Cornelius Energize6 Service Manual
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Cornelius Energize6 Service Manual

Cornelius Energize6 Service Manual

Backroom soda chiller package
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ENERGIZE6
Service Manual
Release Date: August 3, 2012
Publication Number: 621058457SER
Revision Date: August 8, 2013
Revision: A10
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

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Summary of Contents for Cornelius Energize6

  • Page 1 ENERGIZE6 Service Manual Release Date: August 3, 2012 Publication Number: 621058457SER Revision Date: August 8, 2013 Revision: A10 Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
  • Page 2 Commercial Warranty. Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal...

  • Page 3: Table Of Contents

    Safety Instructions..............1 Read and Follow ALL Safety Instructions .
  • Page 4 Thawing the Ice Bank ............16 Component Service .

  • Page 5: Safety Instructions

    Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or infirm persons without supervision. Y oung children should be supervised to ensure that they do not play with the appliance. © 2012, IMI Cornelius Inc. - 1 - Publication Number: 621058457SER...

  • Page 6: Qualified Service Personnel

    Strict attention MUST be observed in the prevention of CO gas leaks in the entire CO and soft drink system. If a CO gas leak is suspected, par- Publication Number: 621058457SER - 2 - © 2012, IMI Cornelius Inc.
  • Page 7 IMMEDIATELY ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO experience tremors which are followed rapidly by loss of consciousness and DEATH. © 2012, IMI Cornelius Inc. - 3 - Publication Number: 621058457SER...

  • Page 8: System Overview

    • Intelligent variable speed recirculation • Syrup conditioning at the point of dispensing • Improved water bath insulation for more unit efficiency • Individual supply shutoffs • SMART Capable • Snooze mode Publication Number: 621058457SER - 4 - © 2012, IMI Cornelius Inc.

  • Page 9: Energy Efficiency

    After dispensing, Energize switches back to standby mode automatically. PECIFICATIONS Table 1. Model Energize6 USA 220V 60Hz Continuous Dispense Rate at 75 °F (24 °C) 7 x 12 oz. (355 ml) ambient Peak Dispense Rate for 2 hours at 75 °F 10 x 12 oz.

  • Page 10: Operation

    Figure 10. Do not turn on the recirculation switches (Figure 7) until ice starts to form on the evaporator coils. Replace the cover on the unit. Figure 2. Publication Number: 621058457SER - 6 - © 2012, IMI Cornelius Inc.
  • Page 11 Energize6 Service Manual Water Fill Valve Figure 3. Fill Valve Figure 4. Top of Drain Pipe Figure 5. Indicator Light Main Controller Slave Controller Figure 6. © 2012, IMI Cornelius Inc. - 7 - Publication Number: 621058457SER...
  • Page 12 Blinks Fast Over Temp/Motion Controller Check/Reset Power Red/Green Red/Green Blinks Main Controller Call Service Carbonator Tanks Master Controller Recirculation Compressor Carbonator Tanks Slave Controller Recirculation (Not Used) Figure 7. Publication Number: 621058457SER - 8 - © 2012, IMI Cornelius Inc.
  • Page 13 Figure 9. Relief Valve Figure 10. CAUTION: The circulation pump runs even if there is no water in the soda circuit. Running the pumps dry damages the soda recirculation pump. © 2012, IMI Cornelius Inc. - 9 - Publication Number: 621058457SER...

  • Page 14: Ending Operation

    To prevent loss or health hazard in the event of a leak, the CO supply and water supply lines should be turned off when the system is not in use for a extended period of time. Publication Number: 621058457SER - 10 - © 2012, IMI Cornelius Inc.

  • Page 15: Preventive Maintenance

    • Check overflow drain connection on the bottom of the unit and the floor drain. EEKLY Cleaning and Sani- tizing the Quick Dis- To clean and sanitize the BIB quick disconnect fittings, perform the procedure in connect Fittings Table 4. © 2012, IMI Cornelius Inc. - 11 - Publication Number: 621058457SER...

  • Page 16: Quarterly

    Inspect syrup lines for the proper flavor identification labels. Replace the labels as needed. Disconnect and remove the syrup containers. Clean the connectors with soap and warm water. Rinse them with plain water. Return the syrup containers and reconnect them. Publication Number: 621058457SER - 12 - © 2012, IMI Cornelius Inc.

  • Page 17: Co2 Gas Supply

    Verify all power is off to the unit before performing any work. Failure to comply could result in serious injury, death or damage to the equipment. © 2012, IMI Cornelius Inc. - 13 - Publication Number: 621058457SER...

  • Page 18: Service Access

    Replace the cover on the unit. ERVICE CCESS The following procedures describe how to service various subsystems and compo- nents of the Energize6 system. Removing the Unit Cover To remove the top cover from the unit, perform the procedure in Table 9.

