Cornelius Remcor TJ200 User manual

ICE/BEVERAGE DISPENSERS
MODELS:TJ200,TJ200A,TJ200K
TK250,TJ250A,TJ250K
TJ300,TJ300K
Operator’sManual
PRINTEDIN U.S.A
âREMCORINC:
PartNo.90683
August, 1995
Revision F
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i90683
TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS1...................................................
GENERALDESCRIPTION1..................................................
ICEMAKER2...........................................................
FEEDTUBE ORICEMAKERINSTALLATIONKIT2.........................
INSTALLATIONINSTRUCTIONS3............................................
OPERATING INSTRUCTION4................................................
31177 PORTION CONTROLOPERATINGINSTRUCTIONS4.................
CLEANING INSTRUCTIONS6................................................
DISPENSER6..........................................................
MAINTENANCE7...........................................................
DAILYORAS REQUIRED7..............................................
WEEKLYORAS REQUIRED7............................................
MONTHLY7............................................................
GATERESTRICTORPLATE8............................................
ADJUSTMENT8........................................................
TROUBLESHOOTING GUIDE9...............................................
BLOWNFUSE OR CIRCUITBREAKER9..................................
GATEDOES NOTOPEN.AGITATOR DOES NOT TURN 9...................
GATEDOES NOTOPENORIS SLUGGISH.AGITATORTURNS.9...........
GATEOPENS.AGITATOR DOES NOT TURN.9............................
ICEDISPENSES CONTINUOUSLY.9......................................
SLUSHYICE.WATERIN HOPPER.9......................................
ICE SOLIDIFIEDIN HOPPERORICE ATREAR CORNERONLY.9...........
NOICEIN HOPPER9...................................................
ICE PACKEDIN HOPPER9..............................................
EXPLODEDVIEWUPPER AND LOWERPARTSLIST16........................
WARRANTY18..............................................................
LISTOF FIGURES
FIGURE1.PORTION CONTROL 4........................................
FIGURE2.GATERESTRICTORPLATE8..................................
FIGURE3.WIRINGDIAGRAMTJ200 /250 /300 10..........................
FIGURE4.WIRINGDIAGRAMTJ200 /250 /300—A,KDISPENSER11........
FIGURE5.MOUNTINGTEMPLATEMODELTJ300 12........................
FIGURE6.MOUNTINGTEMPLATETJ200 /250 /TJ200 /250-A,K13.........
FIGURE7.EXPLODEDVIEWUPPERSECTION14..........................
FIGURE8.EXPLODEDVIEWLOWERSECTION15.........................
FIGURE9.SOLENOIDASSEMBLY17......................................
LISTOF TABLES
TABLE1.SPECIFICATIONS1............................................
Manufactured UnderOne orMore of the Following PatentNumbers:
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 PatentNumbers912,514 (10/72),936,855 (11,73),4,429,543,4,921,149
OtherPatentsPending

