size button, the indicator light will flash green for five seconds. During this time period a sample can be obtained to check the portion size by pressing the size key. The indicator light will return to amber (normal portion adjustment mode) after the sample is dispensed.

The indicator light will flash red after dispensing a sample, if an open circuit exists in the ice gate cylinder switch wiring to the ice portion control or if an ice gate binding condition occurred during the sample. The indicator light will display solid red briefly after a sample is dispensed if the ice gate cylinder switch was shorted.

To return to normal operation press the decrease and increase buttons at the same time, press twice.

AGITATION REFILL TIME ADJUSTMENT

To adjust the amount of ice chute refill agitation. begin by accessing the Extra Ice Portion Adjustment Mode (red Indicator). Next, press and hold for the decrease and increase buttons for three seconds until the indicator flashes amber. The indicator will flash up to four times, one flash corresponds to the minimum amount of refill agitation and four flashes corresponds to the maximum amount of refill agitation. Change the amount of refill agitation by pressing one of the four size buttons -- the small button representing the minimum amount of refill agitation. Increase the amount of refill agitation if the ice chute does not refill properly after dispensing ice.

To return to Normal Operation Mode, press the decrease and increase buttons at the same time.

MANUAL ICE DISPENSING OPERATION

A pushbutton switch is provided on the upper front panel (see Figure 1) to manualy dispense ice. This system can be used in the event of a malfunction with the ice portion control or for dispensing ice in portions other than cup-size. Depress and hold the pushbutton until the desired amount of ice is dispensed.

If a problem with the Air/CO2ice gate system should occur, a manual air valve is located on the right side of the upper front panel. The function of this valve is to remove Air/CO2pressure on the ice gate should a gate malfunction occur. Move the valve toggle switch to the “manual” position (to the right) and push the gate back to its open position. Ice can now be dispensed by depressing the manual ice dispense. switch. When the problem with the Air/CO2system has been corrected, move the toggle switch left to the “auto” position to restore the unit to the ice portioning mode of operation.

CAUTION: The gate closes immediately when the toggle switch is moved to the auto position. Do not place fingers or foreign objects into the ice chute when operating the toggle switch.

620906904

Page 11

EXTRA ICE PORTION ADJUSTMENT

The adjustment of Extra Ice Portion is accomplished in the same manner as ice portions, except the indicator light displays red. To access this mode press both the decrease and increase buttons simultaneously three times for the Normal Operation Mode (green indicator). The indicator will display red.

CLEANING INSTRUCTIONS

DISCONNECT POWER BEFORE CLEANING: Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper and top cover as damage may result. Do not use solvents or other cleaning agents, as they may attack the plastic material.

Dispenser

1. Clean the ice storage hopper at lease once a month.

2. Remove, (unscrew) agitator retainer and lift off the agitator. Wash and rinse them thoroughly .

3. Wash down the inside of the hopper and top cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent.

4. Replace the agitator and agitator retainer.

5. Sanitize the inside of the hopper and agitator with a solution of 1/2 ounce of household bleach in 1 gallon of water. (200PPM)

6. Clean and sanitize the ice chute as described below: A. Enter the Clean Mode of the ice portion control by pressing the decrease and increase button at the

same time. The indicator light will alternately display red/amber.

B. To empty the ice from the ice chute, press any of the size buttons. The ice gate will then open to allow

the ice chute to empty . The ice gate will automatically close after the ice chute has been emptied. C. Remove the 4 thumbscrews attaching the upper service panel and remove the panel. D. Remove the 2 thumbscrews attaching the ice chute strap and remove the strap. E. Remove the 4 thumbscrews that secure the ice tube to the ice hopper. Remove the ice chute and gate

cover. Power to the ice portion control and beverage valves will be interrupted while the ice chute is

removed. F. Wash ice chute, gate slide and gate cover in detergent soap solution. Then rinse thoroughly with plain

water. Sanitize as described in step 5. G. Replace components removed for cleaning in reverse order of removal. H. Portion control will automatically return to Normal operating mode (green indicator) after the ice chute

is replaced.

