Remcor Ice/Bev Disp Operators Manual Model # TJ45-B
Contents
1. 13 FIGURE 8 UPPER SECTION EXPLODED VIEW TJ45 14 FIGURE 9 EXPLODED VIEW LOWER SECTION TJ 45 14 FIGURE 10 EXPLODED VIEW UPPER SECTION TJ 90 15 FIGURE 11 EXPLODED VIEW LOWER SECTION 90 15 FIGURE 12 SOLENOID ASSEMBLY 17 Manufactured Under One or More of the Following Patent Numbers 3 211 336 3 274 792 3 393 839 3 517 860 3 739 842 4 215 803 4 227 377 4 300 3594 346 824 Canadian Patent Numbers912 514 10 72 936 855 11 73 4 429 543 4 921 149 Other Patents Pending 90627 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 1 ALWAYS be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior and possible contamination of the ice 2 ALWAYS be sure the upper and lower front panels are securely fastened 3 ALWAYS keep area around the dispenser clean of ice cubes CAUTION Dispenser cannot be used with crushed or flaked ice Use of bagged ice which has fr2. 70343 70441 70419 70419 70439 oe 30774 31093 31093 70438 70438 22644 22644 RAE 30794 31763 FINAL ASSEMBLY PARTS LIST 16 Description Gate Slide Foam Shield Depressor Lever Agitator B Models Only Agitator BC Models Only Dispense Switch Switch Boot Switch Insert Transformer Agitator Motor Motor Shaft Seal Motor Gasket Lid B BC Sink B Models Only Models Only Ice Chute Back Section Ice Chute Cover Gate Gasket Sink Grill Leg Leg BC Models Only Capacitor Solenoid Assembly Rebuilding Kit Depressor Retainer Agitation Motor Heater B KBC Models Only Agitation Timer BC Models Only 4 NJ 19 H 22 EN 21 4 2 15 7 14 17 FIGURE 12 SOLENOID ASSEMBLY Index No Part No Qty Name 1 21493 1 Solenoid Mounting Plate 2 31551 1 Solenoid Service Kit 3 70171 2 8 32 x 3 8 Phil Tr HD Screw 70121 2 No 8 Lockwasher 5 50752 3 Isolator 6 50789 2 Bumper Assembly 15 70423 1 Cotter P in 8 10080 1 Gate Lift Rod 9 10081 1 Gate Lift Rod Bushing 10 50754 1 Gate Arm Bearing 11 21492 1 Gate lift Arm 12 70043 1 Flatwasher 13 70422 1 Spring 14 70263 1 1 4 20 x 3
3. 4 Hex Hd Screw 15 70048 1 1 4 Lockwasher 16 70066 1 1 4 Flatwasher 17 10077 1 Pivot Bearing 18 30227 1 1 4 Quick Connect Tab 19 50305 Lubricant 20 21592 1 Solenoid Linkage P in 21 70433 2 Retainer Ring 22 51088 Loctite 70438 Rebuilding Kit NOTE Parts supplied with rebuilding kit 31551 solenoid supplied with items 20 amp 21 17 90627 ela gt REMCOR IMI CORNELIUSINC ONE CORNELIUS PLACE ANOKA MN 55303 6234 TELEPHONE 800 238 3600 FACSIMILE 612 422 3232 TECH SVC 1 800 535 4240 WARRANTY IM Cornelius Inc Remcor Products Company warrants that all equipment and parts are free from defects in material and workmanship under normal use and service For a copy of the warranty applicable to your Cornelius and or Remcor product in your country please write fax or telephone the IM Cornelius office near est you Please provide the equipment model number serial number and the date of purchase IMI Cornelius Offices AUSTRALIA P O 210 RIVERWOOD NSW 2210 AUS A B B E FRANCE 71 ROUTE DE ST ERMANY CARL LEVERKUS USTRIA AM LANGEN FE ELGIUM BOSKAPELLEI NGLAND TYTHING ROA REECE 488 MESSOGION ONG KONG 1104 TAIKO ALY VIA PELLIZZARI 11 RALIA 61 2 533 3122 FAX 61 2 534 2166 LDE 32 A 1222 VIENNA AUSTRIA 43 1 233 520 FAX 43 1 2335 2930 22 B 2930 BRAASCHAAT B LCESTER WARWICKSHI ELGIU
