Remcor TJ150R-BC User manual

ICE/BEVERAGE DISPENSER
MODEL TJ150R-BC
Operator’sManual
PRINTEDIN U.S.A
âREMCORINC:1994--95
PartNo.91589
February,1997
Revision D
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

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TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS1...................................................
GENERALDESCRIPTION1..................................................
INSTALLATIONINSTRUCTIONS2............................................
MAINTENANCE3...........................................................
DAILYORAS REQUIRED3..............................................
WEEKLYORAS REQUIRED3............................................
MONTHLY3............................................................
START-UP AND OPERATINGINSTRUCTIONS3...........................
CLEANING INSTRUCTIONS3................................................
DISPENSER3..........................................................
COLDPLATE4.........................................................
BEVERAGE SYSTEM4..................................................
OPERATING INSTRUCTIONS6...............................................
TROUBLESHOOTING GUIDE7...............................................
BLOWNFUSE OR CIRCUITBREAKER7..................................
GATEDOES NOTOPEN.7...............................................
GATEDOES NOTOPENORIS SLUGGISH.AGITATORTURNS.7...........
GATEOPENS.AGITATOR DOES NOT TURN.7............................
ICEDISPENSES CONTINUOUSLY.7......................................
SLUSHYICE.WATERIN HOPPER.7......................................
BEVERAGES DONOTDISPENSE 7......................................
BEVERAGES TOO SWEET.7............................................
BEVERAGES NOTSWEETENOUGH.7...................................
BEVERAGES NOTCOLD7..............................................
ADJUSTMENT8............................................................
WARRANTY16..............................................................
LISTOF FIGURES
FIGURE1.MOUNTINGTEMPLATE2.....................................
FIGURE2.GATERESTRICTORPLATE8..................................
FIGURE3.MOUNTINGTEMPLATETJ150R-- BC9.........................
FIGURE4.SPECIFICATION DRAWING10..................................
FIGURE5.WIRINGDIAGRAMTJ150R-- BC DISPENSER11.................
FIGURE6.BEVERAGE SYSTEMSCHEMATIC12...........................
FIGURE7.EXPLODEDVIEW-- LOWERSECTIONAND PARTSLIST13.......
FIGURE8.EXPLODEDVIEW-- UPPERSECTIONAND PARTSLIST14........
FIGURE9.SOLENOIDASSEMBLY-- EXPLODEDVIEW& PARTSLIST15.....
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

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SAFETY PRECAUTIONS
Always disconnectpowertothe dispenserbeforeservicing orcleaning.
Neverplace handsinside ofhopperorgate area withoutdisconnecting powertothe dispenser.Agitator rotation
occursautomaticallywhen the dispenserisenergized!
Thisice dispenserhasbeen specificallydesigned to provide protection againstpersonal injuryand eliminates
contamination ofice.To ensurecontinued protection and sanitation,observethe following:
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 RemcorTJ150R-BCseriesofice dispensersmanufactured forCoca-Colasolveyourice and beverage
service needsinthe sanitary,spacesaving,economical way.Designed tobemanuallyfilled withicefromany
remoteicemaking source, these dispenserswill dispensecubes(up to 1-1/4? insize),cubeletsand hard-
chipped orcracked ice;and in addition,severalflavorsofpost-mixbeverages.“BC”unitsinclude beverage fau-
cetsand a cold plate and are designed tobesupplied directlyfromsyrup tanks and carbonator,with no
additionalcooling required.
The unitmustneverbe lifted or moved bythe sink.
Table 1.Specifications
Model:TJ150R-BC
IceStorage:150 lbs.
MaximumNumberofFaucetsAvailable:8
Built-inColdPlate:Yes
Electrical:120/1/60
Dimensions:30? Wx30? Dx34-1/2? H
LEGEND
S-Stainless Cabinet
R-Red UpperCabinetFinish
BC -Beverage ValveswithColdPlateCooling System