COLD PLATE

1. Carefully remove screws holding beverage faucet panel and bring forward.

2. Slide the cold plate cover back. (Remove shipping tape and discard).

3. Remove any debris from the drain trough and spring. Check that drain holes are not clogged.

4. Wash down the inside of the cold plate, tray, and cover with a mild detergent solution and rinse. A small, long-handled brush will be found helpful in reaching the corners.

5. Slide the cover forward, taking care that it is securely positioned on the cold plate.

620906904

Page 12

6. Replace beverage faucet panel.

BEVERAGE SYSTEM CLEANING AND SANITIZING

1. Prepare the following cleaning, rinsing and sanitizing using a clean, empty figal (5 gallon syrup tank) for each solution.

CLEANING TANK -- Fill with a solution of 1/2 ounce of a mild liquid detergent (for example, ivory liquid) to 1 gallon of warm (120_) potable water.

RINSING TANK -- Fill with warm (120_F) potable water. SANITIZING TANK -- Fill with a chlorine sanitizing solution in the strength of 1/2 ounce of household

bleach (sodium hypochlorite) to 1 gallon of cold (ambient) potable water to obtain a solution strength of 200 PPM.

NOTE: Repeat the following procedure on each of the unit’s syrup product lines and beverage faucets.

2. Using a suitable pail or bucket, fill one with a detergent solution and a second container with a sanitizing solution is the strengths as described in step 1.

A. Remove the syrup line quick disconnect fitting from the product tank and submerge in the detergent

solution. Clean with a nylon bristle brush (do not use a wire brush). Rinse with clean potable water.

B. Wearing sanitary gloves, next submerge the quick disconnect fitting in the sanitizing container for 15

minutes. Remove and air dry .

3. Hook-up the sanitized product line fitting (step 2) to the cleaning tank. Hook-up a gas disconnect fitting to the tank and pressurize with 60 to 80 psig CO2. Energize the beverage faucet continuously for 1 minute to remove all air bubbles. Continue to operate the faucet until liquid dispensed is free of any syrup. Cycle the faucet for 15 seconds on, off and then immediately on again. Repeat this procedure for 15 cycles. Then energize the faucet to remain flowing for 3 minutes.

4. Hook-up the rinsing tank and pressurize with 60 to 80 psig CO

2 .

Flush the cleaning solution from the product line by cycling the faucet as described in step 3 and then energize the faucet to flow continuously for 3 minutes.

5. Hook-up the sanitizing tank and pressurize with 60 to 80 psig CO

2 .

Flow the sanitizing solution through the beverage faucet by cycling the faucet as described in step 3. Next energize the faucet continuously to flush at least 2 cups of the sanitizing solution through the system. Finally deenergize the faucet and allow the sanitizer to remain pressurized in the line for 20 minutes.

6. Wearing sanitary gloves, remove the faucet nozzle and diffuser. Repeat the cleaning and sanitizing procedures as described in step 2, then reassemble to the faucet.

7. Disconnect the sanitizing tank. Hook-up the product tank to the unit and to the CO

2 .

system. Energize the faucet to flush the sanitizing solution from the syrup line and the faucet. Continue flow on the faucet until only syrup is dispensed.

620906904

Page 13

MAINTENANCE

The following dispenser maintenance should be performed at the intervals indicated below .

DAILY (or as required)

Remove foreign material from vending area sink to prevent drain blockage.

WEEKLY (or as required)

Clean vending area. Check for proper water drainage from the vending area sink.

MONTHLY

Clean and sanitize the hopper interior (see cleaning instructions).

