ICE/BEVERAGE DISPENSER
Contents
1. LID AND STRAW HOLDER ICE PORTION JE CONTROL 4 SIZES MANUAL AIR VALVE ot 4 MANUAL DISPENSE SWITCH L UF 1 OPTIFILL gt VALVES E 35 1 2 imm a d 13 16 41 2 30 E bd 111 16 8 14 Ll REMOVABLE PANEL FOR REAR HOOKUP 4112 OF BEVERAGE TUBING _ LAT AND AIR CO2 LINES qo ELECTRICAL 1018 POWER CORD REMOVABLE HOLE PLUGS 2 FOR REAR 23 HOOKUP OF DRIP 30 TRAY DRAIN FIGURE 3 DISPENSER DIMENSIONS BACK 3 8 E 11 8 DI 116 7 7 16 20 3 4 14 1 2 30 612 17 30 FRONT NOTE SHADED AREA INDICATES OPENING IN CABINET BOTTOM NEEDED FOR UTILITIES AND BEVERAGE TUBING FIGURE 4 MOUNTING TEMPLATE 620906904 4 3915 SIHL IWOUd Q3A lA 5132 OPTIONAL FOR cj DIETOR REGULATORS A OCH ROOT BEER amp 5 15 PSIG FAUCETS 5 50 PSIG 1 51 1 5 52 s 62 53 s4 65 561167 65 COJTANK 153 Le J 3 o 54 SYRUP 5 4 T FAUCET NO s ub 5 WATER HOOK UPS M2. 24 CAPACITOR AGITATOR MOTOR BLK BLK _ RED BLK ICE CHUTE RELAY BLK BLUE uh BLK RED o 7 A MAGNETIC ICE YEL CHUTE SWITCH WHT o NG w 5 B N H T AGITATOR MOTOR B MERCURY RELAY BLK L K DIODE WHT BLK BLK YLW BEVERAGE BLK FAUCET 4 wr WHT YLW WHT YLW B YLW BLK 1 2w L K vint H AGITATOR MOTOR Y HEATER BEVERAGE YLWANHT o wW TRANSFORMER FAUCET ON OFF ORG GRN SWITCH Ya WHT ORG GRN ORG RED vw BLK AGITATION SOLID R TRANSFORMER STATE RELAY 1l ORG RED G 5 1 L WHT BEVERAGE BLK ORG e FAUCET TYP 4 2 WHT 4 al S L 1 wir RED K xs WHT PNEUMATIC GATE WHT RED B wl N WHT L H N MANUAL DISPENSE T RED DIODE PUSHBUTTON SWITCH 1 WHT B GRN L K 2 RED RED c c 3 RECTIFIER B LN I 4 L DIODE TERMINAL J n BLK K STRIP 9 9 Yd B GRN N N RED dE MNS w E 2 WATT SNe R N B PNEUMATIC L s SATE SOLENOID B o 6 B T To CYLINDER R MAGNETIC N SWITCH Q C CONNECTOR amp A RED B R 3 L E A K D 1 2 3 4 5 6 7 8 9 ICE PORTION CONTROLLER DANGER DISCONNECT POWER BEFORE SERVICING UNIT FIGURE 8 WIRING DIAGRAM 11 620906904 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs WARNING If repairs are to be made to a pro
3. gg x wn 620906904 Item No SI 0 VI KB UJ NJ NF 13 620906904 FIGURE 13 MOTOR ASSEMBLY DETAIL EXPLODED VIEW AND PARTS LIST Part No 51101 30794 28377 28378 70250 70048 70341 52777 28210 70061 52778 52779 32939 18 Motor Shaft S eal Agitator Motor Heater Bracket Back Motor Plate Bracket Motor Plate 1 4 20 x 1 2 Truss Hd Phl MS Screw 1 4 Int tooth Lw P lated Spring Insulation Motor Bracket Motor 5 16 ID x 3 4 OD x 1 16 Washer Motor Plate Insulation 3 8 Thick Motor Plate Insulation 3 4 Thick Agitator Motor WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workmanship un der normal use and service For a copy of the warranty applicable to your Cornelius Remcor or Wilshire prod uct in your country please write fax or telephone the IM Cornelius office nearest you Please provide the equipment model number serial number and the date of purchase IMI Cornelius Offices AUSTRALIA e P O 210 e RIVERWOOD e NSW 2210 AUSTRALIA e 61 2 533 3122 e FAX 61 2 534 2166 AUSTRIA LANGEN FELDE 32 e A 1222 e VIENNA AUSTRIA 43 1 233 520 e FAX 43 1 2335 2930 BELGIUM e BOSKAPELLEI 122 e B 2930 BRAASCHAAT BELGIUM e 32 3 664 0552 e FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL e 55 21 591 7150 e FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER
4. WARWICKSHIRE B49 6 EU ENGLAND 44 789 763 101 e FAX 44 789 763 644 FRANCE e 71 ROUTE DE ST DENIS e F 95170 DEUIL LA BARRE PARIS FRANCE 33 1 34 28 6200 e FAX 33 1 34 28 6201 GERMANY eCARL LEVERKUS STRASSE 15 e D 4018 LANGENFELD GERMANY e 49 2173 7930 e FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE AGIA PARASKEVI e 153 42 e ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 ONG KONG 1104 TAIKOTSUI CENTRE 11 15 KOK CHEUNG ST e TAIKOKTSUE HONG KONG 852 789 9882 e FAX 852 391 6222 ALY e VIA PELLIZZARI 11 e 1 20059 e VIM ARCATE ITALY e 39 39 608 0817 e FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES e BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND e 64 9 8200 357 e FAX 64 9 8200 361 SINGAPORE 16 TUAS STREET SINGAPORE 2263 65 862 5542 e FAX 65 862 5604 S U T PAIN e POLIGONO INDUSTRAIL e RIERA DEL FONOLLAR e E 08830 SANT BOI DE LLOBREGAT e BARCELONA SPAIN e 34 3 640 2839 e FAX 34 3 654 3379 SA eONE CORNELIUS PLACE eANOKA MINNESOTA e 612 421 6120 e FAX 612 422 3255 LD004 4 21 98 19 620906904 REMCOR CORPORATE HEADQUARTERS R emcor Incorporated 500 Regency Drive Glendale Heights IL 60139 630 539 6850
