Wax Base Heater & Dispenser Service Manual Models: IDWB2/0900, IDWB2/0775, IDWB3/0900, IDWB3/0775, IDWB4/0900, IDWB4/0775 Introduction............................................................................ 2 Unpack & Set-up........................................................................ 2 Installation & Operating Instructions...................................................... 2 Maintenance............................................................................ 3 Dinex Warranty......................................................................... 5 Replacement Parts....................................................................... 6 Wiring Diagram......................................................................... 8 Printed in the USA For Service Information, call 1-888-673-4639 Please provide following information: Model number Serial number Part Description and number as shown in parts list. Manual No. WBHD Rev-03/03 DINEX INTERNATIONAL, INC. 628-2 HEBRON AVENUE, GLASTONBURY CT 06033 WWW.DINEX.COM
Congratulations You have just purchased one of the finest pieces of equipment on the market today. Before installing or operating our new Dinex Products equipment you should read through this material. This manual should be retained for further reference as it contains installation and operating instructions, service tips, part list and warranty information. Should you have any questions concerning the Equipment, please call the Dinex Hotline at 1-888-673-4639 (Monday through Friday from 8 am to 5 pm, Eastern Standard Time). IMPORTANT: For your safety, read and follow all cautions, information and warnings FREIGHT DAMAGE CLAIMS Your Dinex Products equipment was carefully inspected and packed before leaving our factory. The transportation company assumes full responsibility for safe delivery of this equipment. Dinex Products cannot assume responsibility for damage or loss incurred in transit. Visible damage or loss should be noted on freight bill and signed by person making delivery. A freight claim should be filed immediately with the transportation company. If damage is unnoticed or concealed until equipment is unpacked, notify the transportation company immediately and tell them you want to file a concealed damage claim. This must be done within fifteen (15) days after delivery was made. Be sure to retain all packing material and cartons. Introduction: WARNING: Installation of this equipment should be performed only by persons qualified or licensed to install electrical equipment. Adjustments and service work should be performed only by a qualified service technician. Service is available through Authorized Dinex Products Parts & Service Distributors throughout the United States. For a complete listing of these consult your distributor listing or write Dinex Products for the name of the nearest distributor. This equipment in intended for commercial use only. Not for household use. Use of other than genuine Dinex Products replacements parts or service work performed by other than authorized Dinex Products service agents will void the warranty. Do not use any corrosive cleaners. Use only cleaners approved for stainless steel. Installation: 1. Carefully remove carton or crate from unit Remove all loose packing material, making sure that no small parts or accessories are lost Inspect unit for concealed damage before discarding packing material. NOTE: It is the responsibility of the installer to comply with all local codes. 2. Make sure that the master switch is in the OFF position. Turn thermostat control knob to the off position. 3. Connect unit to proper electrical service- Unit can operate on 208 or 240 V.A.C., single phase. Receptacles required are: a. Models: IDWB2/0900 81 IDWB2/0775 6-20R (20 Amp) Receptacle b. Models: IDWB3/0900, IDWB3/0775. IDWB4/0900 & IDWB4/0775 = 6-30R (30 Amp) Receptacle 4. Turn master switch ON, power ON pilot light will glow and blower motor will start to run. CAUTION: If excessive noise or vibration is noticed, turn master switch OFF and check blower wheel for freight damage or loose objects. THEORY OF OPERATION 1. The Dinex Unitized Base Dispenser is designed to heat 7-3/4 or 9 Dinex Wax Bases. 2. The unitized base silo is designed to heat the unitized bases thoroughly and efficiently, by circulating hot air over the electric heating elements and around the bases using a high efficiency blower system. 3. Once the bases have been heated, the dispenser can be electrically disconnected and moved to the tray makeup line. Due to the high quality insulation characteristics, it is not necessary to electrically reconnect the dispenser during the serving period. WARNING: Unit should not be operated continuously twenty-four (24) hours a day. The master switch should be turned OFF after serving the last meal of the day. LOADING OF BASES WARNING: Over filling dispenser silos or use of other than Dinex brand bases may cause injury to the operator or damage to the dispenser, thus voiding the warranty. 1. Each silo is designed for use with Dinex unitized bases, depending on the model purchased. 2. There is an easy way to determine when the correct number of unitized bases have been loaded into a silo. Fill the silo until the bases are flush with the top of the unit, then remove one base. You should now have the proper number of bases in the silo. Operation Instructions: NOTE: Never drop stacks of bases into the silo assembly. This can damage the silo components and void the warranty. Place three to four bases at a time into the silo. Page 2