4. amp CGintiu gt REMCOR ICE BEVERAGE DISPENSER MODEL NUMBERS TJ 45 B TJ 90 B TJ 90 BC Operator s Manual Part No 90627 Date 11 3 96 Revision B THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment REMCOR INC 1996 PRINTED IN U S A TABLE OF CONTENTS Page SAFETY PRECAUTIONS rm a ae oa aa nin 1 DESCRIPTION il a dees tees en 2 INSTALLATION INSTRUCTIONS 3 CLEANING INSTRUCTIONS 4 SERVICE AND MAINTENANCE 6 TROUBLESHOOTING GUIDE 8 PARTS LIST 5225 E EE oral A RUE 16 WARRANTY uiui cert TEE Modo teenie RI EE 18 LIST OF FIGURES FIGURE 1 SINK DRAIN ASSEMBLY FIGURE 2 GATE RESTRICTOR PLATE FIGURE 3 MOUNTING TEMPLATE 9 FIGURE 4 TYPICAL POST MIX BEVERAGE SYSTEM SCHEMATIC B DISPENSER 10 FIGURE 5 TYPICAL POST MIX BEVERAGE SYSTEM SCHEMATIC DISPENSER 11 FIGURE 6 TJ 45 90 DISPENSER WIRING DIAGRAM 12 FIGURE 7 90 BC DISPENSER WIRING DIAGRAM
5. 70 SWALI 321 U3SN3dSIQ 32743A38 32 87 YOONSY wala QJLVHJDIHJJU Brun gt 1 4 31779 4702 Y 93u WNOLLdO i 91 NOILINGISNOD 804 N XTNO 383338 804 SION EE NWA ee 5132073 9154 09 5 zm 2154 SES CO 580 93H 8338 1008 80 1310 HO43 1VNOULdO 10 90627 UJSNAdSIQ 28 JILVIN3HOS UND G3GNTONI LON S3NI1 40 3015170 SW ill 1 88 8317143 FS 24000 3 8 5 AV M GRO Y BOIYTSZU 34155384 iVNOLLdO 9158 001 09 MI MAINO 3338 310N NIE 1 XNVI 205 11 WU 51320113 9154 05 51 gu dm a LO 17 U 592 SuOLY 1N93U 8338 1004 13 HOd IVNOLLdO 835 34510 39V43A38 321 28 H029W3H 90627 SERVICE INFORMATION DANGER ELECTRIC SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING UNIT GATE SOLENOID 5 N WHT 2 THERMOSTAT GRD N LIGHT 1 U o BLK U ICE LEVEL SIGNAL OPTIONAL 1 4 AIAP TIME DELAY FUSE AGITATOR oe Ceo E33 nore U CAPACITOR EE P 90 ONLY ry DISPENSE SWITCH STANDARD NN PORTION i TIMER PORTION CONTROL COPTIONAL BEVERAGE SYSTEM TO TERM
6. Connectthe power cord to a 120 volt 60 cycle 3 wire grounded receptacle SINK DRAIN ASSEMBLY 1 Use tube clamp and insulation provided to assemble drain 2 To assure proper drainage do not allow trap to form in drain line Be sure drain line runs flat with bottom of dispenser see Figure 1 DRAIN LINE DISPENSER BOTTOM FIGURE 1 SINK DRAIN ASSEMBLY 3 90627 CLEANING INSTRUCTIONS WARNING Disconnect power before cleaning Do not use metal scrapers sharp objects or abrasives on the surface of the liner as damage may result Do not use solvents or other cleaning agents as they may attack the plastic liner DISPENSER l Clean the ice dispenser interior at least once a month 2 Lift off agitator assembly and wash and rinse it thoroughly 3 Wash down the inside of hopper and top cover with mild detergent solution and rinse thoroughly to remove all traces of detergent 4 Replace agitator 5 Sanitize the inside of hopper and agitator with a solution of 1 ounce of household bleach in 2 gallons of wa ter 200 PPM Remove ice chute cover as follows A Flexsides outward to disengage lower pins B Liftice chute cover to disengage upper pins C Lower ice chute cover down out of unit Note it may be helpful to twist cover slightly With the brush provided clean the inside of the ice chute with a mild detergent solution and rinse thorough ly to remove all traces of detergent Reverse above ste
7. INAL BOARD BEVERAGE FAUCET CTYPICAL m di SWITCH ICOPTL WHEN REPLACING SOLENOID ADJUST TO 7 8 AS SHOWN BEFORE TIGHTENING MOUNTING SCREWS FIGURE 6 TJ 45 90 DISPENSER WIRING DIAGRAM 90627 12 SERVICE INFORMATION ZN DANGER ELECTRIC SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING UNIT 4 T STAT LN LIGHT us M AGITATION TIMER mnn MOTOR HEATER AMP TIME INPUT DELAY FUSE WT vo IGKBRATE 11 4 TRANS AGITATOR MOTOR i _ ted Ee Key CJ TYPICAL BWITCH OPTION 1 BEVERAGE SYSTEM 7 6 WHEN REPLACING SOLENOID ADJUST TO 7 8 AS SHOWN BEFORE TIGHTENING MOUNTING SCREWS 90768 REV FIGURE 7 TJ 90 BC DISPENSER WIRING DIAGRAM 13 90627 FIGURE 9 EXPLODED VIEW LOWER SECTION TJ 45 90627 FIGURE 10 EXPLODED VIEW UPPER SECTION TJ 90 FIGURE 11 EXPLODED VIEW LOWER SECTION TJ 90 90627 Item No 1 gt UJ 14 15 16 17 18 19 20 21 22 23 90627 Part No TJ 45 Part No TJ 90 21491 21491 23062 23062 21515 21515 21517 21629 21854 30895 30895 31007 31007 31163 31163 31091 31091 31106 31112 50454 50454 50481 50806 50748 50791 50750 50793 ZE 51019 53015 53015 53016 53016 50770 50770