5. 1 25 70833 Fitting Air Valve 1 8 Barb x 1 8 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 14 Index z 0 VI RK 4 FIGURE 10 CABINET ICE BIN ASSEMBLY EXPLODED VIEW AND PART LIST Part No 28075 70928 51101 32939 52777 28117 52162 30439 32682 28081 70215 52778 52779 28210 30794 70341 28377 28378 15087 15 Description Ice Agitator Drain S pring Motor Seal Motor 120 VAC Motor Insulation Motor Support Cover Cold Plate J unction Box Transformer Assembly 24 VAC Cover Electric Box Screw 8 Self Tapping Insulation Motor Plate Insulation Motor Plate Bracket Motor Heater 120 VAC Spring Bracket Motor Plate Black Bracket Motor Plate Agitator R etainer Quantity m op PNP LH MN HB ON LB FH LB 620906904 Item No VI gt ON NJ NJ NJ NJ MJ NJ MJ MJ PP DURE WN EO O DU 28 620906904 FIGURE 11 ICE CHUTE ASSEMBLY EXPLODED VIEW AND PARTS LIST Part No 70906 70173 28417 70170 52139 52179 52236 31981 70122 32953 70828 620025615 70017 51856 70016 70056 52816 620025601 620701204 62
6. of this equip ment 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 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 CAUTION Dispenser cannot be used with crushed or flaked ice Use of bagged ice which 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 dis p
7. the hopper and agitator with a solution of 1 2 ounce of household bleach in 1 gallon of water 200P PM 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 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 2 3 4 5 Carefully remove screws holding beverage faucet panel and bring forward Slide the cold plate cover back Remove shipping tape and discard Remove any debris from th
8. 0701201 620025607 620701202 620701205 620701207 70663 50299 70833 50822 16 Description Screw 48 32 x 1 2 Nylock Thumbscrews Ice Chute Retainer Ice Chute Thumbscrew 48 32 x 1 2 Ice Chute Gasket Ice Chute Cover Ice Gate Activator Magnet Screw 4 x 3 8 Type A S witch Ice Chute Interlock Air Valve Solenoid Assembly Bracket Air Valve Regulator Mounting Nut 10 32 Locking Gasket Conduit Nut 410 32 Washer Flat 410 Ice Conduit Assembly Ice Gate Assembly Air CO Regulator Ice Gate Air Cylinder Ice Gate Hex J am Nut 1 4 28 Stn 54 Pressure Gauge Fitting 1 8 NPT Fitting 1 4 Barb x 1 8 MPT Tubing Air CO Line Fitting 1 8 Barb x 1 8 MPT Plastic Cable Tie Quantity LH LH LB HB EWE 36 In FIGURE 12 ELECTRICAL CONTROL BOX ASSEMBLY EXPLODED VIEW AND PARTS LIST Item No Part No 31375 31206 32714 31107 32503 30995 32956 620305405 6 32958 7 32244 8 620305406 620305401 620305403 620305402 31237 amp WN Items Not Shown 17 Name Relay Agitator Motor Relay Ice chute Interlock Diode Assembly Terminal Board Relay Solid State Power Cord Cable Ice Chute Interlock Harness Ice Portion Control Rectifier Terminal Strip Resistor Harness Manual Ice Dispense Harness Rectifier Harness Pneumatic Gate Harness Agitator Motor Quantity 1 PPP PPP
9. AY BE m 3 CARBONATED Bare OR PLAIN Sz lu Sr 2 WATER AS 2 o 220 REQUIRED 4 a gt 8 Sme a D o j o Ze 16 2 9 EA 55 mo e S6 8 57 S8 COLD PLATE NOTES 1 FOR REFERENCE ONLY NOT FOR CONSTRUCTION t FILTER WATER 2 SEE PLUMBING SCHEMATIC LABEL VN ICE SOFT DRINK POST MIX OPTIONAL SUPPLY UNDER LOWER PANEL FOR APPROPRIATE DISPENSER ITEMS OUTSIDE PRESSURE HOOK UP SEE MANUAL CARBONATOR BROKEN LINES ARE NOT INCLUDED REGULATOR FIGURE 5 BEVERAGE SYSTEM SCHEMATIC PLUMBING SCHEMATIC 1 2 3 4 FAUCETS 5 6 7 8 o o o COLDPLATE 1 2 3 4 4 3 5 6 7 8 1 5 6 7 SYRUP 8 SYRUP INLETS WATER INLETS 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 2 MAKE SURE ALL DRAIN CONNECTIONS ARE PROPERLY POSITIONED FOR DRAINING AFTER SERVICE BEFORE PANELS ARE INSTALLED FIGURE 6 PLUMBING SCHEMATIC 5 620906904 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
