ICE/BEVERAGE DISPENSERS

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1 Operator s Manual ICE/BEVERAGE DISPENSERS MODELS: TJ150-B TJ150-KB TJ150-BC TJ150-KBC Part No February, 1997 Revision E THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment REMCOR INC: PRINTED IN U.S.A

2 TABLE OF CONTENTS Page SAFETY PRECAUTIONS GENERAL DESCRIPTION ICE MAKER INSTALLATION INSTRUCTIONS SINK DRAIN ASSEMBLY INSTRUCTIONS CLEANING INSTRUCTIONS DISPENSER COLD PLATE BEVERAGE SYSTEM MAINTENANCE DAILY OR AS REQUIRED WEEKLY OR AS REQUIRED MONTHLY OPERATING INSTRUCTIONS GATE RESTRICTOR PLATE ADJUSTMENT TROUBLESHOOTING GUIDE 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 ICE SOLIDIFIED IN HOPPER OR ICE AT REAR CORNER ONLY NO ICE IN HOPPER ICE PACKED IN HOPPER BEVERAGES DO NOT DISPENSE BEVERAGES TOO SWEET BEVERAGES NOT SWEET ENOUGH BEVERAGES NOT COLD (UNITS WITH BUILT-IN COLD PLATE) FINAL ASSEMBLY PARTS LIST WARRANTY 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, 4,300,359, 4,346,824 Canadian Patent Numbers: 912,514 (10/72), 936,855 (11/73), 4,429,543, 4,921,149 Other Patents Pending i 90956

3 TABLE OF CONTENTS (cont d) LIST OF FIGURES Page FIGURE 1. SINK DRAIN ASSEMBLY FIGURE 2. GATE RESTRICTOR PLATE FIGURE 3. TJ150-K ICE CUBER INSTALLATION FIGURE 4. MOUNTING TEMPLATE TJ150-B, BC FIGURE 5. SPECIFICATION DRAWING TJ150-B, BC FIGURE 6. BEVERAGE SYSTEM SCHEMATIC -B MODELS FIGURE 7. BEVERAGE SYSTEM SCHEMATIC -BC MODELS FIGURE 8. WIRING DIAGRAM TJ150-BC DISPENSER FIGURE 9. FINAL ASSEMBLY FIGURE 10. SOLENOID ASSEMBLY LIST OF TABLES TABLE 1. SPECIFICATIONS ii

4 SAFETY PRECAUTIONS This ice dispenser has been specifically designed to provide protection against personal injury and eliminate contamination of ice. To ensure continued protection and sanitation, observe the following: 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 the dispenser is energized! ALWAYS be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior and possible contamination of ice. ALWAYS be sure the upper and lower front panels are securely fastened. ALWAYS keep area around the dispenser clean of ice cubes. CAUTION: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice, that 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 that 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, cube-sized pieces before filling into the dispenser hopper. GENERAL DESCRIPTION The Remcor TJ series of ice and beverage 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, or automatically filled from a top-mounted ice cuber, these dispensers will dispense cubes (up to1?in size), cubelets, hard-chipped or cracked ice and in addition, several flavors of post-mix beverages. B models contain beverage faucets only and must be supplied with cold product from any remote cold plate or refrigerated soda factory. -BC models include faucets and a coldplate and are designed to be supplied directly from the syrup tanks and carbonator, with no additional cooling required. Table 1. Specifications Model: TJ150E/S-B, KB Ice Storage: 150 lbs. Electrical: 120 /1 /60 Maximum Number of Faucets Available: 8 Dimensions: 30? W x 30? D x 34-1/2? H Model: TJ150E/S-BC, KB Ice Storage: 150 lbs. Electrical: 120 /1 /60 Maximum Number of Faucets Available: 8 Dimensions: 30? W x 30? D x 34-1/2? H CABINETRY OPTIONS E -- Neutral Beige or White Baked Enamel Finish S -- All Stainless Steel