620906904

Page 14

BEVERAGE FAUCET TYP. (4)

BEVERAGE FAUCET ON/OFF SWITCH

BEVERAGE FAUCET TYP. (4)

PNEUMATIC GATE

MANUAL DISPENSE PUSHBUTTON SWITCH

W H T

AGITATOR MOTOR HEATER

DIODE

WHT

AGITATOR MOTOR

RED

WHT

AGITATIONSOLID

STATERELAY

WHT

RED

GRN

RED

BLK

STARTING RELAY YEL

PRP

BLUE

YEL

RED

BLK

AGITATORMOTOR MERCURY RELAY

B L K

DIODE

TERMINAL STRIP

CAPACITOR

B L U E

115VACPOWER

DIODE

B L K

BLK

RED

W H T

BLK

WHT

WHT/RED

B L K

GROUND

BLK

ICE CHUTE RELAY

ORG/GRN

ORG/RED

RED

WHT

YLW

YLW/BLK

ORG

YLW/BLK

YLW/WHT

WHT

RED

MAGNETIC ICE CHUTE SWITCH

BLK

YLW/WHT

BLK

ORG/GRN

O R G

BLK

WHT

BLK

WHT

BLK

B L K

BLK

YLW

24V

YLW

Y L W

TRANSFORMER

YLW

TRANSFORMER

2 4 V

RECTIFIER

Q.C. CONNECTOR

G R N

B L U / B R N

ICE PORTION CONTROLLER

GRN

PNEUMATIC GATE SOLENOID

BLK

SERVICE INFORMATION

DANGER! ELECTRIC SHOCK HAZARD.

DISCONNECT POWER BEFORE SERVICING UNIT.

FIGURE 8. WIRING DIAGRAM

RED

100

(2 WATT)

CYLINDER MAGNETIC

BLK

SWITCH

RED

765

RED

620906904

Page 15

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

BREAKER

SLUSHYICE.WATERIN

DISPENSE.

BEVERAGESTOOSWEET

BEVERAGESNOTSWEET

WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs

are to be made to the CO2system, stop dispensing, shut off the CO2supply , then relieve the system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit.

Trouble Probable Cause Remedy

NOTE: should your unit fail to operate properly, check that there is power to the unit and that the

hopper contains ice. If the unit does not dispense, check the following chart under the appropriate symptoms(s) to aid in locating the defect.

BLOWN FUSE OR CIRCUIT BREAKER.

SLUSHY ICE. WATER IN HOPPER

BEVERAGES DO NOT DISPENSE.

BEVERAGES TOO SWEET.

A. Short circuit in wiring (115V

A. Replace defective wiring.

circuit). B. Defective agitator motor. B. Replace agitator motor. A. Blocked drain. A. Open--up/flush out drain. B. Unit not level. B. Level unit. C. Poor ice quality due to water

quality or ice maker problems.

C. Install water filter system. For

Icemaker problems, consult icemaker manual.

D. Improper use of flaked ice. D. Replaced flaked ice with “cube

style ice (see page2, Unit Description).

A. No 24 volt power to faucets. A. Check that beverage switch is

“on”. Check 24V transformers.

B. No CO2pressure. B. Check CO2regulator. Check CO

tank pressure. A. Carbonator not working. A. Check carbonator. B. No CO2pressure in

carbonator.

B. Check CO2regulator. Check CO

tank pressure. C. Faucet brix requires adjusting. C. Brix Faucet.

BEVERAGES NOT SWEET ENOUGH.

BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE).

A. Empty syrup tank. A. Refill syrup tank. B. Faucet Brix requires adjusting. B. Brix Faucet. A. Unit standing with no ice in

A. Refill hopper with ice. hopper - no ice in cold plate cabinet.

NOTE: Contact your local syrup or beverage equipment distributor for additional information and trouble shooting of beverage system.

620906904

Page 16

Trouble RemedyProbable Cause

ICEPORTIONCONTROLLE

NOICEDISPENSEDFRO

PUSHBUTTONSWITC

NO ICE DISPENSED FROM ICE PORTION CONTROLLER

NO ICE DISPENSED FROM MANUAL ICE DISPENSE

A. Insufficient ice supply in ice

bin.

B. Ice in ice bin bridged (stuck

A. Replenish ice supply as

instructed.