10. Bracket Bracket n a 32977 Keylock Assy W Keys n a n a 70739 Key JLS 01 27 03 Key is marked D001 n a 30995 Power Cord n a 28708 Lid amp Straw Holder n a 29328 Z Style Lower 29 43x10 468 Splash Panel n a 08052 Splash Guard Kit JLS 01 27 03 Includes two clear side guards n a n a 33160R Start Capacitor n a n a 33162 Motor Start Relay n a 70478R Push On Clips JLS 01 27 03 For drip tray n a n a 28004 Drip Tray JLS 101 27 03 30x7 stainless steel Extension FIGURE 9 ICE SOFT DRINK POST MIX DISPENSER EXPLODED VIEW AND PARTS LIST Index No Part No Description Quantity 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 S witch 1 23 620305408 Manual Ice Dispense Push Button S witch 1 24 620701203 Manual Air Valve Toggl Switch
11. CC REMGOR ICE BEVERAGE DISPENSER Model DB275 BCP Operator s Manual 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 CORNELIUS INC 1997 PRINTED IN U S A TABLE OF CONTENTS Page GENERAL DESCRIPTION 2 SAFETY PRECAUTIONS ve Bee a 2 UNIT DESCRIPTION aars eee en 2 SPECIFICATIONS ising onteren aaa RHET a ar peer d 2 ICEMAKER ADAPTER KITS ada ne d 2 INSTALLATION INSTRUCTIONS 3 START UP AND OPERATING INSTRUCTIONS 6 ICE PORTIONING SYSTEM OPERATION 6 NORMAL OPERATION ER ona ee S pedo e Pme Ren 7 CEEAN MODE Ate at te Mee eda x ea cays 7 NORMAL ICE PORTION ADJ 5 7 AGITATION REFILL TIME ADJUSTMENT 7 MANUAL ICE DISPENSING OPERATION 7 EXTRA ICE PORTION ADJUSTMENT 8 CLEANING INSTRUCTIONS sssss HH 8 DISPENSER tn eed ede etie C era ati en AC eon 8 COED PLATE e te ha ena M De M ea dake 6 8 BEVERAGE SYSTEM CLEANI
12. 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 9 620906904 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 10 WHT 115VAC POWER STARTING RELAY YEL GROUND L N 3 1 PRP
13. NG AND 5 9 522 65 a 10 DAILY OR AS 10 WEEKLY OR AS REQUIRED irr IRE ERE HEN EL headin EE RR s 10 10 TROUBLESHOOTING ehe 12 BLOWN FUSE OR CIRCUIT 12 SLUSHY ICE WATER IN HOPPER 12 BEVERAGES DO NOT 5 12 BEVERAGES TO SWEET 25 uam a 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 2 nrden ed veen nenten nennen eens 19 620906904 TABLE OF CONTENTS cont d LIST OF FIGURES FIGURE 1 PARTS IDENTIFICATION overe sere sand end 1 FIGURE 2 DRIP TRAY DRAIN ASSEMBLY FOR BOTTOM HOOK UP 3 FIGURE 3 DISPENSER 10 5 4 FIGURE 4 MOUNTING TEMPLATE 4 FIGURE 5 BEVERAGE SYSTEM SCHEMATIC 5 FIGURE 6 PLUMBING SCHEMATIC 5 FIGURE 7 CUP SIZE LABEL
14. TED 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 amp 6 This work should be done by a qualified serviceman 5 ICE PORTION CONTROLLER Regulated and filtered 5 pressure or compressed air is required to operate the ice portion control dispensing system Proceed as follows to connect the CO gas pressure source line to the dispenser A Connect and route the Air CO line from outlet side of the source regulator assembly up to the dis penser NOTE Thatthe minimum source regulated pressure is 40 psig B Connectthe Air CO source line to dispenser inlet line labeled AIR CO C The dispenser regulator outlet pressure is factory preset to 34 psig 2 psig DO NOT ADJUST IMPORTANT Maximum Air CO operating pressure is 35 psig 6 Clean the hopper interior see cleaning Instructions 3 620906904 Connect the power cord to 115 volt 60 cycle 3 wire grounded receptacle BEVERAGE VALVE ON OFF SWITCH
15. duct system remove quick disconnects from are to be made to the CO system stop dispensing shut off the supply 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 NOTE Probable Cause Remedy 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 BEVERAGES NOT SWEET ENOUGH BEVERAGES NOT COLD UNITS WITH BUILD IN COLD PLATE A B A B C UJ gt Slo Short circuit in wiring 115V circuit Defective agitator motor Blocked drain Unit not level Poor ice quality due to water quality or ice maker problems Improper use of flaked ice No 24 volt power to faucets No CO pressure Carbonator not working No pressure in carbonator Faucet brix requires adjusting Empty syrup tank Faucet Brix requires adjusting Unit standing with no ice in hopper no ice in cold plate cabinet A B A B C UJ gt Slo Replace defective wiring Replace agitator motor Open up flush out drain Level unit Install water filter system For Icemake