5 ICE MAKER REMCOR K model ice/beverage dispensers are designed to be used with one of several top-mounted ice cubers. These cubers must be obtained from the appropriate manufacturer or distributor in your area. The following ice makers are approved for use on the TJ150 K models: ICE MAKER MODEL SERIES Ross Temp. RCV--404 / 604 Scotsman CM500 / 650 Mile High Equipment Company C20 / C40 / C61 Manitowas E200 / E400 / G600 * Kold-Draft GT300 / 400 / 500 ** Reynolds MCC700 * Order Installation Kit No ** Order Installation Kit No Consult the factory for other ice maker applications

6 INSTALLATION INSTRUCTIONS 1. Locate the dispenser indoors on a level counter top. MODELS B, BC Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility lines to permit shifting the position of the dispenser sufficiently to clean the area beneath it. MODEL KB, KBC The ice dispenser must be sealed to the counter. The template drawing (Figure 4) indicates openings which must be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter. Apply a continuous bead of NSF International (NSF) listed 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. All excess sealant must be wiped away immediately. 2. Carefully pull the beverage tubes, drain line and power cord through the large opening in the bottom of the unit. See Figure 4 (MOUNTING TEMPLATE) for locating the required clearance holes in the counter for these utility lines. 3. Connect the drain tube to an open drain. If additional piping is provided, it must be 3/4? IPS (or equal). This line must continually pitch downward away from the unit and must contain no traps, or improper drainage will result. 4. Connect the beverage system product lines as indicated in Figure 6 ( B units) and Figure 7 ( BC units). This work should be done by a qualified service person. Note that the hoses are marked with numbers (1 through 8) for syrup connections and CW for carbonated water connection. IMPORTANT: The water supply to the carbonator must comply with the basic plumbing code of the Building Officials and Code Administrators International, Inc. (BOCA) and local plumbing codes. 5. Clean the hopper interior (see CLEANING INSTRUCTIONS). 6. K Models Only: Install the ice maker on the dispenser as shown in Figure 3 or according to the instructions supplied with the kit, as appropriate. Follow the icemaker manufacturer s instructions to complete the installation. 7. Connect the dispenser cord to a 120 volt, 60 hertz, 3-wire grounded receptacle. SINK DRAIN ASSEMBLY INSTRUCTIONS 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 the dispenser (See Figure 1). 3. The unit is now ready for operation. DRAIN LINE DISPENSER BOTTOM FIGURE 1. SINK DRAIN ASSEMBLY

7 CLEANING INSTRUCTIONS WARNING: DISCONNECT POWER BEFORE CLEANING! Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper, top cover and the agitator disk, as damage may result. Do not use solvents or other cleaning agents, as they may attack the plastic material. DISPENSER 1. Clean the ice storage hopper at least once a month. 2. Lift off the agitator and the agitator disk. Wash with a mild detergent solution and rinse them thoroughly to remove all traces of detergent. 3. Wash the inside of the hopper and top cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 4. Replace the agitator. 5. Sanitize the inside of the hopper and agitator with a solution of 1/2 ounce of household bleach in 1 gallon of water. (200 PPM) 6. Replace the agitator disk. Sanitize as described in Step Remove ice chute cover as follows: A. Flex sides outward to disengage lower pins. B. Lift ice chute cover to disengage upper pins. C. Lower ice chute cover down out of unit. NOTE: It may be helpful to twist cover slightly. 8. With brush provided, clean the inside of the ice chute with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 9. Reverse steps above to reassemble ice chute. 10. Sanitize as described in Step 5. COLD PLATE 1. Remove splash panel and merchandiser. 2. Remove the bottom two (2) screws on the ice chute and loosen the top two (2) screws. You do not have to remove the ice chute. (During reassembly, make sure the ice gate restrictor is relocated to it s correct position.) 3. Remove the screw, hold the beverage faucet panel and bring forward. 4. Remove the tape holding the lower cold plate cover to the top cold plate cover. 5. Lift the lower cold plate cover up into the top cover. 6. Remove any debris from the drain trough and spring. Check that the drain hole is not clogged. 7. Wash down the inside of the cold plate, tray and cover with a mild detergent solution and rinse. A small, long-handled brush is helpful to reach the corners