B. Gently tap on ice to break it loose.

together).

C. No electrical power to

dispenser.

D. Insufficient or no Air/CO

C. Plug in dispenser power cord, or

check fuse or circuit breaker.

D. Restore CO2supply to dispenser.

supply to dispenser. E. Inoperative ice agitator motor. E. Replace ice agitator motor. F. Inoperative gate cylinder. F. Replace gate cylinder. G. Inoperative gate solenoid. G. Replace gate solenoid. H. Inoperative ice portion

H. Replace ice portion controller.

controller. I. Defective motor capacitor. I. Replace capacitor. J. Ice gate not aligned to ice

chute.

J. Check alignment of ice gate to

slot in ice chute.

K. Agitate relay wiring incorrect. K. Red wire should be connected to

“+” terminal of relay coil. A. 24VAC transformer defective. A. Replace transformer. B. Defective rectifier. B. Replace rectifier.

ICE DISPENSING DURING AUTOMATIC AGITATION

C. Incorrect wiring or loose

C. Check wiring.

terminal / defective wire.

D. Ice gate not aligned to ice

chute.

D. Check alignment of ice gate to

slot in ice chute. E. Defective air cylinder. E. Replace air cylinder A. Manual air valve toggle switch

in “manual” position.

B. No air/CO2supply to

A. Move toggle switch to “auto”

position.

B. Restore air/CO2pressure to unit.

dispenser.

C. Defective manual ice dispense

C. Replace switch.

pushbutton switch.

620906904

Page 17

26 25 24

FIGURE 9. ICE/SOFT DRINK POST-MIX DISPENSER EXPLODED VIEW AND PARTS LIST

Index

No.

1 620504201 Gasket, Cold Plate Drain 2 2 52154 Ice Bin Cover, Gray 1 3 28708 Cup Lid Holder 1 4 28617 Service Panel 1 5 52201 Insulation, Cold Plate Drain 2 6 32839 Module Ice Portion Control 1 7 70986 Cup Rest 1 8 70188 Thumbscrew, Service Panel 4

9 70055 Nut Clip 2 10 620025701 Splash Panel 1 11 52216 Drip Tray 1 12 10145 Mounting Pin, Drip Tray 2 13 51455 Rear, Panel 1 14 70075 Nut 5 15 70171 Screw, Phil Truss Hd, No. 8-32 By 3/8-In. Long 8 16 27906R Extension, Controller Mounting 1 17 620025704 Panel, Upper Front 1 18 52837 Tube, Cold Plate Drain 2 19 51740 Drain Assembly 1 20 70339 Hose Clamp 2 21 52842 Hose Clamp 1 22 31934 Beverage Faucet On/Off Switch 1 23 620305408 Manual Ice Dispense Push Button Switch 1 24 620701203 Manual Air Valve 1 25* 70833 Fitting, Air Valve I/8 Barb x 1/8 MPT. 2 26* 51955 Air line tubing 1/8 ID x 1/16 WALL 18”

27* 70299 Screw, Slotted Truss Hd, No. 6-32 2

NOTE: *Not Shown

620906904

Part No. Description Quantity

Page 18

2808128081

15 16

3049330493

FIGURE 10. CABINET/ICE BIN ASSEMBLY EXPLODED VIEW AND PART LIST

Index

No.

Part No. Description Quantity

1 28075 Ice Agitator 1 2 70928 Drain Spring 1 3 51101 Motor Seal 1 4 32939 Motor, 120 VAC 1 5 52777 Motor Insulation 1 6 28117 Motor Support 1 7 52162 Cover, Cold Plate 1 8 30439 Junction Box 1

9 32682 Transformer Assembly (24 VAC) 2 10 28081 Cover, Electric Box 1 11 70215 Screw, #8 Self-Tapping 2 12 52778 Insulation, Motor Plate 1

13* 52779 Insulation, Motor Plate 1

14 28210 Bracket, Motor 1 15 30794 Heater, 120 VAC 1 16 70341 Spring 2 17 28377 Bracket, Motor Plate (Black) 1 18 28378 Bracket, Motor Plate 1 19 15087 Agitator, Retainer 1

