CORNELIUS INC www.cornelius.com Operator’s Manual ICE/BEVERAGE DISPENSERS MODELS: TJ200/250/300B TJ200/250/300BC TJ200/250AB TJ200/250ABC TJ200/250/300KB TJ200/250/300KBC Part No. 91678 Release Date: March 26, 2002 Revision Date: May 12, 2014 Revision: F THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment E Cornelius Inc; 2002–2005 PRINTED IN U.S.
TABLE OF CONTENTS Page SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ICE MAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES FIGURE 1. GATE RESTRICTOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIGURE 2. WIRING DIAGRAM TJ200 / 250 / 300-B . . . . . . . . . . . . . . . . . . . . . . . . 11 FIGURE 3. WIRING DIAGRAM TJ200 / 250 / 300—BC, AB, ABC, KB, KBC . . . 12 FIGURE 4. PLUMBING SCHEMATIC (8 VALVES) . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIGURE 5. PLUMBING SCHEMATIC (10 VALVES) . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS 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 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.
SPECIFICATIONS Model Designation: TJ 1 2 - 3 4 5 1 2 Ice Storage Capacity Cabinetry Options: TJ200 = 200 lbs. TJ250 = 250 lbs. TJ300 = 300 lbs. (E) Neutral beige, baked enamel finish and wood grain vinyl-clad upper front panel. (S) All Stainless Steel. 3 Ice-Fill Options: (No Letter) Manually filled from remote ice maker. (A) Automatic fill from a “piped ice” type ice maker. (K) Automatic fill from a top-mounted “ice cuber”.
ICE MAKER REMCOR “A” and “K” model ice/beverage dispensers are designed to be used with one of several “piped ice” type ice makers or top-mount “ice cubers.” These 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: FEED TUBE OR ICE MAKER INSTALLATION KIT This kit contains parts and instructions necessary to connect the ice maker to the ice dispenser. Be sure the kit you receive is proper for your ice maker.
INSTALLATION INSTRUCTIONS 1. The ice dispenser must be sealed to the counter The template drawing (Figure 10 and 11) indicate 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.
OPERATING INSTRUCTION 1. Ice Dispensing: Depressing the operating lever activates a micro switch 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 ice to push out the gate opening. 2. Ice level (Standard Models): When ice level light is on, remove the lid and fill the hopper with ice. Replace lid to avoid contamination of ice. CAUTION: Use caution to avoid spilling ice when filling dispenser.
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 dispenser interior at least once a month. 2. Remove the agitator bolt and lift off the agitator and the agitator disk, taking care not to lose the shaft key.
CLEANING TANK – Fill with a solution of 1/2 ounce of a mild liquid detergent (for example, Ivory liquid) to 1 gallon of warm (120_F) potable water. RINSING TANK – Fill with warm (120_F) potable water. SANITIZING 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 to obtain a solution strength of 200 PPM.
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). If the dispenser fails to dispense ice when operated, check that the hopper has ice in it and that power is being supplied to the unit.
GATE RESTRICTOR PLATE CAUTION: Disconnect power to dispenser before installing, removing or adjusting restrictor INSTALL PLATE ON STUDS AS SHOWN FIGURE 1. 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.
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 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. A.
LOW ICE LIGHT ICE LEVEL T’STAT BLU BRN TERMINAL BLOCK 1 1/4 AMP TIME DELAY FUSE AGITATOR MOTOR RELAY BLK 120V. 60HZ 1PH WHT BLK WHT YEL WHT AGITATOR MOTOR YEL DISPENSE BUTTON WHT RED GATE SOLENOID OPTIONAL PORTION CONTROL PORTION TIMER SERVICE INFORMATION WHT OR RED YEL DISPENSE SWITCH 7 DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. 8 BRN SOLENOID ADJUSTMENT WHEN REPLACING SOLENOID ADJUST TO 7/8 AS SHOWN BEFORE TIGHTENING MOUNTING SCREWS FIGURE 2.