16. e drain trough and spring Check that drain holes are not clogged 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 Slide the cover forward taking care that it is securely positioned on the cold plate 620906904 8 6 Replace beverage faucet panel BEVERAGE SYSTEM CLEANING AND SANITIZING l 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 Repeatthe following procedure on each of the unit s syrup product lines and beverage fau cets 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 n
17. e 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 di mensions 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 CO line 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 bot tom 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 drip tray 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 INSULA
18. eea 6 FIGURE 8 WIRING DIAGRAM 11 FIGURE 9 ICE SOFT DRINK POST MIX DISPENSER EXPLODED VIEW AND PART LIST 35 5 r Rebbe ted FUE TEE 14 FIGURE 10 CABINET ICE BIN ASSEMBLY EXPLODED VIEW AND PART LIST 22822 tte te DR e eet Cete C testi ie uel a x OR e 15 FIGURE 11 ICE CHUTE ASSEMBLY EXPLODED VIEW AND PARTS LIST 16 FIGURE 12 ELECTRICAL CONTROL BOX ASSEMBLY EXPLODED VIEW AND PARTS EIS T sucer m e rere E Rm and EYE DR we ae DE Kn a ce 17 FIGURE 13 MOTOR ASSEMBLY DETAIL EXPLODED VIEW LIS eek te nee gea eene a 18 620906904 i RETAINER ICE BIN COVER 1 ICE AGITATOR ICE PORTION CONTROL MODULE ICE CHUTE REMOVABLE STRAW HOLDER PANEL LID STRAW HOLDER BEVERAGE BEVERAGE FAUCET FAUCETS 8 ON OFF SWITCH LOWER ACCESS MANUAL AIR VALVE PANEL MANUAL ICE DISPENSE C PREST PUSH BUTTON SWITCH DRIP TRAY FIGURE 1 PARTS IDENTIFICATION 1 620906904 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 per taining to questions that arise during installation operation service or maintenance
19. ensers 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 Storage 275 lbs Maximum Number of Faucets Available 8 Built in Cold P late Yes Electrical 115 1 60 Dimensions 30 W x 30 D x 41 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 top mounted 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 2 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 A112 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 l Locat
20. ently active CLEAN MODE Access this mode when cleaning the ice chute Refer to Cleaning Instructions on pages 7 thru 9 NORMAL ICE PORTION ADJ USTMENT 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 por tion 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 ti
21. ext 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 CO2 Flush the cleaning solution from the prod uct line by cycling the faucet as described in step 3 and then energize the faucet to flow continuously for minutes 5 Hook up the sanitizing tank and pressurize with 60 to 80 psig 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 atleast 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 proce dures 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 system
