Cornelius Beverage Dispenser TJ45 A User Manual

ICE/BEVERAGE DISPENSERS  
MODELS: TJ 45--A, TJ 45--AB  
TJ 90--A, TJ 90--AB,  
TJ 90--ABC  
WITH AUTOMATIC ICE FILLING FROM A REMOTE ICEMAKER SOURCE  
Operators Manual  
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  
PRINTED IN U.S.A  
â REMCOR INC:  
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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: Dis pens er cannot be us ed with crus hed of flaked ice.  
Us e of bagged ice which has frozen into large chunks can void warranty. The dis pens er  
agitator is not des igned to be an ice crus her. Us e of large chunks of ice which “jam up” ins ide the  
hopper will caus e failure of the agitator motor and damage to the hopper. If bagged ice is us ed, it  
mus t be carefully and completely broken into s mall, cub-s ized pieces before filling into the  
dis pens er 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 com-  
bination 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 dis-  
penser. 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.  
1913  
1922  
1923  
1924  
Icemaker  
Reynolds  
Reynolds  
Jeito  
Model  
CF--3--TT  
CF--6--TT  
MD700  
EC900  
Scotsman  
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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 out-  
line 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 con-  
form 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 mark-  
ings 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: Dis connect power before cleaning. Do not us e metal s crapers , s harp objects or  
abras ives on the s urface of the liner, as damage may res ult. Do not us e s olvents or other  
cleaning agents , as they may attack the plas tic 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 wa-  
ter.  
7. 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. 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 CO2 regulator 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 units syrup product lines.  
A. Connect the cleaning tank to the syrup line to be sanitized and to the CO2 system.  
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 CO2 system.  
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 CO2 system.  
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 ener-  
gizes the agitator motor and gate solenoid. This causes the agitator to rotate and the gate slide to left, al-  
lowing ice to push out the gate opening.  
2. Automatic Ice Filling. Two thermostatic capillary controls are utilized. The control capillary of the ice dis-  
penser (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 re-  
mains at the deflector after agitation, the icemaker control capillary (icemaker bulb) stops icemaker opera-  
tion 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 opera-  
tion. 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 experi-  
enced.  
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SERVICE AND MAINTENANCE  
CAUTION: Dis connect power to dis pens er before ins talling, removing or adjus ting 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, carafes 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 type 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.  
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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  
Probable Cause  
A. Short circuit in wiring.  
BLOWN FUSE OR CIRCUIT BREAKER.  
B. Defective gate solenoid.  
C. Defective agitator motor.  
A. No power.  
GATE DOES NOT OPEN. AGITATOR DOES NOT  
TURN.  
B. Bent depressor plate (does not actuate  
switch).  
C. Defective dispensing switch.  
A. Defective gate solenoid.  
GATE DOES NOT OPEN OR IS SLUGGISH.  
AGITATOR TURNS.  
B. Weak gate spring.  
C. Excessive pressure against gate slide.  
A. Ice solidified in hopper.  
GATE OPENS. AGITATOR DOES NOT TURN.  
ICE DISPENSES CONTINUOUSLY.  
B. Defective agitator motor.  
C. Defective capacitor (TJ90 only).  
A. Stuck or bent depressor plate (does not  
release switch)  
B. Defective dispensing switch.  
C. Improper switch installation.  
A. Blocked drain.  
SLUSHY ICE. WATER IN HOPPER.  
B. Unit no level.  
ICE SOLIDIFIED IN HOPPER, OR ICE AT REAR  
CORNER ONLY.  
A. Defective or improperly adjusted thermostat.  
B. Defective agitation timer.  
A. Icemaker malfunction.  
NO ICE IN HOPPER  
ICE PACKED IN HOPPER.  
A. Defective or improperly adjusted control (not  
shutting off).  
BEVERAGES DO NOT DISPENSE.  
BEVERAGES TOO SWEET.  
A. No 24 volt power to faucets.  
B. No CO2 pressure.  
A. Carbonator not working.  
B. No CO2 pressure in carbonator.  
C. Faucet brix requires adjusting.  
A. Empty syrup tank.  
BEVERAGES NOT SWEET ENOUGH.  