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INSTALLATION INSTRUCTIONS
1.Locatethe dispenserindoorsonalevelcountertop.
LEG OPTION
Unpack the four (4)legsand install themintothe threaded holesprovided inthe bottomof the unit. Before
installing,removethe four (4)plasticthread plugs;pushcenterin and remove plug.The installer mustpro-
vide flexibilityinthe productand utilitylinesto permitshifting the position of the dispensersufficientlyto
clean the area beneathit.
COUNTERMOUNTING
The ice dispensermustbe sealedtothe counter.The template drawing indicatesopeningsthatmustbe
cutinthe counter.Locatethe desired position forthe dispenser, then markthe outline dimensionson the
counterusing the template drawing.Cutopeningsinthe counter.
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.
2.The beverage tubes,drainline and powercord arerouted through the large opening inthe bottomof the
unit. See the MOUNTINGTEMPLATEforlocating the required clearance holeinthe counterforthese
utilitylines.
3.SINKDRAINASSEMBLY:Connect the draintube to an open drain.Additionaldraintubing isprovided with
the unit. The drainline mustcontinuouslypitch downward awayfromthe unitand containno“traps”orim-
properdrainage will result.
DRAINLINE
STAINLESS STEELELBOW
DRAINTUBINGPROVIDED
WITH DISPENSER
DISPENSER BOTTOM
FIGURE1.MOUNTINGTEMPLATE
A.Usetube,clamp and insulation provided to assemble drain.
B.To assure properdrainage,do notallow“trap”toform in drainline.Besure drainline runsflatwith
bottomofdispenser.(See Figure 1)
4.Connect the beverage systemproductlinesasindicated inthe Beverage SystemSchematic(See Figure
6).Thiswork should be done bya qualified service person.Notethat the hosesaremarked with numbers
1through 8 forsyrup connectionsand “CW”forcarbonatedwaterconnections.
5.Clean the hopperinterior (see CLEANING INSTRUCTIONS).
6.Connect the powercordtoa120volt, 60 cycle,3-wire grounded receptacle.
NOTE:Waterpipe connections and fixtures directly connectedtoapotablewatersupplymustbe
sized, installedand maintainedaccording tofederal, state and local laws.

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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).
START-UPAND OPERATINGINSTRUCTIONS
Fill the hopperwithice.With a built-incold plate,dispenseseveral large cupsofice(approximatelyone (1) min-
utetotaldispensing time)to allow icetofill the cold plate.Add icetothe hopperasnecessarytorefill, then re-
placethe lid.Allow10 to15minutesforthe cold platetocooldown.Repeat thisprocedurewheneverthe dis-
penserhasbeen standing overnightorotherlong periodswithoutice use.Startup the beverage systemand
adjust faucetstothe properbrix.Contactyourlocal Coca-Cola distributorforcompleteinformation on the bever-
age system.
In normaloperation,pushing the ice dispenserleverwill causeicetoflowfromthe icechute. Iceflow will contin-
ue until the leverisreleased.Pushing the switch on anyfaucetwill provide beverage of the appropriateflavor.
CAUTION:Use caution toavoidspilling ice whenfilling dispenser. Immediately clean up
any spilledice fromfilling oroperating theunit.To preventcontamination ofice,thelid
mustbeinstalledontheunitatall times.
CLEANINGINSTRUCTIONS
WARNING:DISCONNECTPOWER BEFORECLEANING!Do notuse metalscrapers,sharp
objectsorabrasives on theice storagehopper,top coverand the agitatordisk,as damage
may result.Do notuse solventsorothercleaning agents.They may attack theplastic
material.
DISPENSER
1.Clean the icestorage hopperatleastonceamonth.
2.Lift off the agitatorassembly.Wash and rinsethoroughly.
3.Wash downthe inside of the hopperand top coverwithamild detergentsolution and rinsethoroughlyto
remove all tracesofdetergent.