190683
SAFETY PRECAUTIONS
Thisice dispenserhasbeen specificallydesigned to provide protection againstpersonal injuryand eliminates
contamination ofice.Toinsurecontinued protection and sanitation,observethe following
Always disconnectpowertothe dispenserbeforeservicing orcleaning.
Neverplace handsinside ofhopperorgate area withoutdisconnecting powertothe dispenser.Agitator rotation
occursautomaticallywhen the dispenserisenergized!
ALWAYS be surethe removablelidisproperlyinstalled to preventunautho-
rized access tothe hopperinteriorand possiblecontamination ofice.
ALWAYS be surethe upperand lowerfrontpanelsaresecurelyfastened.
ALWAYS keep area around the dispenserclean oficecubes.
CAUTION:Dispensercannotbeusedwithcrushed orflakedice.
Use ofbaggedice which has frozenintolarge chunks canvoidwarranty.Thedispenser
agitatorisnotdesignedto be anice crusher.Use oflarge chunks ofice which“jamup”
insidethehopperwill cause failureof the agitatormotorand damagetothehopper. Ifbaggedice
isused, itmustbe carefully and completelybrokenintosmall, cube-sized pieces beforefilling into
thedispenserhopper.
GENERALDESCRIPTION
The RemcorTJ220 /250 /300 seriesofice dispensers solveyouriceservice needsthe sanitary,spacesaving,
economical way.Designed tobemanuallyfilled withicefromanyremoteicemaking source,orto be used with
one ofseveral“piped ice”type icemakersortop-mounted “Icecuber,”
These dispenserswill dispensecubes(up to1-3/8”insize),cubelets,hard-chipped orcracked ice.Remcordis-
pensers cannotbe used withcrushed orflaked ice.
Model Designation:TJ 123
CabinetryOptions:
(E)Neutralbeige,baked enamelfinish and wood grainvinyl-clad upperfrontpanel.
(S)All Stainless Steel.
Ice Fill Options:
(No Letter) Manuallyfilled from remoteicemaker.
(A)Automaticfill froma“piped ice”type icemaker.
(K)Automaticfill fromatop-mounted “icecuber”.
Example:ModelTJ205s “K”has a 250 pound ice storage capacitywitha stainless steelcabinetand
isdesignedforautomaticfilling fromatop-mountedice maker.
Table 1.Specifications
Model:TJ200 TJ250 TJ300
IceStorage:200 lbs.250 lbs.300 lbs.
Electrical:115 Volts1Phase60Hertz,6.0Amps
Electrical Connection:Standard and “K”models:supplied with 6’,3-wireCordwith 3-prong
Ground Type Plug
“A”Models:Supplied with2x4junction boxlocated inlowercabinet
enclosureforpermanentwiring installation.
DrainConnection:7/8”ID Hose 7/8”ID Hose 7/8”ID Hose
Dimensions:32”Wx38-5/8”Hx
36”D32”Wx42-1/4”Hx 36”D32”Wx44-1/4”Hx 36”D
Shipping Weight220 lbs.245 lbs.260 lbs.
Operating Weight(Less IceMaker) 420 lbs495 lbs.560 lbs.

290683
ICEMAKER
REMCOR“A”and “K”model ice dispensersare designed to be used with one ofseveral“piped ice”type ice
makersortop-mount“icecubers.”Thesemustbe obtained fromthe appropriatemanufacturerordistributorin
yourarea.
FEEDTUBEORICEMAKERINSTALLATION KIT
This kitcontainspartsand instructionsnecessarytoconnect the icemakertothe ice dispenser.Besurethe kit
you receiveisproperforyouricemaker.The following kitsare approved foruseonthe TJ200 /250 /300 “A,”
“K”dispensers:
“A”MODELDISPENSERS
KITNUMBERICEMAKERMODEL
1913 ReynoldsCF-3-TT
1922 ReynoldsCF-6-TT
1923 JietoMD700
1924 Scotsman EC900
“B”MODELDISPENSERS
KITNUMBERICEMAKERMODEL
1930 (TJ300)Ice-O-MaticC20 /40 /60
2097 (TJ250)Ice-O-MaticC20 /40 /60
1931 Manitowoc200 /400 /600
1932 KoldDraft GT300 /400 /500 /600
2011 Scotsman CM250 /450 /500 /650
2012 HoshizakiKM451 /452 /630 /632

390683
INSTALLATION INSTRUCTIONS
1.The ice dispenser mustbe sealed tothe counterThe template drawing (Figure 6)indicate openingswhich
mustbe cutinthe counter.Locatethe desired position forthe dispenser, then markthe outline dimensions
on the counterusing the template drawings.Cutopeningsincounter.
Applyacontinuousbead ofNSFInternational(NSF)listed silastic sealant(Dow732 orequal)approximate-
ly1/4”inside of the unitoutline dimensionsand around all openings.Then position the uniton the counter
withinthe outline dimensions.All excess sealantmustbe wiped awayimmediately.“A”modelsmustbe
fastened in placewithmounting hardware provided.
2.“A”and “K”ModelsOnly:Install the icemakeraccording tothe instructions supplied withthe kit, and
manufacturer’sinstructions supplied withthe icemaker.
3.Connect the draintube to an open drain.Ifadditionalpiping isrequired,itmustbe 3/4”IPS (orequal).This
line mustcontinuallypitch downward awayfromthe unitand mustcontainnotraps,orimproperdrainage
will result.
4.Clean the ice dispenserinterior (see CLEANING INSTRUCTIONS).
5.Connect the powercordtoa115volt, 60 cycle,3-wire grounded receptacle.“A”modelsmustbe perma-
nentlywired and conform toNECand localcodes.