CONTROL SETTINGS 1. The master switch in the control panel on the front of the unit controls the power to the unit. 2.The pilot light in the control panel will indicate power ON when the master switch is turned to the ON position. WAX BASE SILO THERMOSTAT SETTINGS 1. The heaters in the unitized base are controlled by an adjustable thermostat located in the control panel. The thermostat knob has an OFF position and is numbered 1 to 10. With the master switch ON and the thermostat set to OFF, the blower motor will run but the heaters will not operate. Thermostat must be turned to a setting of 1 or higher to operate the heaters in the base silo. 2. Turn the thermostat knob clockwise to the number 7.5 setting. The number 10 setting is the highest temperature setting for the dispenser. If you find that the bases are too hot for your application, reduce the temperature by turning the thermostat knob back to the 5, 6, or 7 setting. Since virtually all facilities operate differently, the best way to determine your thermostat setting is to start with the No. 7.5 setting, and adjust up or down for the next meal. Keep turning the knob until the proper temperature is reached. 3. Once the proper temperature setting is determined, it is not necessary to reset the thermostat at every meal. Leave the thermostat at the desired setting and turn the unit on and off using the master switch. APPROXIMATE HEAT-UP TIMES Cold bases (first meal of the day): 1-1/2 to 2 hours. Warm bases: 1 to 1-1/2 hours All times are approximate only and may vary depending on each facilities operation, locations of units and supply voltage. Make sure that silo doors are closed during the heating cycle. DISPENSING BASES 1. Turn master switch OFF and disconnect electrical plug from receptacle. Move dispenser to start of the tray make-up line. WARNING: Severe burns may be caused if instructions are not followed. Operator must wear heavy gloves when dispensing bases. 2. Never touch bases with your bare hands, always use heavy gloves and a suction lifter to handle bases. 3. If, when using a suction lifter, a base comes loose, do not try to catch the base...let it fall. 4. Never assume that a base is cool enough to handle with your bare hands. Bases retain enough heat to cause burns for several hours after being removed from the dispenser. 5. If a base becomes jammed in the silo, never reach into the silo to free it. Use a long stick (such as a broom handle) to free the base. 6. Dispense bases using the Dinex Suction Lifter No. TMP1097HNDLIFT. Hold the lifter in the palm of your hand with your thumb over the release button. Use a snap action of your wrist to attach the lifter to the base, lift the base out of the silo and onto a waiting tray or base underliner, press the release button with your thumb to release base with the lifter. Do not leave the suction lifter attached to a hot base. This will greatly shorten the life of the suction lifter cup. Dinex equipment is constructed with the best quality material and is designed to provide you with durable service when treated with ordinary care. To obtain the best performance from your equipment, it should be cleaned daily and maintained in good condition. CAUTION: Prior to cleaning or maintenance, turn the master switch OFF and disconnect the power cord from the receptacle. DAILY CLEANING 1. Cleaning and sanitizing agents for stainless steel and aluminum should be used with a soft cloth and water. CAUTION: Never use chlorinated cleaners, cleaners containing QUARTENARY salts or other harsh chemicals. 2. The exterior of the dispenser should be cleaned daily using a mild detergent suitable for stainless steel and warm water. 3. Open the silo door and clean the inside of the door and door gasket with detergent and warm water. 4. Wipe the cord and plug using a cloth with detergent and warm water. 5. The thermostat knob should be removed by pulling it straight out of the thermostat. The thermostat behind the knob should be cleaned. CAUTION: Do not use excessive water that could short out the controls. INTERIOR CLEANING Maintenance CAUTION: Prior to cleaning or maintenance, turn the master switch, OFF and disconnect the power cord from the receptacle and allow time for the dispenser to cool down. 1. The interior of the dispenser and silos should be cleaned as required, at least once every three months. 2. Open silo door and unload unitized bases. CAUTION: Bases may be hot so use gloves and lifter to remove. 3. Using gloves, remove the silo by grasping the top of the silo assembly and lifting straight up out of the dispenser. Page 3