8. M 32 3 664 0552 FAX 32 3 665 2307 RAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 DA DENIS F 95170 DEUIL LA BARRE PARIS FRANCE 33 1 34 28 6200 FAX 33 1 34 28 6201 STRASSE 15 D 4018 LANGENFELD GERMANY 49 2173 7930 FAX 49 2173 77 438 AVENUE AGIA PARASKEVI RE B49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 SU CENTRE 11 15 KOK CH PAIN POLIGONO INDUS RA EUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 20059 VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 EW ZEALAND 20 LANSFORD CRES P O BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND 64 9 8200 357 FAX 64 9 8200 361 NGAPORE 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 L RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 FAX 34 3 654 3379 SA ONE CORNELIUS PLACE ANOKA MINNESOTA 612 421 6120 FAX 612 422 3255 Manual number 18 IMI CORNELIUS INC Corporate H eadquarters One Cornelius Place Anoka M innesota 55303 6234 612 421 6120 800 238 3600
9. Number of Faucets Available 6 Built in Cold Plate Yes Electrical 120 1 60 Dimensions 22 wide x 28 Deep x 32 High CABINETRY OPTIONS E Neutral Beige or White Baked Enamel finish with wood grain vinyl clad upper front S All Stainless Steel 90627 INSTALLATION INSTRUCTIONS 1 Locate the dispenser indoors on a level counter top Unpack the four 4 legs and install them into the threaded holes provided in the bottom of the unit The installer must provided flexibility in the product and utility lines to permit shifting the position of the dispenser sufficiently to clean the area beneath it 2 Carefully pull the beverage tubes drain lines and power cord through the large openings in the bottom of the unit See figure 3 MOUNTING TEMPLATES for locating the required clearance holes in the counter for these utility lines 3 Connectthe drain tube to an open drain If additional piping is required it must be 3 4 IPS or equal and must continuously pitch downward away from the unit and contain no traps or improper drainage will re S ult 4 Connectthe beverage system product lines as indicated in Figure 4 B units and 5 BC units This work should be done by a qualified service person NOTE that the hoses are marked with numbers 1 through 6 for syrup connections and CW for car bonated water connection 5 Clean the hopper interior see CLEANING INSTRUCTIONS 6
10. ispenser has been standing over night or other long periods without ice use Start up the beverage system and adjust faucets to the proper brix Contact your local syrup distributor for complete information on the beverage system In normal operation pushing the ice dispenser lever will cause ice to flow from the ice chute Ice flow will contin ue until the lever is released Pushing the lever on any faucet will provide beverage of the appropriate flavor NOTE Use caution to avoid spilling ice when filling dispenser Immediately clean up any spilled ice from filling or operation of the unit To prevent contamination of ice the lid must be installed on the unit at all times 7 90627 TROUBLESHOOTING GUIDE Should your unit fail to operate properly check that there is power to the unit and that the hopper contains ice If the unit still does not dispense check the following chart under the appropriate symptoms to aid in locating the defect Trouble BLOWN FUSE OR CIRCUIT BREAKER GATE DOES NOT OPEN AGITATOR DOES NOT TURN GATE DOES NOT OPEN OR IS SLUGGISH AGITATOR TURNS GATE OPENS AGITATOR DOES NOT TURN ICE DISPENSES CONTINUOUSLY SLUSHY ICE WATER IN HOPPER BEVERAGES DO NOT DISPENSE BEVERAGES TO SWEET BEVERAGES NOT SWEET ENOUGH BEVERAGES NOT COLD UNITS WITH BUILT IN COLD PLATE gt gt gt pla gt o o Slo Probable Cause Short circuit in wiring Defec