B. Faucet brix requires adjusting.  
BEVERAGES NOT COLD (UNITS WITH BUILT-IN  
COLD PLATE).  
A. Unit standing with no ice use - no ice in cold  
plate cabinet.  
NOTE: contact your local s yrup or beverage equipment dis tributor for additional information and trou-  
bles hooting of beverage s ys tem.  
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FIGURE 6. INSTALLATION  
ROUTE ICEMAKER  
BULB AS SHOWN  
FASTEN & SEAL  
TO COUNTER  
ELECTRIC  
CONDUIT  
DISPENSER  
DISPENSER  
DRAIN  
ICEMAKER  
ICEMAKER  
SEE INSTALLATION KIT INSTRUCTION FOR FEED TUBE DETAILS  
FIGURE 7. FIELD WIRING  
FIELD WIRING  
COMPARTMENT  
LOWER CABINET  
GRND.  
WHT.  
BLK.  
NEUTRAL  
HOT  
FIELD SUPPLY CONDUIT  
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STAINLESS  
DEFLECTOR  
ICEMAKER  
BULB -- TOP  
END OF INSTALLED  
BULB PROTRUDES  
APPROX 1/4” TYPICAL  
AGITATION  
BULB --  
BOTTOM  
ALUMINUM  
PLATE  
FIGURE 8. DEFLECTOR ASSEMBLY  
DEFLECTOR ASSEMBLY  
INSTALL BARE BULBS  
AS SHOWN ABOVE  
AGITATION BULB  
ICEMAKER BULB  
INSULATING TUBING  
UP TO DEFLECTOR  
WITH INSULATION  
TUBING UP TO  
DEFLECTOR  
FIGURE 9. HOPPER INTERIOR  
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DANGER: ELECTRIC SHOCK HAZARD DISCONNECT  
POWER BEFORE SERVICING UNIT  
GRN.  
N
L
GATE  
SOL.  
WHT.  
“OFF”  
“ON”  
GRD.  
* T’STAT IS SHOWN IN  
WARM POSITION.  
MOTOR HEATER  
1-1/4 AMP TIME  
DELAY FUSE.  
WHT  
BLK  
INPUT  
3
C
B
L
U
COLD PLATE  
MOTOR OPTION  
2
1
WHT  
NO  
NC  
T’STAT*  
CAP.  
BLK  
WHT  
R
E
D
AGITATION TIMER  
R
E
D
LID SWITCH  
(LID SCREW MUST BE  
IN PLACE FOR AGITA-  
TOR OPERATION)  
WHT  
BLK  
BLK  
RD  
RED  
B
AGITATOR  
R
E
D
TERMINAL  
BOARD  
LU MOTOR  
E
TRANS.  
24V.  
CAP.  
(TJ 90 ONLY)  
BEVERAGE  
FAUCET  
TYPICAL  
DISPENSE  
SWITCH  
KEY  
SWITCH  
OPTION  
BLK  
SW  
PORTION  
TIMER  
TD  
BEVERAGE SYSTEM  
PORTION  
CONTROL  
OPTION  
DISPENSE  
SWITCH  
OR  
WHT  
TO  
TERMINAL  
BOARD  
RED  
BLK  
RED  
SOLENOID ADJ USTMENT  
7/8 WHEN REPLACING SOLENOID  
ADJ UST TO 7/8 AS SHOWN  
BEFORE TIGHTENING MOUNTING  
SCREWS  
FIGURE 10. WIRING DIAGRAM TJ 45, 90-A DISPENSER  
SERVICE INFORMATION  
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22  
24  
12  
10  
11  
9
15  
1
23  
14  
15  
18  
26  
2
28  
27  
FIGURE 11 UPPER SECTION EXPLODED VIEW TJ 45  
8
16  
5
3
20  
13  
7
6
FIGURE 12 EXPLODED VIEW LOWER SECTION TJ 45  
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4
12  
14  
10  
11  
21  
9
26  
18  
15  
28  
1
15  
23  
8
2
17  
27  
FIGURE 13 EXPLODED VIEW UPPER SECTION TJ 90  
16  
5
3
20  
13  
7
6
FIGURE 14 EXPLODED VIEW LOWER SECTION TJ 90  
15  
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PARTS LIST  
Part No. TJ 45  
-A -AB  
21491  
30528  
21515  
21948  
----------  
30895  
31007  
31163  
Part No. TJ 90  
Item No.  