22. ish ice supply as instructed Gently tap on ice to break it loose Plug in dispenser power cord or check fuse or circuit breaker Restore CO supply to dispenser Replace ice agitator motor Replace gate cylinder Replace gate solenoid Replace ice portion controller Replace capacitor Check alignment of ice gate to slot in ice chute Red wire should be connected to terminal of relay coil Replace transformer Replace rectifier Check wiring Check alignment of ice gate to slot in ice chute Replace air cylinder Move toggle switch to auto position Restore air CO pressure to unit Replace switch 620906904 gt BEVCORe Part Corrections Update Document Unit Type Model Manual ICE BEVERAGE 620906904 DISPENSER MODEL DB275 BCP OPERATOR S MANUAL Revision 2 6 27 06 Page Item Old Description New Part Description Agent Date Notes Part 14 2 52154 Ice Bin Cover 52154 1 Bin Lid Kit JLS 01 27 03 Gray 14 6 629081401 Touch Panel JLS 01 27 03 Overlay for Ice Portion Overlay Module 15 4 32939 Motor 08049 Motor Kit JLS 01 27 03 Includes motor motor relay start capacitor 18 13 and hardware 16 20 620701201 Gate Air SRV 6 27 06 Has 250 diameter Cylinder rod 70888 Ice Gate Air Has a 188 diameter Cylinder rod 18 4 28378 Motor Plate 28378R Motor Plate JLS 01 27 03
23. 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 lo cated above the ice chute An extra ice portion may be obtained by pressing the increase key 4 before press ing 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 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 CAUTION Use caution to avoid spilling ice when filling dispenser Clean up immediately ICE PORTIONING SYSTEM OPERATION INDICATOR LIGHT DECREASE SMALL MEDIUM LARGE X LARGE INCREASE FIGURE 7 CUP SIZE LABEL The ice portioning system consists of three main components l Ice Portion Control 2 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
24. me press twice AGITATION REFILL TIME ADJ USTMENT 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 atthe 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 ice 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 CO pressure on the ice gate should a gate malfunction occur Move the valve toggle switch to the manual position to the righ
25. r problems consult icemaker manual Replaced flaked ice with cube style ice see page2 Unit Description Check that beverage switch is on Check 24V transformers Check CO regulator Check CO tank pressure Check carbonator Check CO regulator Check CO tank pressure Brix Faucet Refill syrup tank Brix Faucet Refill hopper with ice NOTE Contact your local syrup or beverage equipment distributor for additional information and trouble shooting of beverage system 620906904 12 Trouble NO ICE DISPENSED FROM ICE PORTION CONTROLLER NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH ICE DISPENSING DURING AUTOMATIC AGITATION zo mm Probable Cause Insufficient ice supply in ice bin Ice in ice bin bridged stuck together No electrical power to dispenser Insufficient or no Air CO supply to dispenser Inoperative ice agitator motor Inoperative gate cylinder Inoperative gate solenoid Inoperative ice portion controller Defective motor capacitor Ice gate not aligned to ice chute Agitate relay wiring incorrect 24VAC transformer defective Defective rectifier Incorrect wiring or loose terminal defective wire Ice gate not aligned to ice chute Defective air cylinder Manual air valve toggle switch in manual position No air CO supply to dispenser Defective manual ice dispense pushbutton switch 13 zo mm Remedy Replen
26. t 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 CO system 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 7 620906904 EXTRA ICE PORTION ADJ USTMENT 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
27. 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 oper ated for a period of one minute whenever one of the three adjustment modes have been accessed 620906904 6 NORMAL OPERATION To dispense ice hold a cup directly under the ice chute then press the appropriate size button on the ice por tion 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 avail able in the ice chute to dispense the selected size The indicator light will return to solid green and ice dispens ing 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 ac cess 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 curr
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