Remcor DB200/275R User manual

ICE/BEVERAGE DISPENSER
MODELS:DB200/275R
DB200/275RS-B
DB200/275RS-BC
DB200/275RS-KBC
Operator’sManual
PRINTEDIN U.S.A
âREMCORINC:1993--97
PartNo.91792
May1997
Revision F
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

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TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS1...................................................
GENERALDESCRIPTION1..................................................
ICEMAKER2...........................................................
INSTALLATIONINSTRUCTIONS2............................................
GATERESTRICTORPLATE3............................................
ADJUSTMENT3........................................................
MAINTENANCE10...........................................................
DAILYORAS REQUIRED10..............................................
WEEKLYORAS REQUIRED10............................................
MONTHLY10............................................................
START-UP AND OPERATING INSTRUCTIONS10...........................
CLEANING INSTRUCTIONS10................................................
DISPENSER(ALL MODELS)10..........................................
COLDPLATE(-BCMODELS)11...........................................
BEVERAGE SYSTEM (-B,-BCMODELS)11................................
TROUBLESHOOTING GUIDE13...............................................
BLOWNFUSE OR CIRCUITBREAKER13..................................
GATEDOES NOTOPEN.13...............................................
GATEDOES NOTOPENORIS SLUGGISH.AGITATORTURNS.13...........
GATEOPENS.AGITATOR DOES NOT TURN.13............................
ICEDISPENSES CONTINUOUSLY.13......................................
SLUSHYICE.WATERIN HOPPER.13......................................
BEVERAGES DONOTDISPENSE 13......................................
BEVERAGES TOO SWEET.13............................................
BEVERAGES NOTSWEETENOUGH.13...................................
BEVERAGES NOTCOLD(UNITSWITHBUILT-IN COLDPLATE).13...........
WARRANTY21..............................................................

