Remcor DB200 User manual

ICE/BEVERAGE DISPENSER
MODELSDB200/220/275S
DB200/220/275S-B
DB200/220/275S-BC
DB200/220/275S-KBC
Operator’sManual
PRINTEDIN U.S.A
âREMCORINC:1993--97
PartNo.91679
May1997
Revision E
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

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TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS1...................................................
GENERALDESCRIPTION1..................................................
INSTALLATIONINSTRUCTIONS2............................................
MAINTENANCE11...........................................................
CLEANING INSTRUCTIONS11................................................
TROUBLESHOOTING GUIDE14...............................................
WARRANTY22..............................................................
LISTOF FIGURES
FIGURE1. GATERESTRICTORPLATE3..................................
FIGURE2.MOUNTINGTEMPLATE4.....................................
FIGURE3.MOUNTINGTEMPLATE5.....................................
FIGURE4.BEVERAGE SYSTEMSCHEMATIC-BMODEL 6.................
FIGURE5.BEVERAGE SYSTEMSCHEMATIC-BCMODEL 7................
FIGURE6.PLUMBINGSCHEMATIC6FAUCETS8.........................
FIGURE7.PLUMBINGSCHEMATIC8FAUCETS9.........................
FIGURE8.PLUMBINGSCHEMATIC10 FAUCETS10........................
FIGURE9.WIRINGDIAGRAMICEONLY AND “B”MODELS15...............
FIGURE10.WIRINGDIAGRAM“C”AND “K”MODELS16.....................
FIGURE11.SOLENOIDASSEMBLY AND PARTSLIST17....................
FIGURE12.EXPLODEDASSEMBLY(UPPERAND PARTSLIST)18...........
FIGURE13.EXPLODEDVIEW(LOWERAND PARTSLIST)19................
FIGURE14.MOTORASSEMBLYDETAILAND PARTSLIST20................
LISTOF TABLES
TABLE1.SPECIFICATIONS2............................................
Manufactured UnderOne or More of the following PatentNumbers:3,211,336,3,274,792,3,393,839,3,517,860
3,739,842,4,215,803,4,227,377,4,300,359,4,346,824
Canadian PatentNumbers912,514(10/72),936,855 (11/73),4,429,543,4,921,149
OtherPatentsPending

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SAFETY PRECAUTIONS
Always disconnectpowertothe dispenserbeforeservicing orcleaning.
Neverplace handsinside ofhopperorgate area withoutdisconnecting powertothe dispenser.Agitator rotation
occursautomaticallywhen the dispenserisenergized!
Thisice dispenserhasbeen specificallydesigned to provide protection againstpersonal injuryand eliminates
contamination ofice.Toinsurecontinued protection and sanitation,observethe following
ALWAYS be surethe removablelidisproperlyinstalled to preventunautho-
rized access tothe hopperinteriorand possiblecontamination ofice.
ALWAYS be surethe upperand lowerfrontpanelsaresecurelyfastened.
ALWAYS keep area around the dispenserclean oficecubes.
CAUTION:Dispensercannotbeusedwithcrushed orflakedice.
Use ofbaggedice which has frozenintolarge chunks canvoidwarranty.Thedispenser
agitatorisnotdesignedto be anice crusher.Use oflarge chunks ofice which“jamup”
insidethehopperwill cause failureof the agitator motorand damagetothehopper. Ifbaggedice
isused, itmustbe carefully and completelybrokenintosmall, cube-sized pieces beforefilling into
thedispenserhopper.
GENERALDESCRIPTION
The Remcor“DB”seriesofice dispensers solveyourice and beverage service needsinasanitary,spacesav-
ing,economical way.Designed tobemanuallyfilled withicefromanyremoteicemaking source, these
dispenserswill dispensecubes(up 1-1/4”insize),cubeletsand hard-chipped orcracked ice.
“B”modelsalsocontain beverage faucetsand mustbe supplied withcold product fromanyremotecold plate or
refrigerated soda factory.
“BC”unitsinclude bothfaucetsand cold platesand are designed tobesupplied direct fromsyrup tanks and car-
bonator,with no additionalcooling required.
Table 1.Specifications
Model:DB200SDB220SDB275S
IceStorage:200 lbs.220 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:N/AN/AN/A
Built-inColdPlate:NoNoNo
Dimension:30Wx30Dx33H30Wx30Dx36H30Wx30Dx40H
Model:DB200S-BDB220S-BDB275S-B
IceStorage:200 lbs.220 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:10 10 10
Built-inColdPlate:NoNoNo
Dimension:30Wx30Dx33H30Wx30Dx36H30Wx30Dx40H
Model:DB200S-BC DB220S-BC DB275S-BC
IceStorage:200 lbs.220 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:10 10 10
Built-inColdPlate:YesYesYes
Dimension:30Wx30Dx33H30Wx30Dx36H30Wx30Dx40H
Electrical(forall models)120V,1ph., 5.5Amps
DrainConnection 7/8ID Hose

