Cornelius TJ90-A, TJ90-AB, TJ45-AB, TJ90-ABC, TJ45-A User Manual
ICE/BEVERAGE DISPENSERS
MODELS: TJ45--A, TJ45--AB
WITH AUTOMATIC ICE FILLING FROM A REMOTE ICEMAKER SOURCE
Operator’s Manual
TJ90--A, TJ90--AB,
TJ90--ABC
Part No. 90632
Revision H
Revised March 21, 1996
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
âREMCOR INC:
PRINTED IN U.S.A
TABLE OF CONTENTS
SAFETY PRECAUTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLA TION INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SINK DRAIN ASSEMBLY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD PLATE WHEN REQUIRED 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGE SYSTEM (WHEN REQUIRED) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND MAINTENANCE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING GUIDE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOWN FUSE OR CIRCUIT BREAKER 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GATE DOES NOT OPEN. AGITATOR DOES NOT TURN. 7. . . . . . . . . . . . . . . . . .
GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS. 7. . . . . . . . . . .
GATE OPENS. AGITATOR DOES NOT TURN. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE DISPENSES CONTINUOUSLY. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLUSHY ICE. WATER IN HOPPER 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE SOLIDIFIED IN HOPPER, OR ICE AT REAR CORNER ONLY. 7. . . . . . . . . . .
NO ICE IN HOPPER 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE PACKED IN HOPPER. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES DO NOT DISPENSE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TO SWEET. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT SWEET ENOUGH. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT COLD (UNITS WITH BUILT-IN COLD PLATE) 7. . . . . . . . . . .
PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
LIST OF FIGURES
FIGURE 1. SINK DRAIN ASSEMBLY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. GATE RESTRICTOR PLATE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. MOUNTING TEMPLATE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. TYPICAL POST-MIX BEVERAGE SYSTEM
SCHEMATIC “--B” DISPENSERS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. TYPICAL POST-MIX BEVERAGE SYSTEM
SCHEMATIC “--BC” DISPENSERS 10.......................................
FIGURE 6. INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. FIELD WIRING 11..............................................
FIGURE 8. DEFLECTOR ASSEMBLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 9. HOPPER INTERIOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 10. WIRING DIAGRAM TJ45, 90-A DISPENSER
SERVICE INFORMATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 11 UPPER SECTION EXPLODED VIEW TJ45 14. . . . . . . . . . . . . . . . . . . .
FIGURE 12 EXPLODED VIEW LOWER SECTION TJ45 15. . . . . . . . . . . . . . . . . . . .
FIGURE 13 EXPLODED VIEW UPPER SECTION TJ90 16. . . . . . . . . . . . . . . . . . . .
FIGURE 14 EXPLODED VIEW LOWER SECTION TJ90 17. . . . . . . . . . . . . . . . . . . .
FIGURE 15. SOLENOID ASSEMBLY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 of flaked ice.
Use of bagged ice which has frozen 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
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DESCRIPTION
The REMCORâ Ice and Ice/Beverage dispensers with model numbers suffixed with--A, --AB, and --ABC (e.g.
model TJ90E--ABC) are designed to be used with one of several remote “piped ice” type machine. This combination automatically provides a continuous supply of sanitary ice at the touch of a lever, In order to complete
an automatic filling installation, the following items must be obtained.
1. Icemaker. This must be obtained from the appropriate manufacturer.
2. Feed Tube Kit This kit contains parts and instructions necessary to connect the ice machine to the ice dispenser. Be sure the feed tube kit is proper for your icemaker. The following tube kits are approved for use
on the TJ45/90--A dispensers:
Kit No. Icemaker Model
1913 Reynolds CF--3--TT
1922 Reynolds CF--6--TT
1923 Jeito MD700
1924 Scotsman EC900
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INSTALLATION INSTRUCTIONS
1. The ice dispenser must be fastened and sealed to the counter, using the hardware supplied with the unit.
The template drawings (Figure NO TAG) indicate openings which must be cut in the counter for the ice
feed tube and utilities. Check that the counter mounting surface for the dispenser is level.
Apply a continuous bead of NSF approved 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. Fasten the ice dispenser in place with mounting hardware provided. All excess sealant
must be wiped away immediately.
2. Position the icemaker and install the feed tube and other components according to the instruction supplied
with the feed tube kit.
3. Route the icemaker control bulb along the outside of the dispenser cabinet, and into the hopper as shown
in Figure 2. Install insulating tubing and mount the bulb to the deflector assembly as shown in Figure 5.
Use care when handling the bulb to avoid damaging or kinking it. Do not allow the bulb to contact any cold
surfaces, or false sensing will occur. Route the bulb away from electrical terminals, moving parts, or sharp
metal edges.