90683 4
OPERATINGINSTRUCTION
1. IceDispensing:Depressing the operating leveractivatesamicroswitch behind the frontpanel which ener-
gizesthe agitator motorand gatesolenoid.This causesthe agitatortorotate and the gateslide tolift, al-
lowing iceto push out the gate opening.
2. Icelevel(StandardModels):When icelevel lightison,removethe lid and fill the hopperwithice.Replace
lidto avoidcontamination ofice.
CAUTION:Use caution toavoidspilling ice whenfilling dispenser.Cleanupimmediately
any spilledice fromfilling oroperating theunit.To preventcontamination ofice,thelid
mustbe stalledontheunitatall times.
AutomaticIceFilling (“A”models):Whilethe icemakerisrunning, the ice entering the hopperfromthe feed
tube shouldbeloose and insmall pieces. Ice entering inthe form ofhard-packed cylindersindicatesare-
striction ordistortion of the feed tube and couldresultinicemaker malfunction,ifnotcorrected.The auto-
maticagitation timercausesthe the icetolevel which allowsthe entirestorage bintofill beforethe icema-
chine shutsoff. When the icelevelremainsat the deflectorafteragitation, the icemakercontrolcapillary
(icemakerbulb)stopsicemakeroperation until the leveldropsand the bulbswarm up.
Immediatelyaftericemakershut-off, observethe iceinthe hopperbetween the feed tube entrance and the
deflector.itshouldbelooselypressed against the top of the deflector,indicating correct thermostatopera-
tion. If the icelevel isloworif the iceispacked hard against the deflector,itwill be necessarytore-adjust
the icemakerbincontrol,according tothe icemakerinstructions.Adjust the control warmertolowerthe
iceleveland coldertoraisethe icelevel.
AutomaticIceFilling (“K”Models):Asthe “A”models, the agitation tiercausesthe icetolevel which allows
the entirestorage bintofill beforethe icemachine shutsoff. The icemakercontrolcapillarybulbmaintains
the icelevel inthe storage hopper.Consult the instructionsprovided withthe installation kitand the ice
maker manualforlocation and operation of the icemakercontrol.
31177 PORTION CONTROLOPERATINGINSTRUCTIONS
Foruse on all “TJ”series ice dispensers
ON
OFF
100
PORTION
ON/OFF SWITCH
PORTION ADJUSTMENT
FIGURE1.PORTION CONTROL

590683
Switch“Off”Ice dispenses continuously(no portion control)when operating leverisdepressed.
Switch“On”Ice dispensesforpreset time period and stop automatically.Timer resetswhen operating
leverisreleased.
Portion
AdjustmentTurnknob clockwisetoincrease portion,counterclockwiseto decrease portion.Numbered
dial isfor reference only.Approximatesettingsare asfollows:
6 oz.cup .5-1.5 or12 oz.cup 1-3
Adjust the knob to obtainthe desired ice portion.