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4.Replacethe agitator.
5.Sanitizethe inside of the hopperand agitatorwithasolution of1/2 ounce ofhousehold bleachin 1 gallon of
water.(200 PPM)
6.Removeicechutecoverasfollows:
A.Flex sidesoutwardto disengage lowerpins.
B.Lift icechutecoverto disengage upperpins.
C.Lowericechutecoverdown outofunit. NOTE:Itmay behelpfultotwistcoverslightly.
7.Clean the inside of the icechutewithamild detergentsolution and rinsethoroughlytoremove all tracesof
detergent.
8.Reversestepsabovetoreassembleicechute.
9.Sanitize asdescribed inStep 5.
COLDPLATE
1.Removesplash paneland merchandiser.
2.Remove bottomtwo(2)screwson the icechute and loosen the top two(2)screws.You do nothavetore-
movethe icechute.(During reassembly,makesurethe ice gaterestrictorisrelocated toit’s correct
position.)
3.Removethe screws,holdthe beverage faucetpaneland bring forward.
4.Removethe tape holding the lowercold platecovertothe top cold platecover.
5.Lift the lowercold platecoverup intothe top cover.
6.Remove anydebrisfromthe draintrough and spring.Check that the drain holeisnotclogged.
7.Wash downthe inside of the cold plate, trayand coverwithamild detergentsolution and rinse.Asmall,
long-handled brushwill be found helpful inreaching the corners.
8.Slide the coverforward, taking carethatitis securelypositioned on the cold plate.
9.Reassemble.
BEVERAGE SYSTEM
1.Removefaucetspouts,washinmild detergent, rinse and replace.
2.Disconnectelectricalpowertothe carbonator.Shutoff the watersupplyand closethe CO2regulatortothe
carbonator.
3.Disconnect the syrup tanks fromthe system.
4.Energizethe beverage faucetsto purge the remaining soda inthe system.
5.Useaclean 5 gallon tankforeach of the following.
A.Cleaning Tank-Fill with hot(120°-140°)potablewater.
B.Sanitation Tank-Fill withachlorine sanitizing solution inthe strength of1/2 ounce ofhousehold
bleach(sodiumhypochlorite)to 1 gallon ofcold(ambient)potablewater (200 PPM).
6.Repeat the following procedure on each of the units’ syrup productlines:

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A.Connect the cleaning tanktothe syrup line tobesanitized and tothe CO2system.
B.Energizethe beverage faucetuntil the liquid dispensed isfree ofany syrup.
C.Disconnect the cleaning tankand hookup the sanitizing tanktothe syrup line and CO2system.
D.Energizethe beverage faucetuntil the chlorine sanitizing solution isdispensed through the faucet.
Flush atleast2cupsofliquidto ensurethat the sanitizing solution hasfilled the entirelength of the
syrup lines.
E.Disconnect the sanitizing tank.Hookup the product tanktothe syrup line and tothe CO2system.
F.Energizethe faucet toflushthe sanitizing solution fromthe syrup line and faucet. Continue to drawon
the faucetuntil only syrup isdispensed.
7.RepeatStep2inreverse ordertoturnonthe carbonator.Dispense atleast1cup ofbeverage fromeach
faucet. Check taste.Continue toflushifneeded, to obtainasatisfactorytasting drink.

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OPERATINGINSTRUCTIONS
IceDispensing:Depressing the operating leveractivatesamicroswitch behind the front
panel which energizesthe agitator motorand gatesolenoid.This causes
the agitatortorotate and the gateslide tolift, allowing iceto push out the
gate opening.
Ice Level(StandardModels):Removethe lid and fill the hopperwithice.Replacelidto avoidcontami-
nation ofice.
Forunitsequipped withthe optional icelevel light, low icelevel inthe storage hopperwill be indicated when the
lightis“on”.
CAUTION:Use caution toavoidspilling ice whenfilling dispenser. Immediately clean up
any spilledice fromfilling oroperating theunit.To preventcontamination ofice,thelid
mustbeinstalledontheunitatall times.
Beverage System:Beveragesmaybe dispensed byoperating the leveron the appropriate
faucets. On unitswithcold plates(“C”models),periodicmovementof the
iceinthe hopperisnecessarytomaintainthe leveloficeonthe cold
plate.Fill the hopperwithice and dispenseseveral large cupsofice
approximately20-30 secondstotaldispensing time)to allow icetofill the
cold plate.Allow10-15 minutesforthe cold platetocooldown.
Repeat thisprocedurewheneverthe dispenserhasbeen standing over
nightorotherlong periodswithoutice useto preventwarm beverages
on initialuse.Startup the beverage systemand adjust the faucetstothe
properbrix.Contactyourlocal Coca-Cola distributorforcomplete
information on the beverage system.

