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
Operator’s 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:
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 unit’s 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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90632
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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90632
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8
90632
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90632
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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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11
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
90632
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
90632
13
4
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
90632
14
22
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
90632
16
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.
17
90632
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
IMI CORNELIUS INC.
Corporate Headquarters:
One Cornelius Place
Anoka, Minnesota 55303-6234
Telephone (800) 238-3600
Facsimile (612) 422-3246
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