90683 6
CLEANINGINSTRUCTIONS
WARNING:DISCONNECTPOWER BEFORECLEANING!Do notuse metalscrapers,sharp
objectsorabrasives on theice storagehopper,top coverand the agitatordisk,as damage
may result.Do notuse solventsorothercleaning agents,as they may attack theplastic
material.
DISPENSER
1.Clean the ice dispenserinterioratleastonceamonth.
2.Removethe agitatorboltand lift off the agitatorand the agitatordisk.Washwithamild detergentsolution
and rinsethemthoroughlytoremove all tracesofdetergent.
3.Carefullyremove,wash and rinse all internalhoppercomponents.
4.wash downthe inside of the hopperand top coverwithamild detergentsolution and rinsethoroughlyto
remove all tracesofdetergent.
5.Replacethe agitatorand othercomponents.
6.Sanitizethe inside of the hopperand agitatorwithasolution of1 ounce ofhousehold bleachin 2 gallonsof
water.(200 PPM)
7.RemoveIceChutecoverasfollows:
A.Flex sidesoutwardto disengage lowerpins.
B.Lift IceChutecoverto disengage upperpins.
C.LowerIceChutecoverdown outofunit. Note:itmaybe helpfultotwistcoverslightly.
8.With brush provided clean the inside of the icechute and icechutecoverwithamild detergentsolution and
rinsethoroughlytoremove all tracesofdetergent.
9.Reversestepsabovetoreassembleicechute.
10.Sanitize asdescribed inStep 6.

790683
MAINTENANCE
The following dispenser maintenanceshould be performed at the intervalsindicated:
DAILYorasrequired
Removeforeign materialfromthe vending area sinkto preventdrain blockage.
WEEKLYorasrequired
Clean vending area.Check forproperwaterdrainage fromthe vending area sink.
MONTHLY
Clean and sanitizethe hopperinterior (see CLEANING INSTRUCTIONS).
If the dispenserfailsto dispenseicewhen operated,check that the hopperhasiceinitand thatpowerisbeing
supplied tothe unit. If the problempersists,check the following:
1.Determine if the agitatorisrotating (check forthe sound oficemovementinthe hopper).
2. Observewhetherthe gateisoperating.
Afterchecking the above,refertothe TROUBLESHOOTING GUIDEforpossible problemcausesand correc-
tive action.

8
90683
GATERESTRICTORPLATE
CAUTION:Disconnectpowerto dispenserbeforeinstalling,removing oradjusting
restrictor
INSTALL PLATEON
STUDSAS SHOWN
FIGURE2.GATERESTRICTORPLATE
ADJUSTMENT
Thisdispenserisprovided with a gaterestrictorplate,installed initshighestposition.
Thisplate adjuststhe rate oficeflowfromthe dispenser. In applicationsusing buckets,carafesorotherlarge
containers, the platemaybe removed entirelyfor maximumiceflow.Forglassesand cups, the platemaybe
adjusted downwardtoreducethe flowofice.The bestposition dependson the type ofice being used and the
sizecontainer,and mustbe found bytrialand error.Adjustmentismade byloosening the uppertwoicechute
retaining nuts,sliding the restrictorplatetothe desired position and re-tightening the nuts.
If the dispenserfail to dispensethe icewhen operated,check that the hopperhasiceinitand thatpowerisbe-
ing supplied tothe unit. If the problempersists,check the following.
1.Determine if the agitatorisrotating (check forthe sound oficemovementinthe hopper).
2. Observewhetherthe gateisoperating.

990683
TROUBLESHOOTING GUIDE
Shouldyourunit fail to operate properly,check that thereispowertothe unitand that the hoppercontainsice. If
the unitdoesnotdispense,check the following chartunderthe appropriatesymptomsto aidinlocating the de-
fect.
TroubleProbableCause
BLOWNFUSE OR CIRCUITBREAKERA.Shortcircuitinwiring.
B.Defective gatesolenoid.
C.Defective agitator motor.
GATEDOES NOTOPEN.AGITATOR DOES
NOT TURN A.No power.
B.Bentdepressorplate(doesnotactuateswitch).
C.Defective dispensing switch.
GATEDOES NOTOPENORIS SLUGGISH.
AGITATORTURNS.A.Defective gatesolenoid.
B.Weakgatespring.
GATEOPENS.AGITATOR DOES NOT TURN.A.Agitator motorprotectortripped.
B.Defective agitator motor.
C.Defective agitator relay.
ICEDISPENSES CONTINUOUSLY.A.Stuck orbentdepressorplate(doesnotrelease
switch).
B.Defective dispensing switch.
C. Improperswitchinstallation.
SLUSHYICE.WATERIN HOPPER.A.Blocked drain.
B.Unitnotlevel.
C. Icemaker malfunction.
ICE SOLIDIFIEDIN HOPPERORICE AT
REAR CORNERONLY.A.Defective orimproperlyadjusted icemaker thermostat.
NO ICEIN HOPPERA. Icemaker malfunction.
ICE PACKEDIN HOPPERA.Defective orimproperlyadjusted icemakercontrol
(notshutting off).
Refertomanufacturer’sinstructionsfortroubleshooting icemaker.