4. Permanently wire the dispenser to a source of 120V, 60Hz. power as shown in Figure 3. Wiring must conform to N.E.C. and local codes
5. On beverage units --AB, and -- ABC connect the beverage system product lines as indicated in Figures 4,
5, and 9. This work should be done by a qualified service person.
6. Connect the 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 for proper drainage.
7. Complete the installation of the icemaker according to the instructions supplied with the unit and the markings on the icemaker itself.
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
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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
1. Clean the ice dispenser interior at least once a month.
2. Lift off agitator assembly and wash and rinse it thoroughly.
3. Carefully remove and disassemble the deflector assembly and wash and rinse all parts.
4. Wash down the inside of hopper and top cover with mild detergent solution and rinse thoroughly to remove
all traces of detergent.
5. Replace agitator and deflector assembly, using care to reinstall the bulbs properly .
6. Sanitize the inside of hopper and agitator with a solution of 1 ounce of household bleach in 1 gallon of water.
7. With the brush provided, clean the inside of the ice chute with a mild detergent solution and rinse thoroughly to remove all traces of detergent. Sanitize as described in step 6.
COLD PLATE when required
1. Carefully remove the lower front panel of the ice dispenser.
2. Remove cold plate cover by lifting slightly in front and slide forward.
3. Wash down the inside of the cold plate cabinet and cover with mild detergent solution and rinse. A small,
long-handled brush will be found helpful in reaching the corners.
4. Replace the cover, taking care that it is securely positioned in cold plate tray.
5. Replace and lower front panel, carefully feeding the tubes and wires into the cabinet. Be sure not to pinch
any tubing or wires between the panel and cabinet.
BEVERAGE SYSTEM (when required)
1. Remove faucet spouts, wash in mild detergent, rinse and replace.
2. Disconnect electrical power to the carbonator. Shut off the water supply and close the CO2regulator to the
carbonator.
3. Disconnect the syrup tanks from the system.
4. Energize the beverage faucets to purge the remaining soda water in the system.
5. Use a clean 5 gallon tank for each of the following:
A. Cleaning Tank -- Fill with hot (120° -- 140°) potable water.
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B. Sanitation Tank -- Fil with a chlorine sanitizing solution in the strength of 1 ounce of household bleach
(sodium hypochlorite) to 1 gallon of cold (ambient) potable water (410PPM).
6. Repeat the following procedure on each of the unit’s syrup product lines.
A. Connect the cleaning tank to the syrup line to be sanitized and to the CO2system.
B. Energize the beverage faucet until the liquid dispensed is free of any syrup.
C. Disconnect the cleaning tank and hook-up the sanitizing tank to the syrup line and CO2system.
D. Energize the beverage faucet until the chlorine sanitizing solution is dispensed through the faucet.
Flush at least 2 cups of liquid to insure that the sanitizing solution has filled the entire length of the
syrup line.
E. Disconnect the sanitizing tank. Hook up the product tank to the syrup line and to the CO2system.
F. Energize the faucet to flush the sanitizing solution from the syrup line and faucet. Continue draw on
faucet until only syrup is dispensed.
7. 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.
OPERATING INSTRUCTIONS
1. ice Dispensing. Depressing the operating level activates a micro switch behind the front panel, Which energizes the agitator motor and gate solenoid. This causes the agitator to rotate and the gate slide to left, allowing ice to push out the gate opening.
2. Automatic Ice Filling. Two thermostatic capillary controls are utilized. The control capillary of the ice dispenser (agitation bulb) will activate the agitation timer as it senses ice. The agitation timer causes the ice to
level which allows the entire ice storage bin to fill before the ice machine shuts off. When the ice level remains at the deflector after agitation, the icemaker control capillary (icemaker bulb) stops icemaker operation until the level drops, and the bulbs warm up
While the icemaker is running, the ice entering the hopper from the feed tube should be loose and in small
pieces. Ice entering in the form of hard packed cylinders indicates a restriction or distortion of the feed
tube, and could result in icemaker malfunction of not corrected.
Immediately after icemaker shutoff, observe the ice in the hopper between the feed tube entrance and the
deflector. It should be loosely pressed against the top of the deflector, indicating correct thermostat operation. If the ice level is low, or if ice is packed hard against the deflector it will be necessary to readjust the
icemaker bin control, according to the icemaker instructions. (Adjust the control warmer to lower the ice
level, and colder to raise the ice level)
3. Beverage System. (--AB and --ABC models only) Beverages may be dispensed by operating the lever on
the appropriate faucets. On units with cold plates (--ABC), periodic movement of the ice in the hopper is
necessary to maintain the level of ice on the cold plate. On initial startup, of after long idle period with no
use, dispensing ice for 20--30 seconds is necessary to fill the cold plate, or warm beverages may be experienced.
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