  • Page 19: Cleaning And Sanitizing The Syrup System

    Submerge all disconnects in the soap solution and then clean them using a nylon bristle brush. (Do not use a wire brush). Rinse them with clean water. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution. © 2012, IMI Cornelius Inc. - 15 - Publication Number: 621058457SER...

  • Page 20: Cleaning And Sanitizing Procedure

    Thawing the Ice Bank If the unit becomes frozen, it must be carefully Thawed by trained personnel. To Thaw the Energize6 unit, perform the procedure in Table 12. Table 12. Step Action Turn off the electrical supply to the unit.
  • Page 21 Energize6 Service Manual Table 12. Step Action Replace the cover on the unit. Turn on the electrical supply to the unit. © 2012, IMI Cornelius Inc. - 17 - Publication Number: 621058457SER...

  • Page 22: Component Service

    Using a Phillips screwdriver, remove the seven screws around the edges of the service panel, shown in Figure 12 and Figure 13. Lift the service panel away from the base of the Energize6 unit. Publication Number: 621058457SER - 18 -...

  • Page 23: Replacing Recirculating Pump Components

    Turn off the electrical supply to the unit. Remove the cover using the procedure in “Removing the Unit Cover” on page 14. Turn off the appropriate recirculating shutoff valves, shown in Figure 15. © 2012, IMI Cornelius Inc. - 19 - Publication Number: 621058457SER...
  • Page 24 Turn on the water supply to the unit. When the unit is refilled, replace the unit cover. Figure 14. Circuit 1 Shut off Valves Circuit 2 Shutoff Valves Figure 15. Publication Number: 621058457SER - 20 - © 2012, IMI Cornelius Inc.
  • Page 25 Energize6 Service Manual Recirculating Pump Tubing Insulation Figure 16. Recirculating Pump Connections Insulation Figure 17. Recirculating Pump Retaining Collar Figure 18. © 2012, IMI Cornelius Inc. - 21 - Publication Number: 621058457SER...

  • Page 26: Replacing A Recirculating Pump Motor

    Turn on the electrical supply to the unit. Replace the unit cover. Motor Wiring to Control Box Motor Ground Figure 19 Motor Mounting Bolts Figure 20. Publication Number: 621058457SER - 22 - © 2012, IMI Cornelius Inc.

  • Page 27: Replacing Carbonator Pump Components

    Connect the pressure sensor wires to the appropriate sensor. Turn the water supply on and make sure the water bath level is up to the notch in the overflow tube. © 2012, IMI Cornelius Inc. - 23 - Publication Number: 621058457SER...
  • Page 28 Turn on the electrical supply to the unit. Replace the unit cover. Carbonator Shutoff Valves Figure 22. Low Pressure High Pressure Carbonator Carbonator Pump Pump Connection Connection Figure 23. Publication Number: 621058457SER - 24 - © 2012, IMI Cornelius Inc.

  • Page 29: Replacing A Carbonator Pump Motor

    Replace the electrical connection from the recirculating pump to the control box. Turn the water supply on and make sure the water bath level is up to the notch in the overflow tube. © 2012, IMI Cornelius Inc. - 25 - Publication Number: 621058457SER...

  • Page 30: Replacing Carbonator Pump Pressure Switches

    The agitator motor is mounted on the top of the unit, on a mounting bracket, shown in Figure 26. Tie Wrap Agitator Motor Mounting Bracket Figure 26. To remove and replace the agitator motor, perform the procedure in Table 19. Publication Number: 621058457SER - 26 - © 2012, IMI Cornelius Inc.
  • Page 31 Replace the electrical connections from the agitator motor to the control box. Turn on the electrical supply to the unit. Replace the unit cover. Bracket Mounting Screws Figure 27. Splash Guard Agitator Motor Impeller Slinger Figure 28. © 2012, IMI Cornelius Inc. - 27 - Publication Number: 621058457SER...

  • Page 32: Replacing The Electronic Ice Probe

    Reconnect the connector to the control box and replace the cable ties to keep the wiring away from any hot areas of the unit. Turn on the electrical supply to the unit. When the unit is refilled, replace the unit cover. Publication Number: 621058457SER - 28 - © 2012, IMI Cornelius Inc.

  • Page 33: Replacing The Carbonators

    Figure 30. Ice Probe Assembly Figure 31. EPLACING THE ARBONATORS There are two carbonators in the Energize6 unit. To replace a carbonator, perform the procedure in Table 21. Table 21. Step Action Determine which carbonator is malfunctioning. Turn off the electrical supply to the unit.
  • Page 34 Turn on the electrical supply to the unit. When the unit is refilled, replace the unit cover. Carbonator Relief Valve Connector Plumbing Connections Ground Wire Figure 32. O-Ring Figure 33. Publication Number: 621058457SER - 30 - © 2012, IMI Cornelius Inc.

  • Page 35: Replacing The Co2 Pressure Switches

    ALVE SSEMBLIES The Energize6 unit has one compressor and two cooling circuits. There are two expansion valve assemblies to accommodate the two circuits, as shown in Figure 35. The expansion valves are located near the center of the unit, toward the rear. To replace an expansion valve, perform the procedure in Table 23.
  • Page 36 Replace the filter/dryer, located at the left rear of the unit, as shown in Fig- ure 37. Evacuate the system. Restore the proper refrigerant charge to the system and verify proper sys- tem operation. Expansion Valves Sensors (w/Insulation removed) Figure 36. Publication Number: 621058457SER - 32 - © 2012, IMI Cornelius Inc.

  • Page 37: High Pressure Switch Replacement

    Replace the filter/dryer, see Figure 37 on page 33. Evacuate the system. Restore the proper refrigerant charge to the system and verify proper sys- tem operation. Replace the access panel. © 2012, IMI Cornelius Inc. - 33 - Publication Number: 621058457SER...

  • Page 38: Replacing The Solenoid Coil

    Replace the solenoid by pressing the new solenoid onto the valve stem, as shown in Figure 40. Reconnect the wiring to the solenoid. Replace the access panel. Turn on the electrical supply to the unit. Electrical Connections Figure 39. Publication Number: 621058457SER - 34 - © 2012, IMI Cornelius Inc.

  • Page 39: Replacing The Solenoid Valve Body

    Drain the bath by removing the overflow tube from the unit. Thaw the ice bank. This can be accelerated by pouring warm water into the water bath. Reclaim the refrigerant from the system. © 2012, IMI Cornelius Inc. - 35 - Publication Number: 621058457SER...

  • Page 40: Replacing The Mesh Strainer

    Reconnect the outlet plumbing to the pump, using teflon tape to insure a proper seal. Replace the overflow tube, being careful to lubricate the O-rings on the bot- tom of the tube with water before inserting it into the drain. Publication Number: 621058457SER - 36 - © 2012, IMI Cornelius Inc.

  • Page 41: Replacing The Check Valve

    Turn the water supply on and make sure the water bath level is up to the notch in the overflow tube. Turn on the electrical supply to the unit. When the unit is refilled, replace the unit cover. © 2012, IMI Cornelius Inc. - 37 - Publication Number: 621058457SER...

  • Page 42: Replacing The Controller Boards

    Reconnect all the connectors to the control board. Replace the cover on the control board. Turn on the electrical supply to the unit. Replace the unit cover. Figure 43. Publication Number: 621058457SER - 38 - © 2012, IMI Cornelius Inc.

  • Page 43: Troubleshooting

    Pump falls into the 20min max run Water Running closed time. Power reset required. No Carb Carbonator Pump Motor - Not Check LED (Yellow) Check CO2 Out of CO2 Water Running Supply © 2012, IMI Cornelius Inc. - 39 - Publication Number: 621058457SER...
  • Page 44 Continuously runs hi or lo Bad main control board Check and replace board pump Ice bank probe in wrong bend/ Check ice probe position and cor- Freeze up Compressor running wrong location rect Publication Number: 621058457SER - 40 - © 2012, IMI Cornelius Inc.
  • Page 45 Recirculation pump not run- Loose or defective wire connec- Check and tighten connections tion ning tion No recircula- Recirculation pump not run- Low voltage Check and verify voltages tion ning © 2012, IMI Cornelius Inc. - 41 - Publication Number: 621058457SER...

  • Page 46: Flow Charts And Circuit Diagrams

    Energize6 Service Manual FLOW CHARTS AND CIRCUIT DIAGRAMS LUMBING IAGRAM Publication Number: 621058457SER - 42 - © 2012, IMI Cornelius Inc.
  • Page 47 Energize6 Service Manual © 2012, IMI Cornelius Inc. - 43 - Publication Number: 621058457SER...
  • Page 48 Energize6 Service Manual Publication Number: 621058457SER - 44 - © 2012, IMI Cornelius Inc.

  • Page 49: Wiring Diagram

    Energize6 Service Manual IRING IAGRAM © 2012, IMI Cornelius Inc. - 45 - Publication Number: 621058457SER...
  • Page 50 Energize6 Service Manual Publication Number: 621058457SER - 46 - © 2012, IMI Cornelius Inc.
  • Page 52 IMI Cornelius Inc. www.cornelius.com...

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