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ICEMAKER
REMCOR“K”ModelIce/Beverage dispensersare designed to be used with one ofseveraltype top mountice-
makers.Thismustbe obtained fromthe appropriatemanufacturer.
Check withyourREMCORSalesCoordinatorforalistoficemakerkitsavailable.This kitwill contain partsand
instructionsnecessarytoconnect the icemakertothe ice dispenser.
INSTALLATIONINSTRUCTIONS
1.The ice dispensermustbe sealedtothe counter.The template drawing (See Figure 2)indicatesopenings
whichmustbe cutinthe counter.Locatethe desired position forthe dispenser, then markthe outline di-
mensionson the counterusing the template drawings.Cutopeningsinthe counter.
Applyacontinuousbead ofNSFInternational(NSF)listed silastic sealant(Dow732 orequal)approximate-
ly1/4”inside of the unitoutline dimensionsand around all openings.Then position the uniton the counter
withinthe outline dimensions.All excess sealantmustbe wiped awayimmediately. On“BC”Models, the
sinkis shipped loose and isnot tobesealed.Thisisneeded forinstallation of the beverage systemand for
service.
2.“BC”Modelbeverage connectionsaremade inthe frontof the unit. Withthe lowerpanelremoved using
the plumbing schematics (See Figures6,7,or8)orschematicon the rearof the panelto determine syrup
and waterconnections.
3.Carefullypull the beverage tubes,drainline and powercordthrough the large opening inthe bottomof the
unit.
4.“K”Modelsonly: Install icemakeraccording toinstructions supplied withkitand manufacturer’sinstructions
supplied withicemaker.
5.Connect the draintube to an open drain.Ifadditionalpiping isrequired,itmustbe 3/4”IPS (orequal)and
mustpitch downward awayfromthe unit forproperdrainage.
6.Connect the beverage systemproductlinesasindicated (See Figures4 or5).Thiswork should be done by
a qualified service person.
7.Clean the hopperinterior (See CLEANING INSTRUCTIONSon pages11 through NOTAG).
8.Connect the powercordtoa115volt, 60 cycle,3-wire grounded receptacle.All electrical wiring mustcon-
form to nationaland localelectricalcodes.

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GATERESTRICTORPLATE
CAUTION:Disconnectpowerto dispenserbeforeinstalling,removing oradjusting
restrictor.
FIGURE1. GATERESTRICTORPLATE
ADJUSTMENT
Thisdispenserisprovided with a gaterestrictorplate(Figure1),installed initshighestposition.Thisplate ad-
juststhe rate oficeflowfromthe dispenser. In applicationsusing buckets,carafesorotherlarge containers, the
platemaybe removed entirelyfor maximumiceflow.Forglassesand cups, the platemaybe adjusted down-
wardtoreducethe flowofice. the bestposition dependson the type ofice being used and the sizecontainer
and mustbe found bytrialand error.Adjustmentismade byloosening the uppertwoicechuteretaining nuts,
sliding the restrictorplatetothe desired position and re-tightening the nuts.
If the dispenserfailsto dispensethe icewhen operated,check that the hopperhasiceinitand thatpoweris
being supplied tothe unit. If the problempersists,refertotroubleshooting guide on (page 14).