WHT BLK BLU C NO NC AGITATOR TIMER RED BRN TERMINAL BLOCK 1 1/4 AMP TIME DELAY FUSE AGITATOR MOTOR RELAY WHT 120V. 60HZ 1PH BLK WHT BLK WHT WHT YEL AGITATOR MOTOR WHT YEL DISPENSE BUTTON RED GATE SOLENOID OPTIONAL PORTION CONTROL PORTION TIMER SERVICE INFORMATION WHT OR RED YEL DISPENSE SWITCH 7 BRN DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT.
1 2 3 W S1 S1 S3 S3 MANIFOLDS BEHIND VALVES S4 COLDPLATE S4 6 7 8 W S5 5 1,2 SYRUP INLETS 5 VALVES W S2 S2 4 W S6 S5 6,7,8 3,4 S7 S6 S7 S8 S8 SYRUP INLETS WATER INLETS MAY BE CARBONATED OR NONĆCARBONATED NOTE: 1) 2) TO SERVICE COLDPLATE INLET FITTINGS, SINK HAS TO BE REMOVED. TO REMOVE, DISCONNECT SINK DRAIN CONNECTIONS, THEN LIFT TWO (2) SIDE MOUNTING PINS AND PULL SINK FORWARD. REVERSE TO RECONNECT.
1 2 S1 S1 3 S2 S2 S3 4 S3 S4 5 S4 6 VALVES S5 S6 COLDPLATE S5 4 3 2 1,5,6,7, 8,9,10 SYRUP INLETS WATER INLETS MAY BE CARBONATED OR PLAIN WATER NOTE: 1) 2) 91678 TO SERVICE COLDPLATE INLET FITTINGS, SINK HAS TO BE REMOVED. TO REMOVE, DISCONNECT SINK DRAIN CONNECTIONS, THEN LIFT TWO (2) SIDE MOUNTING PINS AND PULL SINK FORWARD. REVERSE TO RECONNECT. MAKE SURE ALL DRAIN CONNECTIONS ARE PROPERLY POSITIONED FOR DRAINING AFTER SERVICE, BEFORE PANELS ARE INSTALLED. FIGURE 5.
L 120 VAC 60 HZ 1 PH N COLD PLATE MOTOR (OPTIONAL) TRANSFORMER 24V. BEVERAGE FAUCET (TYPICAL) FIGURE 6.
91678 OPTIONAL-FOR DIET OR ROOT BEER REGULATORS FAUCETS 5-15 PSIG 1 15-50 PSIG 2 S1 3 S2 S3 S4 S5 S6 S7 S8 CO2 TANK SYRUP TANKS 4 NOTE: REFERENCE ONLY NOT FOR CONSTRUCTION 5 16 6 7 8 60-100 PSIG CW OPTIONAL: PRESSURE REGULATOR CW REMCOR ”B” ICE/BEVERAGE DISPENSER ITEMS OUTSIDE OF BROKEN LINES NOT INCLUDED WITH UNIT. FAUCETS 5 THRU 8 ARE OPTIONAL. WATER SUPPLY COLD PLATE OR ICE BANK CARBONATOR FILTER FIGURE 7.
OPTIONAL-FOR DIET OR ROOT BEER REGULATORS FAUCETS NOTE: REFERENCE ONLY NOT FOR CONSTRUCTION 5-15 PSIG 1 15-50 PSIG 2 S1 3 S2 S3 S4 S5 S6 S7 S8 CO2 TANK SYRUP TANKS 4 5 17 6 7 8 60-100 PSIG CW OPTIONAL: PRESSURE REGULATOR REMCOR ”BC” ICE/BEVERAGE DISPENSER ITEMS OUTSIDE OF BROKEN LINES NOT INCLUDED WITH UNIT. FAUCETS 5 THRU 8 ARE OPTIONAL. CW WATER SUPPLY COLD PLATE CARBONATOR 91678 FIGURE 8.