CAUTION: Silo assembly is heavy and may require two people to remove it. 4. With a bristle-type brush, scrub the silo assembly with a warm detergent solution. Be careful not to knock the cables off their pulleys. 5. Rinse with clear warm water and allow to dry. 6. Lubricate all pulleys and cables after cleaning using lubricant No. IS0197130. DANGER: Disconnect electrical power to dispenser (See Page 8, Figure 2). CAUTION: Always use cold bases for silo adjustments. 1. To bring the bases closer to the top of the dispenser, remove silo from dispenser. 2. Lubricate silos per instructions (above). 7. Clean interior of dispenser while silos are removed using a vacuum cleaner to remove loose material from bottom of unit. 8. A damp cloth may be used to clean the inside of the dispenser. Do not allow water to come in contact with the heating element, use caution not to bend the thermostat bulb. WARNING: The Dinex dispenser cannot be steamed cleaned or cleaned with a spray type mechanism. These cleaning methods can cause damage to the electrical components and will void the warranty. BASE SILO 1. Lubricate base silo at least every three (3) months or sooner if sticking occurs and after every cleaning. 2. Use Dow Corning Hi-Temp grease or its equivalent (NO.1S0197130). 3. Lubricate all pulleys being sure to work grease down into the bearings. 4. Lubricate each cable along its entire length leaving extra grease on the cables. Also, place extra grease around each pulley. 5. Should bases stick or hang up, check the edges of the four (4) stainless steel angle guide posts where the bases ride. If they are rough or uneven, they must be smoothed out using sand paper and/or file. SILO ADJUSTMENT Lubrication Service WARNING: only by a qualified Adjustments service and technician. service work Service should is available be performed through Authorized Dinex Parts and Service Distributors throughout the United States. For a complete listing of these, consult your distributor for a listing or see our website at www.dinex.com for the name of the nearest distributor. Dinex does not recommend that service work be performed by any one other than a qualified service technician. If service or parts are required, contact the nearest Authorized Parts & Service Distributor. Be sure to give them the complete model number, serial number, installation purchase date, voltage unit is operating and a detailed description of the service problem or part required. The Distributor must have this information in order to provide the proper service or parts for your equipment Page 4 3. With the silo setting securely on the floor, fill the silo with 50 bases, they should be flush with the top or within 1 to 1-1/2 inches below the top. If not, then unload the bases and proceed with the next steps. 4. If bases were too low, connect all eight (8) springs into the top hole of the spring frame. (Reference spring frame on Page 7. Figure 2, Key 3.) 5. If bases were too high above silo top, connect all springs onto the lower holes of the spring frame. 6. If still not high enough, repeat Step 4, leave springs connected to top holes of spring frame, connect bottom of springs to bottom holes of silo base plate. 7. If still too high, connect all springs into top holes of silo base plate. 8. Repeat Step 4. If bases still do not come up high enough, remove rollers from base assembly Page 7, Figure 2, Keys 4, lifting cables off rollers. Remove bolt and nut securing roller to base assembly and move roller to next lower hole; Repeat for roller on other side of base assembly. 9. If bases were too high, move rollers to next higher hole in base assembly. 10. If bases continue to stick or hang up, check the edge of the four (4) stainless steel angle guide posts where the base rides. If they are rough or uneven, they must be smoothed out using sand paper and/or a file. Lubricate cables and rollers and repeat Step 4. 11. If bases still do not come up to within 1 to 1-1/2 inches of the top after performing all the above, then springs need to be replaced. RESETTING OR REPLACING HI-LIMIT THERMOSTAT Should blower operated but unit does not heat, the hi-limit must be reset. WARNING: Disconnect electrical power before servicing. 1. Remove four (4) screws and remove top access panel located on the top of the unit. 2. Press reset button located in the center of the hi-limit thermostat. Button is located between the two electrical terminals. NOTE: If hi-limit is to be replaced, do so at this time. 3. Replace insulation and top access panel. 4. Reconnect electrical power and operate.