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TROUBLESHOOTING GUIDE
Shouldyourunit fail to operate properly,check that thereispowertothe unitand that the hoppercontainsice.
If the unitdoesnotdispense,check the following chartunderthe appropriatesymptomsto aidinlocating
the defect.
TroubleProbableCause
BLOWNFUSE OR CIRCUITBREAKER.A.Shortcircuitinwiring.
B.Defective gatesolenoid.
C.Defective agitator motor.
GATEDOES NOTOPEN.A.No power.
B.Defective dispensing switch.
C.Blown/defectivefuse orjammed gatesolenoid.
GATEDOES NOTOPENORIS SLUGGISH.
AGITATORTURNS.A.Defective gatesolenoid.
B.Excessive pressure againstgateslide.
GATEOPENS.AGITATOR DOES NOT TURN.A. Icesolidified in hopper.
B.Defective agitator motor.
C.Defectivecapacitor.
ICEDISPENSES CONTINUOUSLY.A.Stuck orbentpush button (doesnotreleaseswitch).
B.Defective dispensing switch.
C. Improperswitchinstallation.
SLUSHYICE.WATERIN HOPPER.A.Blocked drain.
B.Unitnotlevel.
C.Poorice qualitydue towaterqualityoricemaker
problems.
D. Improperuse of flaked ice.
BEVERAGES DONOTDISPENSE.A.No24voltpowertofaucets.
B.NoCO2pressure.
BEVERAGES TOO SWEET.A.Carbonatornotworking.
B.NoCO2pressureincarbonator.
C.Faucetbrixrequiresadjusting.
BEVERAGES NOTSWEETENOUGH.A.Empty syrup tank.
B.Faucetbrixrequiresadjusting.
BEVERAGES NOTCOLD.A.Unitstanding withnoicein hopper,no iceincold
plate.
Contactyourlocal Coca-Cola orbeverage equipmentdistributorforadditional information and troubleshooting of
yourbeverage system.

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GATERESTRICTORPLATEKIT# 01926
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
sizecontainerand mustbe found bytrialand error.Adjustmentismade byloosening the uppertwoicechute
retaining nuts,sliding the restrictorplatetothe desired position and re-tightening the nuts.
If the dispenserfailsto dispensethe icewhen operating,check that the hopperhasiceinitand thatpoweris
being supplied tothe unit. If the problempersists,check the following:
1.Determine if the agitatorisrotating (check forthe sound oficemovementinthe hopper).
2. Observewhetherthe gateisoperating.

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2 5/16
2 9/16
2 1/8DIA.
(POWER CORD
AND DRAIN)
4 1/2
1
14 8 1 1/8
OPENINGREQUIRED
FOR BEVERAGETUBING
18 1/2
30
1/2DIA.
1 1/8
27 3/4
30
FIGURE3.MOUNTINGTEMPLATETJ150R-- BC

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30
11 3/8
33
34 1/2
30
17 5/8
15 3/8
27 5/8
8 5/16
FIGURE4.SPECIFICATION DRAWING

11 91589
MOTOR
HEATER
LIGHTED DISPLAY
OPTION
BALLAST
LIGHT
STARTER
BLK
24 V.
PORTION
CONTROL
OPTION
SERVICEINFORMATION
ELECTRIC SHOCK HAZARD. DISCONNECT
POWER BEFORE SERVICING UNIT.
DANGER!
WHEN REPLACING SOLENOID,
ADJUST TO 7/8 INCH AS SHOWN
BEFORE TIGHTENING
MOUNTING SCREWS.
SOLENOID
ADJUSTMENT
TERMINAL
BOARD
TO
TERMINAL
BOARD
PORTION
TIMER
OR
REDRED
WHT
TD SW
DISPENSE
SWITCH
GRN
GROUNDNL
DISPENSE
SWITCH
BLK
RED
WHT
1 1/4 AMP TIME
DELAY FUSE
RED
WHT
GATE
SOLENOID
BLK
CAPACITOR
AGITATOR
MOTOR
RED
WHT
PNK
AGITATION TIMER
NC
NO
C
BLK
BEVERAGE SYSTEM
COLD PLATE
MOTOR OPTION
KEY
SWITCH
OPTION BEVERAGE
FAUCET
(TYPICAL)
TRANSFORMER
BLK
WHT
BLK
CAP
WHT
ICE LEVEL SIGNAL
OPTION
WHT
LIGHT
T’STAT
{
7/8
FIGURE5.WIRINGDIAGRAM
TJ150R-- BC DISPENSER