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NOTE:SHADED AREAINDICATEOPENINGS
IN CABINETBOTTOMNEEDEDFOR
UTILITIES AND BEVERAGETUBING
27 3/4-IN.1 1/8-IN. 1 1/8-IN.
20 3/4-IN.
30-IN.
14-IN.
8 5/8-IN.
17-IN.6 1/2-IN.
30-IN.
3/8DIA.HOLE(4)PLCS
FIGURE2.MOUNTINGTEMPLATE

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NOTE:SHADED AREAINDICATEOPENINGS
IN CABINETBOTTOMNEEDEDFOR
UTILITIES AND BEVERAGETUBING
27-3/4-IN.
1-1/8-IN.
20 -3/4-IN.
30-IN.
14-IN.
30-IN.
8-IN.
FRONT
7-IN.
23-IN.
7-15/16IN.
4-1/2IN.
1-1/8-IN.
BACK
REMOVABLE
SINK
3/8DIA.HOLE(4)PLCS
FIGURE3.MOUNTINGTEMPLATE

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FIGURE 4. BEVERAGE SYSTEM SCHEMATIC

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FIGURE 5. BEVERAGE SYSTEM SCHEMATICE -BC MODEL

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK HASTOBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
3)DONOTUSE INLETS.
FIGURE6.PLUMBINGSCHEMATIC6FAUCETS

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK HASTOBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
5
FIGURE7.PLUMBINGSCHEMATIC8FAUCETS

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK HASTOBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
FIGURE8.PLUMBINGSCHEMATIC10 FAUCETS

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MAINTENANCE
The following dispenser maintenanceshould be performed at the intervalsindicated:
DAILYorasrequired
Removeforeign materialfromthe vending area sinkto preventdrain blockage.
WEEKLYorasrequired
Clean vending area.Check forproperwaterdrainage fromthe vending area sink.
MONTHLY
Clean and sanitizethe hopperinterior (see CLEANING INSTRUCTIONS).
START-UPAND OPERATINGINSTRUCTIONS
Fill the hopperwithice.For“BC”modelswith a built-incold plate,dispenseseveral large cupsofice(approxi-
mately20 to30secondstotaldispensing time)to allow icetofill the cold plate.Add icetothe hopperasneces-
sarytorefill then replacethe lid.Allow10 to15minutesforthe cold platetocooldown.Repeat thisprocedure
wheneverthe dispenserhasbeen standing overnightorotherlong periodswithoutice use. On“B”and “BC”
models startup the beverage systemand adjust faucetstothe properbrix.Contactyourlocaldistributorfor
completeinformation on the beverage system.
In normaloperation,pushing the ice dispenserleverwill causeicetoflowfromthe icechute. Iceflow will contin-
ue until the leverisreleased.Pushing the leveron anyfaucetwill provide beverage of the appropriateflavor.
Forautomaticicefilling “K”models, the agitation timercausesthe icetolevel which allowsthe entirestorage bin
tofill beforethe icemachine shutsoff. The icemakercontrolcapillarybulbmaintainsthe icelevel inthe storage
hopper.Consult the instructionsprovided withthe installation kitand the icemaker manualforlocation and op-
eration of the icemakercontrol.
CAUTION:Use caution toavoidspilling ice whenfilling dispenser. Immediately clean up
any spilledice fromfilling oroperation of theunit.To preventcontamination ofice,thelid
mustbeinstalledontheunitatall times.
CLEANINGINSTRUCTIONS
WARNING:DISCONNECTPOWER BEFORECLEANING!Do notuse metalscrapers,sharp
objectsorabrasives on theice storagehopper,top coverand the agitatordisk,as damage
may result.Do notuse solventsorothercleaning agents,as they may damagetheplastic
material.
DISPENSERAll Models
1.Clean the icestorage hopperatleastonceamonth.