8 8. Slide the cover forward, taking care that it is securely positioned on the cold plate. 9. Reassemble. BEVERAGE SYSTEM 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 CO 2 regulator to the carbonator. 3. Disconnect the syrup tanks from the system. 4. Energize the beverage faucets to purge the remaining soda in the system. 5. Use a clean 5 gallon tank for each of the following. A. Cleaning tank - fill with hot ( ) potable water. B. Sanitation tank - fill with a chlorine sanitizing solution in the strength of 1/2 ounce of household bleach (sodium hypochlorite) to 1 gallon of cold (ambient) potable water (200 PPM). 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 CO 2 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 CO 2 system. D. Energize the beverage faucet until the chlorine sanitizing solution is dispensed through the faucet. Flush at least 2 cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup lines. E. Disconnect the sanitizing tank. Hookup the product tank to the syrup line and to the CO 2 system. F. Energize the faucet to flush the sanitizing solution from the syrup line and faucet. Continue to draw on the faucet until only syrup is dispensed. 7. Repeat Step 2 in reverse order to turn on the carbonator. Dispense at least 1 cup of beverage from each faucet. Check taste. Continue to flush if needed, to obtain a satisfactory tasting drink

9 MAINTENANCE The following dispenser maintenance should be performed at the intervals indicated: DAILY or as required Remove foreign material from the vending area sink to prevent drain blockage. WEEKLY or as required Clean vending area. Check for proper water drainage from the vending area sink. MONTHLY Clean and sanitize the hopper interior (see CLEANING INSTRUCTIONS). OPERATING INSTRUCTIONS Ice Dispensing: Depressing the operating lever activates a microswitch behind the front panel which energizes the agitator motor and gate solenoid. This causes the agitator to rotate and the gate slide to lift, allowing the ice to push out the gate opening. Ice Level: (Standard Models): Remove the lid and fill the hopper with ice. Replace lid to avoid contamination of ice. For units equipped with the optional ice level light, low ice level in the storage hopper will be indicated when the light is on. CAUTION: Use caution to avoid spilling ice when filling dispenser. Immediately clean up any spilled ice from filling or operating the unit. To prevent contamination of ice, the lid must be installed on the unit at all times. Automatic Ice Filling: ( K Models): The automatic agitation timer causes the ice to maintain a constant level which allows the entire storage bin to fill before the ice machine shuts off. The ice maker control capillary bulb maintains the ice level in the storage hopper. Consult the ice maker manual for location and operation of the ice maker control. Beverage System: Beverages may be dispensed by operating the lever on the appropriate faucets. On units with cold plates ( C models), periodic movement of the ice in the hopper is necessary to maintain the level of ice on the cold plate. On initial start-up or after long, idle periods with no use, dispense several large cups of ice (approximately seconds total dispensing time) to allow ice to fill the cold plate cabinet. For manual-fill units, add ice to the hopper as necessary to refill and then replace the lid. Allow minutes for the cold plate to cool down. Repeat this procedure whenever the dispenser has been standing overnight or other long periods without ice use to prevent warm beverages on initial use. Start up the beverage system and adjust the faucets to the proper brix. Contact your local syrup distributor for complete information on the beverage system. GATE RESTRICTOR PLATE CAUTION: Disconnect power to dispenser before installing, removing or adjusting restrictor

10 INSTALL PLATE ON STUDS AS SHOWN FIGURE 2. GATE RESTRICTOR PLATE ADJUSTMENT This dispenser is provided with a gate restrictor plate installed in its 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 restrictor plate to the desired position and re-tightening the nuts