11. o the system Energize the beverage faucet until the liquid dispensed is free of any syrup Disconnect the cleaning tank and hook up the sanitizing tank to the syrup line and CO system Energize the beverage faucet until the chlorine sanitizing solution is dispensed through the faucet Flush atleast 2 cups of liquid to insure that the sanitizing solution has filled the entire length of the syrup line Disconnect the sanitizing tank Hook up the product tank to the syrup line and to the system Energize the faucet to flush the sanitizing solution from the syrup line and faucet Continue draw on faucet until only syrup is dispensed Repeat Step 2 in reverse order to turn on the carbonator Dispense at lease 1 cup of beverage from each faucet Check taste continue to flush if needed to obtain satisfactory tasting drink 5 90627 SERVICE AND MAINTENANCE N CAUTION Disconnect power to dispenser before installing removing or adjusting this kit INSTALL PLATE ON STUDS AS SHOWN FIGURE 2 GATE RESTRICTOR PLATE ADJ USTMENTS This dispenser is provided with a gate restrictor plate installed in it highest position This plate adjusts the rate of ice flow from the dispenser In applications using buckets carefes or other large containers the plate may be removed entirely for maximum ice flow For glasses and cups the plate may be adjusted downward to reduce the flow of ice The best position depends on the t
12. ozen into large chunks can void warranty The dispenser agitator 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 cub sized pieces before filling into the dispenser hopper 1 90627 DESCRIPTION The REMCOR TJ series of ice dispensers solve your ice and beverage service needs the sanitary space saving economical way Designed to be manually filled with ice from any remote ice making source these dis pensers will dispense cubes up to 1 in size cubelets and hard chipped or cracked ice and in addition sever al flavors of post mix beverages B models contain only beverage faucets and must be supplied with cold product from any remote cold plate of refrigerated soda factory BC units include both faucets and cold plates designed to be supplied direct from syrup tanks and carbonator with no additional cooling required SPECIFICATIONS Model 45 5 Ice Storage 45 Ibs Maximum Number of Faucets Available 4 Built in Cold Plate No Electrical 120 1 60 Dimensions 16 Wide x 22 Deep x 26 1 2 High Model 90 5 Ice Storage 90 Ibs Maximum Number of Faucets Available 6 Built in Cold Plate No Electrical 120 1 60 Dimensions 22 Wide 28 Deep x 32 High Model 90E S BC Ice Storage 90 Ibs Maximum