1090683
7
8
SERVICEINFORMATION
ELECTRICSHOCKHAZARD.DISCONNECTPOW-
ERBEFORE SERVICINGUNIT.
DANGER!
SOLENOID
ADJUSTMENT
WHEN REPLACINGSOLENOID
ADJUST TO7/8AS SHOWN
BEFORETIGHTENING
MOUNTINGSCREWS
LOWICE
LIGHTICELEVEL
T’STAT
TERMINAL
BLOCK
BLU
BRN
BLKWHTWHT
WHT
WHT
BLK
GATE
SOLENOID
AGITATOR
MOTOR
YEL
YEL
RED
DISPENSE
BUTTON
120V.
60HZ
1PH
WHT
RED
BRNYEL
OR
DISPENSE
SWITCH
PORTION
TIMER
OPTIONALPORTION CONTROL
AGITATOR
MOTOR RELAY
1 1/4AMP
TIMEDELAY
FUSE
FIGURE3.WIRINGDIAGRAMTJ200 /250 /300

11 90683
7
8
SERVICEINFORMATION
ELECTRICSHOCKHAZARD.DISCONNECTPOW-
ERBEFORE SERVICINGUNIT.
DANGER!
SOLENOID
ADJUSTMENT
WHEN REPLACINGSOLENOID
ADJUST TO7/8AS SHOWN
BEFORETIGHTENING
MOUNTINGSCREWS
TERMINAL
BLOCK
BLU
BRN
BLKWHTWHT
WHT
WHT
BLK
GATE
SOLENOID
AGITATOR
MOTOR
YEL
YEL
RED
DISPENSE
BUTTON
120V.
60HZ
1PH
WHT
RED
BRNYEL
OR
DISPENSE
SWITCH
PORTION
TIMER
OPTIONALPORTION CONTROL
AGITATOR
MOTOR RELAY
1 1/4AMP
TIMEDELAY
FUSE
RED
BLK
AGITATOR
TIMER
C
NO
NC
WHT
WHT
FIGURE4.WIRINGDIAGRAMTJ200 /250 /300—A,K DISPENSER

1290683
6
1 1/4
63 1/16 36
36 3/64
NOTE:SHADEDAREAS INDICATEOPENINGSIN COUNTER
REQUIREDFOR UTILITIES AND BEVERAGETUBING.
FIGURE5.MOUNTINGTEMPLATEMODEL TJ300

13 90683
6
1 1/4
63 1/836
36
6
1 1/4
63 1/816
19 1/4
2
10 1/2
16
36
1 1/4
2 5/32 27 11/16
32
SEE NOTE2
SEE NOTE3
SEE NOTE4
NOTES:1.SHADEDAREAS INDICATEOPENINGSIN CABINET
BOTTOMNEEDEDFOR UTILITIES.
2.1 1/8DIA.ACCESS HOLEFORELECTRICALSUPPLYCONDUIT.
3.FOUR 3/8DIA.HOLES FORSECURINGUNIT TOCOUNTER.
4 1/2DIA.ACCESS HOLEFORICEMAKER CONTROLBULB.
FIGURE6.MOUNTINGTEMPLATETJ200 /250 /TJ200 /250-A,K