620906904

Page 19

23 19

242526

11 12

FIGURE 1 1. ICE CHUTE ASSEMBLY EXPLODED VIEW AND PARTS LIST

Item

No. Part No. Description Quantity

1 70906 Screw, #8-32 x 1/2 Nylock 2 2 70173 Thumbscrews, Ice Chute 4 3 28417 Retainer, Ice Chute 1 4 70170 Thumbscrew, #8-32 x 1/2 2 5 52139 Ice Chute 1 6 52179 Gasket, Ice Chute 1 7 52236 Cover, Ice Gate 1 8 31981 Activator Magnet 1

9 70122 Screw, #4 x 3/8 Type A 4 10 32953 Switch, Ice Chute Interlock 1 11 70828 Air Valve Solenoid Assembly 1 12 620025615 Bracket Air Valve Regulator Mounting 1 13 70017 Nut, #10-32 Locking 3 14 51856 Gasket, Conduit 1 15 70016 Nut, #10-32 4 16 70056 Washer, Flat, #10 4 17 52816 Ice Conduit Assembly 1 18 620025601 Ice Gate Assembly 1 19 620701204 Air/CO2Regulator 1 20 620701201 Ice Gate Air Cylinder 1 21 620025607 Ice Gate 1 22 620701202 Hex Jam Nut 1/4-28 Stn. Stl. 1 23 620701205 Pressure Gauge 1 24 620701207 Fitting, 1/8 NPT 1 25 70663 Fitting 1/4 Barb x 1/8 MPT 1 26 50299 Tubing Air/CO2Line 36 In. 27 70833 Fitting, 1/8 Barb x 1/8 MPT 2

28* 50822 Plastic Cable Tie 2

620906904

Page 20

FIGURE 12. ELECTRICAL CONTROL BOX ASSEMBLY -- EXPLODED VIEW AND PARTS LIST

Item

No. Part No Name Quantity

1 31375 Relay, Agitator Motor 1 2 31206 Relay, Ice chute Interlock 1 3 32714 Diode Assembly 1 4 31107 Terminal Board 1 5 32503 Relay, Solid State 1

30995* Power Cord 1 32956* Cable, Ice Chute Interlock 1

620305405* Harness, Ice Portion Control 1 6 32958 Rectifier 1 7 32244 Terminal Strip 1 8 620305406 Resistor 1

620305401* Harness, Manual Ice Dispense 1

620305403* Harness, Rectifier 1

620305402* Harness, Pneumatic Gate 1

31237* Harness, Agitator Motor 1

* Items Not Shown

620906904

Page 21

FIGURE 13. MOTOR ASSEMBLY DETAIL -- EXPLODED VIEW AND PARTS LIST

Item

No. Part No. Name

1 51101 Motor Shaft Seal 2 30794 Agitator Motor Heater 3 28377 Bracket, Back, Motor Plate 4 28378 Bracket, Motor Plate 5 70250 1/4-20 x 1/2 Truss Hd Phl MS Screw 6 70048 1/4 Int tooth Lw Plated 7 70341 Spring 8 52777 Insulation, Motor

9 28210 Bracket, Motor 10 70061 5/16 ID x 3/4 OD x 1/16 Washer 11 52778 Motor Plate Insulation, 3/8 Thick 12 52779 Motor Plate Insulation, 3/4 Thick 13 32939 Agitator Motor

620906904

Page 22

WARRANTY

IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or W ilshireproduct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.

IMI Cornelius Offices

AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166 AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930 BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT , BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307 BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829 ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644 FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201 GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438 GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491 HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222 ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814 NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361 SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604 SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379 USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255

LD004

4/21/98

620906904

Page 23

CORPORATE HEADQUARTERS:

Glendale Heights, IL 60139

Remcor Incorporated

500 Regency Drive

630--539--6850

Remcor DB275-BCP Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual