Cornelius Energize Series Installation And Service Manual
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Cornelius Energize Series Installation And Service Manual

Undercounter cooler
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Undercounter cooler
Energize 3-5 (R134a)

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  • Page 1 Installation and service manual Undercounter cooler Energize 3-5 (R134a)
  • Page 2 Violations shall result in an obligation to pay damages. All rights reserved with regard to filing for/registering patents, utility models or design patents. www.cornelius-emea.com Cornelius Deutschland GmbH Tel.: +49 (0) 21 73 / 79 3 – 0 Carl-Leverkus-Str. 15 Fax: +49 (0) 21 73 / 77 4 –...

  • Page 3: Table Of Contents

    ............Replacing the circulation pump Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no.
  • Page 4 ........10.5 Wiring diagram Undercounter cooler Energize 3-5 (R134a) Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 5: Safety

    Improper use of the unit and unauthorised modifications to the unit and its components may cause personal injury and equipment damage for which Cornelius Deutschland GmbH shall assume no liability. Improper use of the unit is prohibited. You can find further information about the improper use of the unit – and the meaning of improper use – in the undercounter cooler operator manual, document no.

  • Page 6: Safety Information For Using Electrical Assemblies

    When installing cables, be mindful of any bending radiuses that the manufacturer may have specified. • To fix cables in place using cable ties, use the mounting bases provided. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 7: Transport And Packaging

    Transport and packaging Choose a suitable packaging when returning the unit itself or one of its components to Cornelius Deutschland GmbH, e.g. for re- pairs. In particular, make sure that the unit and any components are protected from shock/impact, moisture, dirt and electrostatic discharge (ESD).

  • Page 8: Description

    Circulation pump Agitator motor Sheet casing (service) Cover 10 Refrigerant compressor Transformer 11 Carbonator tank Circulation pump motor 12 Sheet casing (fixed) Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 9: Undercounter Cooler Energize 4 (R134A)

    Sheet casing (fixed) Circulation pump Connecting plate with tube connections Sheet casing (service) Agitator motor 10 Refrigerant compressor Cover 11 Water bath Transformer Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 10: Undercounter Cooler Energize 5 (R134A) Single

    Connecting plate with tube connections Sheet casing (service) Agitator motor Compressor fuse Carbonator tank 10 Refrigerant compressor Cover 11 Sheet casing (fixed) Circulation pump motor Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 11: Undercounter Cooler Energize 5 (R134A) Dual

    Run capacitor for carbonator pump motor 12 Water bath Pressure switch for carbonator pump 13 Sheet casing (fixed) Circulation pump motor Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 12: Functions Within The Dispensing System

    The syrup containers are connected directly to the syrup connections on the unit. The BiBs are connected to the syrup pumps and from there to the syrup connections on the unit. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100...

  • Page 13: Technical Data

    2. at -10 °C evaporation temperature 3. Specifications on cooling capacity and dispensing capacity at an ambient temperature of 32 °C and beverage dispensing temperatures of < 5 °C Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...

  • Page 14: Undercounter Cooler Energize 5 (R134A) Single/Energize 5 (R134A) Dual

    The applicable operator manual for this unit includes specifications for the CO working pressures for the unit; see the document “Undercounter cooler operator manual”, document no. TD1005000. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 15: Connections

    1/4" ID and 3/8" OD 1, 2, 3, 4, 5, 6, 7, 8 Syrup tubes 1-8 (input) 1/4" ID and 3/8" OD Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 16: Undercounter Cooler Energize 5 (R134A) Single

    1/4" ID and 3/8" OD 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 Syrup tubes 1-10 (input) 1/4" ID and 3/8" OD Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 17: Undercounter Cooler Energize 5 (R134A) Dual

    1/4" ID and 3/8" OD 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 Syrup tubes 1-10 (input) 1/4" ID and 3/8" OD Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 18: Preparing The Unit

    Wait a minimum of 1 minute before continuing work on the unit. ATTENTION! Risk of equipment damage! A direct “low ohm” discharge may cause equipment damage. • Discharge the components properly. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 19: Installation/Removal

    All wiring and plumbing must be carried out in compliance with national and local laws, regulations and guidelines. Non-compliance with these laws, regulations and guidelines may result in death, serious injury or equipment damage. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...

  • Page 20: Installation Location

    Water pipe connections and fixtures that are directly connected to the drinking water supply must be in- stalled and serviced in compliance with federal, state and local laws. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100...
  • Page 21 8. Perform a visual inspection. See the document “Undercounter cooler operator manual”, doc- ument no. TD1005000. 9. Put the unit into service (“commissioning”); see chapter 8.1. Fig. 19 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 22: Removing The Unit

    5. Disconnect the basic ingredient/beverage tubes from the relevant connection of the unit’s rel- evant connecting plate (Fig. 22/2). Fig. 22 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 23: Maintenance

    Cleaning the tubes is only possible with the tower mounted. A description of how to clean the tubes can be found in the relevant tower installation and service manual. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...

  • Page 24: Changing The Water In The Water Bath

    4.1 1. Wait until the ice has completely thawed. 2. Drain the water from the water bath, see chapter 6.3. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 25: Repairs

    3. Position the new cover (Fig. 25/2) on the unit by first inserting one side with the bolts in the grooves and then lowering the cover onto the unit. 4. Attach the cover (Fig. 25/2) using the fastening bolt(s) (Fig. 25/1). Fig. 25 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 26: Replacing The Sheet Casing (Service)

    7. Position the new sheet casing (Fig. 27/1) on the unit. 8. Attach the sheet casing (Fig. 27/1) using the fastening bolts (Fig. 27/2). Fig. 27 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 27: Replacing The Connecting Plate

    6. Connect all lines and tubes to the relevant connecting plate (Fig. 29/1) using quick disconnect couplings. Fig. 29 Finishing tasks 1. Connect the python; see chapter 5.2. 2. Mount the cover; see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 28: Replacing The Agitator Motor

    3. Remove the fastening bolts (Fig. 32/1) from the agitator motor mount (Fig. 32/2). 4. Lift the agitator motor mount (Fig. 32/2) with agitator motor (Fig. 32/3) out of the unit. Fig. 32 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 29: Replacing The Water Bath Temperature Probe

    Finishing tasks 1. Mount the cover of control system 1; see chapter 7.21. 2. Mount the cover; see chapter 7.1. Fig. 34 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 30: Replacing The Ambient Temperature Probe And Hot Gas Sensor

    1. Mount the cover of control system 1; see chapter 7.21. Fig. 35 2. Mount the sheet casing (service); see chapter 7.2. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 31: Replacing The Circulation Pump

    14. Attach the tubes to the circulation pump (Fig. 37/3). 15. Attach the insulation (Fig. 37/2) to the circulation pump (Fig. 37/3). 16. Open the shut-off valve (Fig. 36/1). Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...
  • Page 32 1. Only on Energize 3 (R134a)/Energize 4 (R134a)/Energize 5 (R134a) single/Energize 5 (R134a) dual: Mount the sheet casing (service); see chapter 7.2. 2. Mount the cover; see chapter 7.1. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 33: Replacing The Carbonator Pump Pressure Switches

    3. Attach the new pressure manometer (Fig. 43/1) to the carbonator pump (Fig. 43/2) by turning Finishing tasks 1. Mount the cover; see chapter 7.1. Fig. 43 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 34: Replacing The Carbonator Pump

    8. Connect the lines to the carbonator pump (Fig. 44/4) by means of the couplings (Fig. 44/1). Finishing tasks Fig. 45 1. Mount the pressure manometer; see chapter 7.9. 2. Mount the pressure switches; see chapter 7.8. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 35: Replacing The Carbonator Pump Motor

    Finishing tasks 1. Mount the condenser for the carbonator pump motor; see chapter 7.24. 2. Mount the cover of control system 1; see chapter 7.21. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 36: Replacing The Carbonator Tank

    9. Disconnect the carbonator pump connecting line from the pre-cooling coil of the coupling (Fig. 49/8). 10. Lift the cooling coil basket (Fig. 50/2) with carbonator tank (Fig. 50/1) out of the unit. Fig. 50 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...
  • Page 37 9. Disconnect the connecting line of carbonator pump 1 from the pre-cooling coil 1 of the coupling (Fig. 53/8). 10. Disconnect the connecting line of carbonator pump 2 from the pre-cooling coil 2 of the coupling (Fig. 53/7). Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no.
  • Page 38 35. Attach the water input line (Fig. 53/11) on the coupling (Fig. 53/2) to the T-fitting of the water inlet pressure reducing valve (Fig. 53/3). 36. Attach the plug (Fig. 52/2) of the solenoid valve (Fig. 52/3) by removing the fastening bolt (Fig. 52/1). Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...
  • Page 39 29. Attach the water input line on the coupling (Fig. 57/5) to the T-fitting of the water inlet pressure reducing valve (Fig. 57/4). 30. Attach the plug (Fig. 57/6) of the solenoid valve (Fig. 57/7) by removing the fastening bolt (Fig. 57/1). Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no.
  • Page 40 26. Attach the soda water line to the coupling (Fig. 65/2). Fig. 65 27. Attach the soda cooling line to the coupling (Fig. 65/1). Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...
  • Page 41 3. Mount the level electrode; see chapter 7.16. 4. Mount the water bath temperature probe; see chapter 7.5. 5. Mount the cover; see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 42: Replacing The Solenoid Valve For The Carbonator Tank

    9. Attach the solenoid valve (Fig. 66/2) and the non-return valve (Fig. 66/3) using the couplings (Fig. 66/1 and Fig. 66/4). Fig. 67 Finishing tasks 1. Mount the cover; see chapter 7.1. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 43: Replacing The Non-Return Valve Of The Solenoid Valve For The Carbonator Tank

    Replace any damaged seals (Fig. 69/2). Finishing tasks 1. Mount the solenoid valve for the carbonator tank; see chapter 7.13. Fig. 69 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 44: Replacing The Non-Return Valve For The Carbonator Tank

    5. Attach the non-return valve (Fig. 72/2) using the couplings (Fig. 72/1 and 3). Finishing tasks Fig. 73 1. Mount the cover; see chapter 7.1. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 45: Replacing The Level Electrode For The Carbonator Tank

    7. Connect the plug (Fig. 74/1) of the level electrode (Fig. 74/2). Fig. 76 Finishing tasks 1. Mount the cover; see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 46: Replacing The Drain Valve For The Carbonator Tank

    4. Attach the protective cap (Fig. 77/2) to the drain valve (Fig. 77/1). Finishing tasks 1. Mount the cover; see chapter 7.1. Fig. 78 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 47: Replacing The Non-Return Valve Co 2 -In

    5. Attach the non-return valve (Fig. 79/2) using the couplings (Fig. 79/1 and 3). Finishing tasks Fig. 80 1. Mount the CO pressure switch; see chapter 7.19. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 48: Replacing The Co Pressure Switch

    5. Connect the plugs (Fig. 81/1) of the CO pressure switch (Fig. 81/3). Finishing tasks 1. Mount the cover; see chapter 7.1. Fig. 81 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 49: Replacing The Temperature Probe For The Soda Water Circulation

    1. Mount the cover of control system 1; see chapter 7.21. 2. Only on Energize 5 (R134a) dual: Mount the cover of control system 2; see chapter 7.22. 3. Mount the cover; see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...

  • Page 50: Replacing Control System 1

    9. Close the cover (Fig. 84/1) of control system 1 (Fig. 85/1). Fig. 86 Finishing tasks 1. Mount the cover; see chapter 7.1. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 51: Replacing Control System 2 (Energize 5 (R134A) Dual Only)

    7. Close the cover (Fig. 87/1) of control system 2 (Fig. 88/1). Finishing tasks Fig. 89 1. Mount the cover; see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 52: Replacing The Fan

    2. Remove the fastening bolts (Fig. 91/2) from the fan (Fig. 91/1). 3. Carefully lift the air scoop with fan (Fig. 91/1) out of the unit. Fig. 91 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 53: Replacing The Starting Capacitor For The Carbonator Pump Motor

    8. Attach the protective cap (Fig. 93/1) to the starting capacitor (Fig. 93/2). Fig. 94 Finishing tasks 1. Mount the sheet casing (service); see chapter 7.1. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 54: Replacing The Starting Capacitor Of The Compressor

    8. Attach the cover (Fig. 95/1) of the electrical assembly. Fig. 96 Finishing tasks 1. Mount the sheet casing (service); see chapter 7.2. Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 55: Replacing The Starter Relay

    7. Attach the cover (Fig. 97/1) of the electrical assembly. Finishing tasks 1. Mount the sheet casing (service); see chapter 7.2. Fig. 99 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 56: Replacing The Overload Protection

    5. Connect all electrical cables to the transformer (Fig. 102/1). Finishing tasks 1. Mount the cover; see chapter 7.1. Fig. 103 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 57: Replacing The Transformer Fuse

    All wiring and plumbing must be carried out in compliance with national and local laws, regulations and guidelines. Non-compliance with these laws, regulations and guidelines may result in death, serious injury or equipment damage. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100...

  • Page 58: Commissioning

    (for the setpoint, see the document “Undercounter cooler operator manual”, document no. TD1005000). Fig. 105 8. Plug the mains plug into the earthed socket. Fig. 106 Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 59: Shutdown

    9. Turn the carbonator pump switch (Fig. 108/1) to position “0”. Fig. 108 10. Pull the mains plug out of the earthed socket. Fig. 109 Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 60: Errors And Malfunctions

    Defective valve on the tower Replace the valve; (see the document “Tower in- stallation and service manual”) Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...
  • Page 61 Crushed ice in the cup may also cause decarbonisation. When the finished beverage comes into contact with sharp-edged ice, CO is released from the dispensed drink. Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a)

  • Page 62: Applicable Documents

    Applicable documents Applicable documents 10.1 Flowchart Undercounter cooler Energize 3 (R134a) Backward Forward Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 63: Flowchart Undercounter Cooler Energize 4 (R134A)

    Applicable documents 10.2 Flowchart Undercounter cooler Energize 4 (R134a) Backward Forward Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 64: Flowchart Undercounter Cooler Energize 5 (R134A) Single

    Applicable documents 10.3 Flowchart Undercounter cooler Energize 5 (R134a) single Backward Forward Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...

  • Page 65: Flowchart Undercounter Cooler Energize 5 (R134A) Dual

    Applicable documents 10.4 Flowchart Undercounter cooler Energize 5 (R134a) dual Backward Forward Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...

  • Page 66: Wiring Diagram Undercounter Cooler Energize 3-5 (R134A)

    Applicable documents 10.5 Wiring diagram Undercounter cooler Energize 3-5 (R134a) Installation and service manual Undercounter cooler Cornelius Deutschland GmbH Energize 3-5 (R134a) Document no. TD1005100 Version 08/10/2019, Index 3...
  • Page 67 Applicable documents Cornelius Deutschland GmbH Installation and service manual Undercounter cooler Document no. TD1005100 Energize 3-5 (R134a) Version 08/10/2019, Index 3...
  • Page 68 Cornelius Deutschland GmbH Tel.: +49 (0) 21 73 / 79 3 – 0 Carl-Leverkus-Str. 15 Fax: +49 (0) 21 73 / 77 4 – 38 40764 Langenfeld E-Mail: info@cornelius.com Germany...

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Energize 3Energize 5Energize 4

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