1490683
FIGURE7.EXPLODEDVIEWLOWERSECTION
FIGURE8.EXPLODEDVIEWUPPERSECTION
1234
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
21
22
19
20
23
24
25
26 27

15 90683
EXPLODEDVIEW UPPER AND LOWERPARTSLIST
ItemNo.PartNo. TJ200/250
PartNo.
TJ200/250
“A”
PartNo.
TJ200/250
“K”
PartNo.
TJ300
“K”Description
1 22644 22644 22644 22644 DepressorRetainer
2 22777 22777 22777 22777 DepressorLever
3 31007 31007 31007 31007 SwitchBoot
4 31163 31163 31163 31163 BootAdapter
5 30895 30895 30895 30895 Dispensing Switch
6 70496 70496 70496 70710 SinkGrill
7 51024 51024 51024 51646 Sink
8 31375 31375 31375 31375 MercuryRelay
9 31763 31763 31763 Agitation Timer
10 22441 Bracket-IceDeflector
11 31001 Ice LevelThermostat
12 30960 30960 30960 30960 TerminalBoard
13 31205 Ice LevelLight
14 31197 31197 31197 31617 AgitatorMotor
15 50967 50967 50967 50967 Insulation (AgitatorMotor)
16 50891 50891 50891 51101 MotorShaft Seal
17 22402 22402 22402 22402 Bracket-HopperSeal
18 50770 50770 50770 50770 GateGasket
19 22519 IceDiverter
20 22081 22081 22081 22081 GateRestrictor
21 21491 21491 21491 21491 GateSlide
22 53015 53015 53015 53015 IceChuteBack Section
53016 53016 53016 53016 IceChuteCover
23 SolenoidAssembly(Figure 9)
31551 31551 31551 31551 Solenoid
70438 70438 70438 70438 Rebuilding Kit
24 50962 50962 22082 25454 Lid-Removable
25 50963 50963 22084 25452 CoverAssembly-Rear
26 22047 22047 22047 25744 Agitator (TJ200)
23692 23692 23692 Agitator (TJ250)
27 22339 DeflectorAssembly

1690683
123
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19
20
21
22
22
22
FIGURE9.SOLENOID ASSEMBLY
Index
No.PartNo.Qty.Name
1 21493 1 SolenoidMounting Plate
2# 31551 1 SolenoidServiceKit
3 70171 2 8--32 x3/8Phil TrHD Screw
4 70121 2 No.8 Lockwasher
5 50752 3 Isolator
6*50789 2 BumperAssembly
7*70423 1 CotterPin
8*10080 1 Gate Lift Rod
9 10081 1 Gate Lift Rod Bushing
10 50754 1 GateArmBearing
11 21492 1 Gatelift Arm
12 70043 1 Flatwasher
13*70422 1 Spring
14 70263 1 1/4-20 x3/4HexHdScrew
15 70048 1 1/4 Lockwasher
16 70066 1 1/4Flatwasher
17 10077 1 PivotBearing
18 30227 1 1/4Quick ConnectTab
19 50305 ---- Lubricant
20*21592 1 Solenoid Linkage Pin
21*70433 2 RetainerRing
22 51088 ---- Loctite
----*70438 ---- Rebuilding Kit
NOTE:*Parts suppliedwithrebuilding kit.
# 31551 solenoidsuppliedwithitems20&21.

SD99-3
1/16/96 90683
IMICORNELIUSINC.
ONECORNELIUSPLACE
ANOKA,MN.55303--6234
TELEPHONE[phone]
FACSIMILE (612)422--3232
TECHSVC1-800-535-4240
WARRANTY
IMICorneliusInc.and RemcorProductsCompany warrantsthatall equipmentand partsarefree from
defectsinmaterialand workmanship undernormaluse and service.Fora copy ofthewarrantyapplicable
to yourCorneliusand orRemcorproduct,in yourcountry,pleasewrite,fax ortelephonethe
IMICorneliusoffice nearestyou.Pleaseprovidethe equipment modelnumber,serialnumberand the
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