11 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 does not dispense, check the following chart under the appropriate symptoms to aid in locating the defect. Trouble BLOWN FUSE OR CIRCUIT BREAKER. A. Short circuit in wiring. GATE DOES NOT OPEN. AGITATOR DOES NOT TURN. GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS. B. Defective gate solenoid. C. Defective agitator motor. A. No power. Probable Cause B. Bent depressor plate (does not actuate switch). C. Defective dispensing switch. A. Defective gate solenoid. B. Weak gate spring. GATE OPENS. AGITATOR DOES NOT TURN. A. Agitator motor protector tripped. B. Defective agitator motor. C. Defective agitator relay. ICE DISPENSES CONTINUOUSLY. A. Stuck or bent depressor plate (does not release switch). B. Defective dispensing switch. C. Improper switch installation. SLUSHY ICE. WATER IN HOPPER. A. Blocked drain. ICE SOLIDIFIED IN HOPPER OR ICE AT REAR CORNER ONLY. B. Unit not level. C. Poor ice quality due to water quality or ice maker problems A. Defective or improperly adjusted ice maker thermostat. NO ICE IN HOPPER. A. Ice maker malfunction. ICE PACKED IN HOPPER. A. Defective or improperly adjusted ice maker control (not shutting off). BEVERAGES DO NOT DISPENSE. A. No 24 volt power to faucets. B. No CO 2 pressure. BEVERAGES TOO SWEET. A. Carbonator not working. B. No CO 2 pressure in carbonator. C. Faucet brix requires adjusting. BEVERAGES NOT SWEET ENOUGH. A. Empty syrup tank. BEVERAGES NOT COLD (UNITS WITH BUILT-IN COLD PLATE). B. Faucet brix requires adjusting. A. Unit standing with no ice in hopper, no ice in cold plate cabinet. Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of your beverage system

12 POSITION ICE MAKER ON DISPENSER TO COVER OPENING INTO STORAGE HOPPER. APPLY RTV AROUND INSIDE OF ICE MAKER OUTLINE ON DISPENSER COVER TO FORM A SEAL. REMOVE SCREWS AND TURN BRACKET AROUND 180. REPLACE SCREWS. FIGURE 3. TJ150-K ICE CUBER INSTALLATION

13 2 1/8 DIA. (POWER CORD AND DRAIN) OPENING REQUIRED FOR BEVERAGE TUBING 3 31/32 5/8 1 1/8 2 1/4 4 1/2 13 1/2 2 5/8 18 1/2 30 1/2 DIA. (4) 27 3/ /8 FIGURE 4. MOUNTING TEMPLATE TJ150-B, BC

14 / / /32 8 5/8 FIGURE 5. SPECIFICATION DRAWING TJ150-B, BC 27 5/ /4 17 5/

15 FAUCETS CW CW REMCOR B ICE/BEVERAGE DISPENSER ITEMS OUTSIDE OF BROKEN LINES NOT INCLUDED WITH UNIT. FAUCETS 5 THROUGH 8 ARE OPTIONAL. OPTIONAL-FOR DIET OR ROOT BEER REGULATORS 5-15 PSIG PSIG S1 S2 S3 S4 S5 S6 S7 S8 CO 2 TANK SYRUP TANKS NOTE: REFERENCE ONLY NOT FOR CONSTRUCTION PSIG OPTIONAL: PRESSURE REGULATOR COLD PLATE OR ICE BANK CARBONATOR FILTER WATER SUPPLY FIGURE 6. BEVERAGE SYSTEM SCHEMATIC -B MODELS

16 NOTE: REFERENCE ONLY NOT FOR CONSTRUCTION FAUCETS REMCOR BC ICE/BEVERAGE DISPENSER ITEMS OUTSIDE OF BROKEN LINES NOT INCLUDED WITH UNIT. FAUCETS 5 THROUGH 8 ARE OPTIONAL. CW CW OPTIONAL-FOR DIET OR ROOT BEER REGULATORS 5-15 PSIG PSIG S1 S2 S3 S4 S5 S6 S7 S8 CO 2 TANK SYRUP TANKS PSIG OPTIONAL: PRESSURE REGULATOR WATER SUPPLY COLD PLATE CARBONATOR FILTER FIGURE 7. BEVERAGE SYSTEM SCHEMATIC -BC MODELS