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TABLEOFCONTENTS(cont’d)
LISTOF FIGURES
Page
FIGURE1. GATERESTRICTORPLATE3..................................
FIGURE2.MOUNTINGTEMPLATE4.....................................
FIGURE3.BEVERAGE SYSTEMSCHEMATIC8VALVE HOOKUP5........
FIGURE4.BEVERAGE SYSTEMSCHEMATICE10 VALVE HOOKUP6.......
FIGURE5.PLUMBINGSCHEMATIC6FAUCETS7.........................
FIGURE6.PLUMBINGSCHEMATIC8FAUCETS8.........................
FIGURE7.PLUMBINGSCHEMATIC10 FAUCETS9........................
FIGURE8.WIRINGDIAGRAMPULL SOLENOID14..........................
FIGURE9.WIRINGDIAGRAMROTARY SOLENOID15......................
FIGURE10.SOLENOIDASSEMBLY16.....................................
FIGURE11.EXPLODEDVIEWROTARY SOLENOIDASSEMBLY AND
PARTSLIST17................................................
FIGURE12.EXPLODEDVIEW-UPPERSECTIONAND PARTSLIST18.......
FIGURE13.EXPLODEDVIEW-LOWERSECTIONAND PARTSLIST19......
FIGURE14.MOTORASSEMBLYDETAILAND PARTSLIST20................
LISTOF TABLES
TABLE1.SPECIFICATIONS1............................................
Manufactured UnderOne or More of the Following PatentNumbers:3,211,336,3,274,792,3,393,839,
3,517,860,3,739,842,4,215,803,4,227,377,4,300,359,4,346,827
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 beforefiling into
thedispenserhopper.
GENERALDESCRIPTION
The Remcor“DB”seriesofice dispensers solveyourice and beverage service needsinthe sanitary,space
saving,economical way.Designed tobemanualfilled withicefromanyremoteicemaking source, these dis-
penserswill dispensecubes(up 1-1/4”insize),cubeletsand hard-chipped orcracked ice;and in addition,sev-
eralflavorsofpost-mixbeverages.“B”unitsinclude beverage faucetsand are designed tobesupplied fromsyr-
up tanks and carbonator.“BC”unitsinclude beverage faucetsand a cold plate and are designed tobesupplied
direct fromsyrup tanks and carbonator;with no additionalcooling required.The sink can be easilyand quickly
removed.Theunitsmustneverbelifted or moved bythe sink.Beverage connectionstothe cold plate are
made withthe lowerfrontpaneland sinkremoved.
Table 1.Specifications
Model:DB200 DB275S
IceStorage:200 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:N/AN/A
Built-inColdPlate:NoNo
Dimension:30Wx30Dx34-3/16H30Wx30Dx39-11/16H
Model:DB200R-BDB275R-B
IceStorage:200 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:10 10
Built-inColdPlate:NoNo
Dimension:30Wx30Dx34-3/16H30Wx30Dx39-11/16H
Model:DB200R-BC DB275R-BC
IceStorage:200 lbs.275 lbs.
MaximumNumberofFaucetsAvailable:10 10
Built-inColdPlate:YesYes
Dimension:30Wx30Dx34-3/16H30Wx30Dx39-11/16H
Electrical(forall models)120V,1ph., 60 hz.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.Thesemustbe 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-
mensionsand cutoutlocationsusing the template drawings.Cutopeningsinthe counter.
Applyacontinuousbead ofNSFInternational(NSF)listed silastic sealant(Dow732 orequal)approximate-
ly1/4”inside of the unitoutline dimensionsand around all openings.Do notapplytothe sinkarea until all
plumbing connectionsare;made and sinkisreinstalled.Then position the uniton the counterwithinthe
outline dimensions.All excess sealantmustbe wiped awayimmediately.
2.Thiswork should be done bya qualified service person.Withthe lowerpaneland sinkremoved,pull the
beverage linesup through the frontopening inthe bottomof the unitand makethe connectionsusing the
plumbing schematics (See Figures5,6,and 7)orinside the lowerpanel.Connect the drainline tothe sink
line elbow.
3.Route drainline and powercordthrough the bottomopening.Reinstall the sinkon 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. Optional:Utilitiesrouting maybe made through the rearof the cabinetbyremoving the plasticrearpanel,
plasticplug and removing the knockout forthe drain hose.
A.90°sinkfittings can be replaced withastraightstainless steelfitting and extra draintube length added
asrequired.
B.Run powercord outofopening next toknock-out. (UseRemcorbushing,partnumber51913).
7.Clean the hopperinterior (See CLEANING INSTRUCTIONSon pages10 and 11).
8.Connect the powercordtoa115volt, 60 cycle,3-wire grounded receptacle.All electrical wiring mustcon-
form to nationaland localelectricalcodes.
NOTE:Waterpipe connections and fixtures directly connectedtoapotablewatersupply shall be
sized, installedand maintainedaccording to Federal, State,and LocalLaws.

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GATERESTRICTORPLATE
CAUTION:Disconnectpowerto dispenserbeforeinstalling,removing oradjusting
restrictor.
FIGURE1. GATERESTRICTORPLATE
ADJUSTMENT
Thisdispenserisprovided with a gaterestrictorplate,installed ititshighestposition.Thisplate adjuststhe rate
oficeflowfromthe dispenser. In applicationsusing buckets,carafesorotherlarge containers, the platemaybe
removed entirelyfor maximumiceflow.Forglassesand cups, the platemaybe adjusted downwardtoreduce
the flowofice. the bestposition dependson the type ofice being used and the sizecontainerand mustbe
found bytrialand error.Adjustmentismade byloosening the uppertwoicechuteretaining nuts,sliding the re-
strictorplatetothe 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,refertothe troubleshooting guide on page 12

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NOTE:SHADED AREAINDICATEOPENINGS
IN CABINETBOTTOMNEEDEDFOR
UTILITIES AND BEVERAGETUBING
FIGURE2.MOUNTINGTEMPLATE