12
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FIGURE 6. BEVERAGE SYSTEM SCHEMATIC
O
P
T
I
O
N
A
L
F
O
R
DIET OR ROOT BEER
5-15 PSIG
WATER
SUPPLY
OPTIONAL NON-CARB
WATERDRINKS CAN
BE MADE TO FAUCET
NO.5
ICE/SOFT DRINK POST-MIX DISPENSER ITEMS OUTSIDE BROKEN LINES ARE NOT IN- CLUDED.

13 91589
1
2
3
4
5
6
7
8
FIGURE7.EXPLODEDVIEW-- LOWERSECTION AND PARTSLIST
Item
No.PartNo.Name
1 21515 DepressorLever
2 02070 SwitchKit
3 31007 SwitchBoot
4 51430 Sink(“B”Models)Black
51598 Sink(“B”Models)Grey
52109 Sink(“BC”Models)Black
52110 Sink(“BC”Models)Grey
5 70570 SinkGrill
6 70439 Leg (“B”and “BC”Modelsonly)
7 22644 DepressorRetainer
8 70847 Washer,SwitchSpacer
40483 DoleBeverage Valve-LEVER,FaucetAssembly(as
applicable)
40730 DoleBeverage Valve-PUSHBUTTON
40944 LancerBeverage Valve-LEVER
41050 LancerBeverage Valve-PUSHBUTTON
41084 Fitting 90°Inlet forDole&Lancervalves
40704 PlainWaterPlug
27107 “PushforIce”Bracket(Push LeverOption)
27126 “PushforIce”Lever

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1
2
3
45
6
7
8
9
10
11
12
13
14
15
16
17
18 19
20
21
22
FIGURE8.EXPLODEDVIEW-- UPPERSECTION AND PARTSLIST
Item
No.PartNo.Name
1 21491 GateSlide
2 23062 FoamShield
3 24069 Agitator
4 31091 Transformer,50VA (before 7--17--92)
32682 75VA (after7--17--92)
5 31889 AgitatorMotor
6 50454 MotorShaft Seal
7 50804 MotorGasket
8 51432 Lid(“B”and “BC”)Black
51596 (“B”and “BC”)Grey
9 53015 IceChute(Clear) Back Section
10 53016 IceChuteCover
11 51891 GateGasket
12 30774 Capacitor
13 31093 SolenoidAssembly
14 91598 Decal,Side
15 91599 Decal,Back
16 91600 Decal,Front
17 31763 Agitation Timer (“BC”&“KBC”ModelsOnly)
18 31406 Fuse
19 70341 Spring
20 30794 AgitatorMotorHeater
21 22081 GateRestrictor
22 50842 MotorPlateInsulation

15 91589
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-- EXPLODEDVIEW&PARTSLIST
Index
No.PartNo.QuantityDescription
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 Gate Lift 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.

1691589 SD99-2
REMCORPRODUCTCOMPANY
500 RegencyDrive
GlendaleHeights,IL60139-2268
Telephone[phone]
Facsimile(708)980--8511
WARRANTY
REMCORwarrantsthatall equipmentand partsarefree fromdefectsinmaterialand workmanship undernor-
maluse and service.Fora copy ofthewarrantyapplicableto yourREMCORproduct,in yourcountry,please
write,fax ortelephonetheIMICorneliusoffice nearestyou.Pleaseprovidethe equipmentmodelnumberand
thedateofpurchase.
IMICorneliusOffices
AUSTRALIADP.O.210,DRIVERWOOD,DNSW2210,AUSTRALIAD(61)2 533 3122 DFAX (61)2 534 2166
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HONG KONG D1104 TAIKOTSUICENTRED11-15 KOK CHEUNG STDTAIKOKTSUE,HONG KONG D(852)789 9882 DFAX [phone]
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USADONECORNELIUS PLACEDANOKA,MINNESOTAD(612)421-6120 DFAX [phone]

CORPORATEHEADQUARTERS:
Remcor Incorporated
500 RegencyDrive
GlendaleHeights,IL60139
708.980.6900