13. ps to reassembly ice chute Sanitize as described in Step 5 COLD PLATE 1 2 Carefully remove the lower front panel of the ice dispenser Remove cold plate cover by lifting slightly in front and slide forward Wash down the inside of the cold plate tray and cover with mild detergent solution and rinse A small long handled brush will be found helpful in reaching the corners Replace the cover taking care that it is securely positioned in cold plate tray Replace and lower front panel carefully feeding the tube and wires into the cabinet Be sure not to pinch any tubing or wires between the panel and cabinet BEVERAGE SYSTEM 1 2 Remove faucet spouts wash in mild detergent rinse and replace Disconnect electrical power to the carbonator Shut off the water supply and close the regulator to the carbonator 90627 Disconnect the syrup tanks from the system Energize the beverage faucets to purge the remaining soda water in the system Use a clean 5 gallon tank for each of the following A B Cleaning Tank Fill with hot 120oc 1409 potable water Sanitation Tank Fil with a chlorine sanitizing solution in the strength of 1 ounce of household bleach sodium hypochlorite to 2 gallons of cold ambient potable water 200 Repeat the following procedure on each of the unit s syrup product lines A B C D Connect the cleaning tank to the syrup line to be sanitized and t
14. tive gate solenoid Defective agitator motor No power Bent depressor plate does not actuate switch Defective dispensing switch Defective gate solenoid Weak gate spring Excessive pressure against gate slide Ice solidified in hopper Defective agitator motor Defective capacitor TJ 90 only Stuck or bent depressor plate does not release switch Defective dispensing switch Improper switch installation Blocked drain Unit not level No 24 volt power to faucets No CO pressure Carbonator not working No CO pressure in carbonator Faucet brix requires adjusting Empty syrup tank Faucet brix requires adjusting No ice in cold plate cabinet due to reduced ice demand NOTE contact your local syrup or beverage equipment distributor for additional information and trou bleshooting of beverage system 3190627 ALV IdIN AL DNILNNOW 330514 ONIS WOLLOG L3NISVOD NI SONINAdO ALVDIGNI 5 31LON lt NI 8 Z ST LINN ANIILNO x TZ 8 06 IL 90627 NI ZE EZ LZ LINN 3NITLOO lt NI Z T z NI 9T G Z YASNaAdSId d DILLYWAHOS WALSAS 39Vu3A 38 XIW LSOd 1 7 84913 LINN TOGLVNOGUVJ JON SSN N3X0H8 40 30151
15. ype of ice being used and the size container and must be found by trial and error Adjustment is made by loosening the upper two ice chute retaining nuts sliding the re strictor plate to the desired position and re tightening the nuts 90627 6 MAINTENANCE The following dispenser maintenance should be performed at intervals indicated DAILY OR AS REQUIRED Remove foreign material from vending area sink to prevent drain blockage WEEKLY OR AS REQUIRED Clean the vending area Check for proper water drainage from the vending area sink MONTHLY Clean and sanitize the hopper interior see CLEANING INSTRUCTIONS If the dispenser fails to dispense ice when operated check that the hopper has ice in it and that power is being supplied to the unit If the problem persists check the following l Determine if the agitator is rotating check for the sound of ice movement in the hopper 2 Observe whether the gate is operating After checking the above refer to the TROUBLESHOOTING GUIDE for possible problem causes and correc tive action START UP AND OPERATING INSTRUCTIONS Fill the hopper with ice For units with a built in cold plate dispense several large cups of ice approximately 20 to 30 seconds total dispensing time to allow ice to fill the cold plate cabinet Add ice to the hopper as necessary to refill and replace the lid Allow 10 to 15 minutes for the cold plate to cool down Repeat this procedure when ever the d
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