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FIGURE 3. BEVERAGE SYSTEM SCHEMATIC 8 VALVE HOOK UP

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FIGURE 4. BEVERAGE SYSTEM SCHEMATICE 10 VALVE HOOK UP

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK MUSTBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
FIGURE5.PLUMBINGSCHEMATIC6FAUCETS

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK MUSTBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
FIGURE6.PLUMBINGSCHEMATIC8FAUCETS

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NOTE:1)TOSERVICECOLDPLATEINLET FITTINGS,SINK MUSTBEREMOVED.
TOREMOVE,DISCONNECTSINK DRAIN CONNECTIONS,THENLIFT
TWO(2)SIDEMOUNTINGPINSAND PULL SINK FORWARD.REVERSE
TORECONNECT.
2)MAKE SUREALL DRAIN CONNECTIONSARE PROPERLY POSITIONED
FOR DRAININGAFTERSERVICE,BEFORE PANELSAREINSTALLED.
FIGURE7.PLUMBINGSCHEMATIC10 FAUCETS

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MAINTENANCE
The following dispenser maintenanceshould be performed at the intervalsindicated:
DAILY(orasrequired)
Removeforeign materialfromthe vending area sinkto preventdrain blockage.
WEEKLY(orasrequired)
Clean vending area.Check forproperwaterdrainage fromthe vending area sink.
MONTHLY
Clean and sanitizethe hopperinterior (see CLEANING INSTRUCTIONS).
START-UPAND OPERATING INSTRUCTIONS
Fill the hopperwithice.With a built-incold plate,dispenseseveral large cupsofice(approximately1minute
totaldispensing time)to allow icetofill the cold plate.Add icetothe hopperasnecessarytorefill then replace
the lid.Allow10 to15minutesforthe cold platetocooldown.Repeat thisprocedurewheneverthe dispenser
hasbeen standing overnightorotherlong periodswithoutice use.Startup the beverage systemand adjust fau-
cetstothe properbrix.Contactyourlocaldistributorforcompleteinformation 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
anyice spilledfromfilling oroperating 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 attack theplastic
material.
DISPENSER(all 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.RemoveIceChutecoverasfollows:
A.Flex sidesoutwardto disengage lowerpins.
B.Lift IceChutecoverto disengage upperpins.
C.LowerIceChutecoverdown outofunit. Note:itmaybe helpfultotwistcoverslightly.
7.Clean the inside of the icechute and icechutecoverwithamild detergentsolution and rinsethoroughlyto
remove all tracesofdetergent.
8.Reversestepsabovetoreassembleicechute.
9.Sanitize asdescribed inStep 5.
COLDPLATE(-BC MODELS)
1.Removelowerpanel.(Refertothe lowerexploded assembly Figure 13).
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 panel.
BEVERAGE SYSTEMCLEANINGAND SANITIZING INSTRUCTIONS
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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STANDARD SOLENOID ADJUSTMENT
WHEN REPLACINGSOLENOID,
ADJUST TO7/8-INCH AS SHOWN
BEFORETIGHTENINGMOUNTING
SCREWS
FIGURE8.WIRINGDIAGRAMPULL SOLENOID

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FIGURE9.WIRINGDIAGRAMDB-275

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FIGURE10.SOLENOID ASSEMBLYAND PARTSLIST
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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1
4 7
(3PLCS.)
3
8 6
2
5
FIGURE11.EXPLODEDVIEWROTARY SOLENOID ASSEMBLYAND PARTSLIST
Item
No.PartNo.Name
1 28172 Mounting plate
2 28173 GateArm
3 32957 RotarySolenoid
4 50752 Isolator
5 50754 Flanged Bearing
6 51689 LocktiteAdhesive
7 70017 10-32 Nylon Insertlocknut
8 70162 8-32 x1/4SlotTruss ‘8-8SS