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2.Lift off the agitatorassembly.Wash and rinsethemthoroughly.
3.Wash downthe inside of the hopperand top coverwithamild detergentsolution and rinsethoroughlyto
remove all tracesofdetergent.
4.Replacethe agitator.
5.Sanitizethe inside of the hopperand agitatorwithasolution of1 ounce ofhousehold bleachin 2 gallonsof
water.(200 PPM)
6.Replacethe agitatordisk.Sanitize asdescribed inStep 5.
7.RemoveIceChutecoverasfollows:
A.Flex sidesoutwardto disengage lowerpins.
B.Lift IceChutecoverto disengage upperpins.
C.LowerIceChutecoverdown outofunit. Note:itmaybe helpfultotwistcoverslightly.
8.Clean the inside of the icechute and icechutecoverwithamild detergentsolution and rinsethoroughlyto
remove all tracesofdetergent.
9.Reversestepsabovetoreassembleicechute.
10.Sanitize asdescribed inStep 5.
COLDPLATE(-BC MODELS)
1.Carefullyremovescrewsholding beverage faucetpaneland bring forward.
2.Slide the cold platecoverback.(Removeshipping tape and discard.)
3.Remove anydebrisfromthe draintrough and spring.Check that the drain holeisnotclogged.
4.Wash downthe inside of the cold plate, trayand coverwithamild detergentsolution and rinse.Asmall,
long-handled brushwill be found helpful inreaching the corners.
5.Slide the coverforward, taking carethatitis securelypositioned on the cold plate.
6.Replace beverage faucetpanel.
BEVERAGE SYSTEMCLEANINGAND SANITIZINGINSTRUCTIONS
1.Preparethe following cleaning,rinsing and sanitizing solutionsusingaclean,emptyfigal(5 gallon syrup
tank)foreachsolution.
CLEANINGTANK -- Fill withasolution of1/2 ounce ofamildliquid detergent(forexample, Ivoryliquid)to
1 gallon ofwarm (120_F)potablewater.
RINSINGTANK -- Fill withwarm (120_F)potablewater.
SANITIZINGTANK -- Fill withachlorine sanitizing solution inthe strength of1/2 ounce ofhousehold
bleach(sodiumhypochlorite)to 1 gallon ofcold(ambient)potablewaterto obtainasolution strength of200
PPM.
NOTE:Repeat thefollowing procedureon each of theunit’s syrup productlines and beveragefaucets.
2.Usingasuitable pail orbucket, fill one with a detergentsolution and a second containerwithasanitizing
solution inthe strengthsasdescribed instep 1.
A.Removethe syrup line quick disconnect fitting fromthe product tankand submerge inthe detergent
solution.Clean withanylon bristle brush(do notuseawire brush).Rinsewithclean potablewater.

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B.Wearing sanitarygloves,nextsubmerge the quick disconnect fitting inthe sanitizing containerfor15
minutes.Remove and airdry.
3.Hook-up the sanitized productline fitting (step 2)tothe cleaning tank.Hook-up a gasdisconnect fitting to
the tankand pressurizewith60to 80 psigCO2.Energizethe beverage faucetcontinuouslyfor1minuteto
remove all airbubbles.Continue to operatethe faucetuntil liquid dispensed isfree ofany syrup.Cyclethe
faucet for15 secondson,off and then immediatelyon again.Repeat thisprocedurefor15 cycles.Then
energizethe faucet toremainflowing for3minutes.
4.Hook-up the rinsing tankand pressurizewith60to 80 psigCO2.Flushthe cleaning solution fromthe prod-
uctline by cycling the faucetasdescribed instep 3 and then energizethe faucet toflowcontinuouslyfor3
minutes.
5.Hook-up the sanitizing tankand pressurizewith60to 80 psigCO2.Flowthe sanitizing solution through the
beverage faucetby cycling the faucetasdescribed instep 3.Nextenergizethe faucetcontinuouslytoflush
atleast2cupsof the sanitizing solution through the system.Finallydeenergizethe faucetand allowthe
sanitizertoremain pressurized inthe line to20minutes.
6.Wearing sanitarygloves.removethe faucetnozzle and diffuser.Repeat the cleaning and sanitizing proce-
duresasdescribed instep 2, then reassembletothe faucet.
7.Disconnect the sanitizing tank.Hook-up the product tanktothe unitand tothe CO2system.Energizethe
faucet toflushthe sanitizing solution fromthe syrup line and the faucet. Continue flowon the faucetuntil
only syrup isdispensed.