HEATER REPLACEMENT - SEE PAGE 6, FIGURE 1 WARNING: Disconnect electrical power to unit. Also, to avoid burns, allow unit to cool down. 1. Open door and remove silo assembly. 2. Remove louvered vent panel No. 0854710. 3. Disconnect the electric wires from the heating elements to be replaced. 4. Remove the retaining screw from the top of the heating element and lift element up and out. 5. Install new element(s) by reversing the above steps. BLOWER WHEEL REPLACEMENT 1. Remove the four (4) screws from the access panel located on the top of the unit and remove panel and insulation located inside access openings. 2. Disconnect the two (2) wires to the hi-limit thermostat. 3. Open doors and remove silo assemblies. 4. Remove louvered shield panels located inside silo openings by removing the six (6) screws from each panel. 5. Slide out the top plate (hi-limit plate assembly). 6. Remove hexagon shaped plate by removing two (2) screws. 7. Remove blower from motor shaft by holding shaft and turning wheel clockwise. Unscrew wheel from shaft and lift up and out through access opening. 8. Reverse above steps to install the new blower wheel. Screw blower wheel onto motor shaft counter-clockwise only and hand tighten. CAUTION: Do not bend motor shaft or blades on blower wheel when installing new wheel. TO REPLACE BLOWER MOTOR 1. Complete Steps A through H under blower wheel replacement. 2. Remove louvered blower motor access panel located on the side of the unit. DINEX Warranty Dinex International, Inc. ( Dinex ) warrants that its DES Equipment ( Equipment ) shall be free from defects in materials and workmanship for a period of one (1) year from the date of delivery to the initial end-user ( End- User ) (the Warranty Period ). Dinex shall be notified of all Equipment claimed to be defective and covered by this warranty. The End-User shall include in this notification the serial number and a copy of the Bill of Lading (showing delivery date) for the Equipment. If Dinex s investigation establishes the existence of the alleged defects, then Dinex shall, at Dinex s choice and expense, repair or replace the affected Equipment (provided that the costs of labor on such repairs shall only be included for proper warranty claims asserted in writing within 1 year of delivery date) and reimburse End-User for the reasonable shipping costs for returning the Equipment to Dinex, if any. This warranty does not apply to defects in any Equipment caused by: (1) normal wear and tear; (2) failure to comply with any Dinex-provided operation or maintenance instructions; (3) alteration or modification(s) by parties other than Dinex or (4) misuse, neglect, accident, Acts of God or other causes beyond the control of Dinex after delivery of the Equipment by Dinex to its authorized distributor. Repaired or replacement Equipment under this warranty shall be warranted for the unexpired portion of the original Warranty Period applicable thereto plus the period from notice to Dinex of such defect until completion of repair or return to the point of original delivery to Buyer. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHETHER ARISING BY LAW, CUSTOM, CONDUCT OR USAGE OF TRADE, AND THE RIGHTS AND REMEDIES PROVIDED HEREIN ARE EXCLUSIVE AND PROVIDED IN LIEU OF ANY OTHER RIGHTS AND REMEDIES. DINEX SHALL HAVE NO LIABILITY OTHER THAN AS PROVIDED IN THIS WARRANTY, WHETHER CLAIMED IN CONTRACT, EQUITY, TORT OR OTHERWISE, FOR OR RESULTING FROM DEFECTS IN MATERIALS OR WORKMANSHIP OR OTHERWISE. IN NO EVENT SHALL DINEX BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE EQUIPMENT, REGARDLESS WHETHER SUCH LIABILITY SHALL BE CLAIMED IN CONTRACT, TORT, EQUITY OR OTHERWISE. 3. Disconnect electrical wires from motor. 4. Remove four (4) screws from top of motor mounting bracket assembly. Remove motor and bracket assembly through rear access opening. 5. Remove old motor from mounting brackets. Check that welds on brackets are not cracked. If they show signs of stress, replace brackets. 6. Install new motor onto mounting brackets. Reinstall motor assembly into dispenser by reversing the above steps. Be sure to reconnect the electrical leads to the motor. Page 5
Replacement Parts Figure 1 Key Description Parts No. Key Description Parts No. 1 Thermostat IS0350100 2 Thermostat Knob IS0178525 3 Hi-Limit Thermostat IS0113063 4 Pilot Light IS0189500 5 Master Switch IS0330875 6 Blower Wheel IS0865280 7 Door Assembly IS08830302 8 Door Handle IS0111494 9 Heating Element 900W IS0151200 10 Push Handle-2 Silo Models IS0844980 10 Push Handle-3 & 4 Silo Models IS0815235 11 Door Gasket IS0141425 12 Door Hinge IS0818585 13 Door Bumper IS0034075 14 Cord-Specify Feet IS0084525 15 Top Motor Mount IS0501218 16 Blower Motor IS0114885 17 Plug 20 AMP-2 Silo Models IS0041100 17 Plug 30 AMP-3 & 4 Silo Models IS0040850 18 Bottom Motor Mount IS0501219 19 Caster With Brake IS0053500 20 Bumper (Specify Length) IS0114452 Page 6
Replacement Parts 9 Silo For Models: IDWB2/0900, IDWB3/0900, IDWB4/0900 Replacement Parts 7-3/4 Silo For Models: IDWB2/0775, IDWB3/0775, IDWB4/00775 Figure 2 Figure 3 Key Description Parts No. Key Description Parts No. 1 Screw IS0283600 2 Pulley IS0271000 3 Spring Frame 9 IS08830358 4 Base 9 IS08830356 5 Cable IS0084066 6 Cable Clip IS0846280 7 Spring 9 Base IS0113462 8 Hi-Temp Grease IS0197130 9 Teflon Block IS0113349 10 Silo Complete IS0830711 1 Screw IS0283600 2 Pulley IS0271000 3 Spring Frame 7-3/4 IS08830358 4 Base 7-3/4 IS0815240 5 Cable IS0084066 6 Cable Clip IS0846280 7 Spring 7-3/4 Base IS0312321 8 Hi-Temp Grease IS0197130 9 Teflon Block IS0113349 10 Silo Assembly Complete IS0822075 Page 7
Wiring Diagram Figure 3 - Wax Base Heater Dispenser WWW.DINEX.COM DINEX INTERNATIONAL, INC. 628-2 HEBRON AVENUE, GLASTONBURY CT 06033 1.800.523.9752 Page 8