91678 NOTE: REFERENCE ONLY NOT FOR CONSTRUCTION OPTIONAL-FOR DIET OR ROOT BEER REGULATORS FAUCETS 5-15 PSIG 1 S1 15-50 PSIG S2 2 S3 S4 S1 3 S2 S3 S4 S5 S6 S7 S8 CO2 TANK SYRUP TANKS 4 1,2 3,4 5 WATER HOOK UPS-MAY BE CARBONATED OR PLAIN WATER AS REQUIRED NON-CARB WATER 18 6,7,8 5 6 S5 7 S6 S7 REMCOR ”BC” ICE/BEVERAGE DISPENSER ITEMS OUTSIDE OF BROKEN LINES NOT INCLUDED WITH UNIT. 8 S8 60-100 PSIG OPTIONAL: PRESSURE REGULATOR COLD PLATE CARBONATOR WATER SUPPLY FILTER FIGURE 9.
14 32 3 1/8 1 1/4 6 6 14 ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉ 2 1/8 3/4 3 1/8 1 1/4 2 25/32 6 SEE NOTE 2 16 6 2 1/8 SEE NOTE 4 ÉÉÉ ÉÉÉÉÉÉ ÉÉÉ ÉÉÉÉÉÉ ÉÉÉ ÉÉÉ SEE NOTE 3 2 3/4 2 25/32 10 1/2 36 36 19 1/4 19 16 OUTLINE OF UNIT TJ 200/250-B, BC, KB, KBC NOTES: 1. SHADED AREAS INDICATE OPENINGS IN CABINET BOTTOM NEEDED FOR UTILITIES. 2. 1 1/8 DIA. ACCESS HOLE FOR ELECTRICAL SUPPLY CONDUIT. 3. FOUR 3/8 DIA. HOLES FOR SECURING UNIT TO COUNTER. 4 1/2 DIA.
91678 32 36 3 1/16 1 1/4 6 6 14 ÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉ 2 1/16 3/4 6 15/16 16 3/4 4 3/32 20 36 3/64 ÉÉÉÉÉÉ ÉÉÉÉÉÉ 17 9/16 36 4 1/2 OUTLINE OF UNIT OUTLINE OF UNIT TJ 300 TJ 250 WITH 19 x 28 COLDPLATE NOTE: SHADED AREAS INDICATE OPENINGS IN COUNTER REQUIRED FOR UTILITIES AND BEVERAGE TUBING. FIGURE 11.
27 28 10 21 26 24 19 22 23 25 18 19 20 17 12 16 13 9 11 15 8 FIGURE 13. EXPLODED VIEW UPPER SECTION 29 6 5 30 4 7 3 2 1 FIGURE 12.
EXPLODED VIEW UPPER AND LOWER PARTS LIST Part No. Part No. Part No. Part No. TJ250–BC TJ200/250 TJ200/250 TJ200/250 Item No. 19x28 CP B, BC AB, ABC KB, KBC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part No.
Part No. Part No. Part No. Part No. TJ250–BC TJ200/250 TJ200/250 TJ200/250 Item No. 19x28 CP B, BC AB, ABC KB, KBC Part No.
1 2 22 4 3 5 4 22 6 19 18 20 22 21 8 16 15 14 11 17 19 13 9 12 7 FIGURE 14. SOLENOID ASSEMBLY Index No. Part No. Qty. 1 2# 3 4 5 6* 7* 8* 9 10 11 12 13* 14 15 16 17 18 19 20* 21* 22 ––* 22889 31551 70171 70121 50752 50753 70423 10080 10081 50754 22890 70043 70422 70263 70048 70066 10077 30227R 50305 21592 70433 51088 70438 1 1 2 2 3 2 1 1 1 1 1 1 1 1 1 1 1 1 –– 1 2 –– –– Name Solenoid Mounting Plate Solenoid Service Kit 8–32 x 3/8 Phil Tr HD Screw No.