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TROUBLESHOOTING GUIDE
Shouldyourunit fail to operate properly,check that thereispowertothe unitand that the hoppercontainsice. If
the unitdoesnotdispense,check the following chartunderthe appropriatesymptomsto aidinlocating the de-
fect.
TroubleProbableCause
BLOWNFUSE OR CIRCUITBREAKERA.Shortcircuitinwiring.
B.Defective gatesolenoid.
C.Defective agitator motor.
GATEDOES NOTOPEN.A.No power.
B.Bentdepressorplate(doesnotactuateswitch).
C.Defective dispensing switch.
D.Blown/defectivefuse orjammed gatesolenoid.
GATEDOES NOTOPENORIS SLUGGISH.
AGITATORTURNS.A.Defective gatesolenoid.
B.Weakgatespring.
C.Excessive pressure againstgateslide.
GATEOPENS.AGITATOR DOES NOT TURN.A. Icesolidified in hopper.
B.Defective agitator motor.
C.Defectivecapacitor.
D.BCmodelsonly:defective agitation timer.
ICEDISPENSES CONTINUOUSLY.A.Stuck orbentdepressorplate(doesnotrelease
switch).
B.Defective dispensing switch.
C. Improperswitchinstallation.
SLUSHYICE.WATERIN HOPPER.A.Blocked drain.
B.Unitnotlevel.
C.Poorice qualitydue towaterqualityoricemaker
problems
D. Improperuse of flaked ice.
BEVERAGES DONOTDISPENSE A.No24voltpowertofaucets.
B.NoCO2pressure.
BEVERAGES TOO SWEET.A.Carbonatornotworking.
B.NoCO2pressureincarbonator.
C.Faucetbrixrequiresadjusting.
BEVERAGES NOTSWEETENOUGH.A.Empty syrup tank.
B.Faucetbrixrequiresadjusting.
BEVERAGES NOTCOLD(UNITSWITH
BUILT-IN COLDPLATE).A.Unitstanding withnoicein hopper,no iceincold plate cabinet.
Contactyourlocalsyrup orbeverage equipmentdistributorforadditional information and troubleshooting ofyour
beverage system.

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7/8”
WHEN REPLACINGSOLENOID,
ADJUST TO7/8”AS SHOWN
BEFORETIGHTENING
MOUNTINGSCREWS.
FIGURE9.WIRINGDIAGRAMICEONLYAND “B”MODELS

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WHEN REPLACINGSOLENOID,
ADJUST TO7/8”AS SHOWN
BEFORETIGHTENING
MOUNTINGSCREWS.
FIGURE10.WIRINGDIAGRAM“C”AND “K”MODELS

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FIGURE11.SOLENOID ASSEMBLY
Index
No.PartNo.QuantityDescription
1 21493 1 SolenoidMounting Plate
2# 31551 1 SolenoidServiceKit
3 70171 2 8--32 x3/8Phil TrHD Screw
4 70121 2 No.8 Lockwasher
5 50752 3 Isolator
6*50789 2 BumperAssembly(GateStop)
7*70423 1 CotterPin
8*10080 1 Gate Lift Rod
9 10081 1 Gate Lift Rod Bushing
10 50754 1 GateArmBearing
11 21492 1 Gatelift Arm
12 70043 1 Flatwasher
13*70422 1 Spring
14 70263 1 1/4-20 x3/4HexHdScrew
15 70048 1 1/4 Lockwasher
16 70066 1 1/4Flatwasher
17 10077 1 PivotBearing
18 30227 1 1/4Quick ConnectTab
19 50305 ---- Lubricant
20*21592 1 Solenoid Linkage Pin
21*70433 2 RetainerRing
22 50188 ---- Loctite
----*70438 ---- Rebuilding Kit
NOTE:*Parts suppliedwithrebuilding kit.
# 31551 solenoidsuppliedwithitems20&21.

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FIGURE12.EXPLODEDVIEW-UPPERSECTION AND PARTSLIST
Item
No.PartNo.Name
1 21491 GateSlide
6 28075 Agitator
11 52239 FoamShield
15 52154 Lid-Gray
17 53015 IceChute(Clear) Back Section
53016 IceChuteCover
18 51891 GateGasket
20 90295 Cleaning label
21 91680 Wiring Diagram(Pull Solenoid)
91699 Wiring Diagram(RotarySolenoidSee FigureNOTAG)
22 31093 GateSolenoidAssembly(See FigureNOTAG)
32954 RotaryGateSolenoid(See FigureNOTAG
25 31763 Agitation Timer
26 31406 Fuse,GateSolenoid
27 31620 FluorescentStarter
28 31375 RelayMercury
29 31521 Ballast
48 52180 Panel,Plexiglass DB200
52171 DB275
423 28235 Assembly,Retainer
50 28313 HoldDown,Graphics
51 32682 TransformerAss’y(See Note)
54 91888 Decal,, Side CokeDB200
91697 DB275
55 91889 Decal,RearCokeDB200
56 91691 Graphics,Coca-ColaDB200
91683 DB275
NOTE:Forunitsmanufactured beforeOctober15,1993 orderpartnumber33087 transformerkit.This
includes a 32682 transformerand two(2)33084 harnesses.