17 T STAT LIGHT L N GROUND GRN WHT ICE LEVEL SIGNAL OPTION BLK MOTOR HEATER WHT GATE SOLENOID 1 1/4 AMP TIME DELAY FUSE WHT AGITATION TIMER BLK WHT 24 V. TRANSFORMER BLK PINK C NO NC KEY SWITCH BEVERAGE OPTION FAUCET (TYPICAL) BEVERAGE SYSTEM TERMINAL BOARD WHT RED RED RED AGITATOR MOTOR CAPACITOR PORTION CONTROL OPTION TO TERMINAL BOARD WHT RED BLK PORTION TIMER SW TD OR RED DISPENSE SWITCH BLK DISPENSE SWITCH 7 8 SERVICE INFORMATION DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. SOLENOID ADJUSTMENT WHEN REPLACING SOLENOID ADJUST TO 7/8 INCH AS SHOWN BEFORE TIGHTENING MOUNTING SCREWS FIGURE 8. WIRING DIAGRAM TJ150-BC DISPENSER 14

18 FIGURE 9. FINAL ASSEMBLY

19 FINAL ASSEMBLY PARTS LIST Item No. Part No. Description Gate Slide Foam Shield Depressor Lever Agitator Dispense Switch Switch Boot Switch Insert Transformer Agitator Motor Motor Shaft Seal Motor Gasket Lid ( B BC ) ( KB KBC ) Sink ( B Models Only) ( BC Models Only) Ice Chute Back Section Ice Chute Cover Gate Gasket Sink Grill Leg ( B, BC Models Only) Capacitor Solenoid Assembly (See page 17) Rebuilding Kit Depressor Retainer Agitation Motor Heater ( B, KBC Models Only) Agitation Timer ( BC, KBC Models Only)

20 FIGURE 10. SOLENOID ASSEMBLY -- EXPLODED VIEW & PARTS LIST Index No. Part No. Quantity Description Solenoid Mounting Plate 2# Solenoid Service Kit x 3/8 Phil Tr HD Screw No. 8 Lockwasher Isolator 6* Bumper Assembly 7* Cotter Pin 8* Gate Lift Rod Gate Lift Rod Bushing Gate Arm Bearing Gate Lift Arm Flatwasher 13* Spring /4-20 x 3/4 Hex Hd Screw /4 Lockwasher /4 Flatwasher Pivot Bearing /4 Quick Connect Tab Lubricant 20* Solenoid Linkage Pin 21* Retainer Ring Loctite ----* Rebuilding Kit NOTE: * Parts supplied with rebuilding kit. # solenoid supplied with items 20 &

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.

21 IMI CORNELIUS INC. ONE CORNELIUS PLACE ANOKA, MN TELEPHONE (800) FACSIMILE (612) TECH SVC 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 nearest you. Please provide the equipment model number, serial number and the date of purchase. IMI Cornelius Offices AUSTRALIAD P.O. 210,D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) D FAX (61) AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) D FAX (43) BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) D FAX (32) BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) D FAX (55) ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) D FAX (44) FRANCE D 71 ROUTE DE ST. DENIS D F DEUIL LA BARRE D PARIS, FRANCE D (33) D FAX (33) GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) D FAX (49) GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D D ATHENS, GREECE D (30) D FAX (30) HONG KONG D 1104 TAIKOTSUI CENTRE D KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) D FAX (852) ITALY D VIA PELLIZZARI 11 D D VIMARCATE, ITALY D (39) D FAX (39) NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) D FAX (64) SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) D FAX (65) SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) D FAX (34) USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) D FAX (612) SD /16/96

22 CORPORATE HEADQUARTERS: Remcor Incorporated 500 Regency Drive Glendale Heights, IL

Telephone (800) Facsimile (800)

Telephone (800) Facsimile (800) IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139-2268 Telephone (800) 551-4423 Facsimile (800) 519-4423 Installation Manual ICE DISPENSER D45 and D90 Part No. 91561 August, 1995