-A, -AB, -ABC  
21491  
30528  
21515  
21932  
21958  
30895  
31007  
31163  
31091  
31112  
Des cription  
Gate Slide  
1
2
3
4
Interlock Switch  
Depressor Lever  
Agitator (-A, -AB Models Only)  
Agitator (-ABC Models Only)  
Dispense Switch  
Switch Boot  
5
6
7
Switch Insert  
8
31091  
31106  
Transformer  
9
Agitator Motor  
10  
11  
12  
13  
50454  
50481  
50800  
50750  
----------  
53015  
53016  
50770  
70426  
----------  
31093  
70438  
22644  
----------  
21575  
21929  
21934  
----------  
23062  
31290  
31001  
50454  
50806  
50801  
50793  
51019  
53015  
53016  
50770  
70441  
30774  
31093  
70438  
22644  
30794  
21575  
21929  
----------  
22081  
23062  
31290  
31001  
Motor Shaft Seal  
Motor Gasket  
Lid  
Sink (-A, -AB, Models Only)  
(-ABC Models Only)  
Ice Chute Back Section  
Ice Chute Cover  
Gate Gasket  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
Sink Grill  
Capacitor  
Solenoid Assembly  
Rebuilding Kit  
Depressor Retainer  
Agitation Motor Heater (ABC Models Only)  
Deflector Assy  
Ice Cutter  
Ice Level Rod  
Gate Restrictor  
Foam Shield  
Agitation Timer  
Thermostat  
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22  
4
3
5
2
1
4
22  
6
19  
18  
20  
8
22  
21  
16  
15  
14  
11  
10  
17  
19  
13  
12  
9
7
FIGURE 15. SOLENOID ASSEMBLY  
Index  
No.  
Part No.  
Qty.  
Name  
1
2#  
3
21493  
1
1
Solenoid Mounting Plate  
Solenoid Service Kit  
8--32 x 3/8 Phil Tr HD Screw  
No. 8 Lockwasher  
Isolator  
31551  
70171  
70121  
50752  
50789  
70423  
10080  
10081  
50754  
21492  
70043  
70422  
70263  
70048  
70066  
10077  
30227  
50305  
21592  
70433  
51088  
70438  
2
4
2
5
3
6*  
7*  
8*  
9
2
Bumper Assembly  
Cotter Pin  
1
1
Gate Lift Rod  
1
Gate Lift Rod Bushing  
Gate Arm Bearing  
Gate lift Arm  
10  
11  
12  
13*  
14  
15  
16  
17  
18  
19  
20*  
21*  
22  
----*  
1
1
1
Flatwasher  
1
Spring  
1
1/4-20 x 3/4 Hex Hd Screw  
1/4 Lockwasher  
1/4 Flatwasher  
Pivot Bearing  
1
1
1
1
1/4 Quick Connect Tab  
Lubricant  
----  
1
Solenoid Linkage Pin  
Retainer Ring  
2
----  
----  
Loctite  
Rebuilding Kit  
NOTE: * Parts s upplied with rebuilding kit.  
# 31551 s olenoid s upplied with items 20 & 21.  
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IMI CORNELIUS INC.  
ONE CORNELIUS PLACE  
ANOKA, MN. 55303--6234  
TELEPHONE (800) 238--3600  
FACSIMILE (612) 422--3232  
TECH SVC 1-800-535-4240  
WARRANTY  
IMI Cornelius Inc. and 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 IMI Cornelius office near-  
est you. Please provide the equipment model number, serial number and the date of purchase.  
IMI Cornelius Offices  
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166  
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930  
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307  
BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829  
ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644  
FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201  
GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438  
GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491  
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222  
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814  
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361  
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604  
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379  
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255  
Manual number  
18  
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IMI CORNELIUS INC.  
Corporate Headquarters:  
One Cornelius Place  
Anoka, Minnesota 55303-6234  
Telephone (800) 238-3600  
Facsimile (612) 422-3246  
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