Cornelius Energize6, Service Manual

Page 1: ...RGIZE6 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: ...occurrences including but not limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper voltage 3 inadequate wiring 4 abuse 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained per sons to perform service and or repair of the Product 10 improper cleaning 11 failure to follo...

Page 3: ...g the Unit 6 Ending Operation 10 Preventive Maintenance 11 Cleaning and Sanitizing 11 Changing to a Different Flavor 11 Daily 11 Daily Inspection 11 Weekly 11 Cleaning and Sanitizing the Quick Disconnect Fittings 11 Quarterly 12 Beverage Tubing 12 Water Filters 12 Syrup Supply 12 CO2 Gas Supply 13 Annually 13 Water Bath 13 Service Access 14 Removing the Unit Cover 14 Cleaning and Sanitizing the Sy...

Page 4: ...r Pump Pressure Switches 26 Replacing the Agitator Motor 26 Replacing the Electronic Ice Probe 28 Replacing the Carbonators 29 Replacing the CO2 Pressure Switches 31 Replacing the Expansion Valve Assemblies 31 High Pressure Switch Replacement 33 Replacing the Solenoid Coil 34 Replacing the Solenoid Valve Body 35 Replacing the Head Master 35 Replacing the Mesh Strainer 36 Replacing the Check Valve ...

Page 5: ...ion which if not avoided COULD result in serious injury death or equipment damage CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS Carefullyread andfollowall safety messages inthismanualandsafety signsonthe unit Keepsafety signsingoodconditionandreplacemissingordamageditems Learnhowtooperatetheunitandhow...

Page 6: ...k out tag out procedures established by the user Verify all of the power is off to the unit before any work is performed Failure to disconnect the power could result in serious injury death or equipment damage CAUTION Always be sure to keep area around the unit clean and free of clutter Failure to keep this area clean may result in injury or equipment damage SHIPPING AND STORAGE CAUTION Before shi...

Page 7: ...n Number 621058457SER ticularly in a small area IMMEDIATELY ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentrations of CO2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH ...

Page 8: ...up The Ener gize unit varies the speed of the circulating pump motors based on the system demand The system consists of the backroom package the cooler carbonator unit and the interconnect pythons These are arranged in a manner similar to Figure 1 Layout details may vary according to the system location Figure 1 FEATURES Environmentally friendly refrigerant R404a Intelligent variable speed recircu...

Page 9: ... of ice After dispensing Energize switches back to standby mode automatically SPECIFICATIONS Table 1 Model Energize6 USA 220V 60Hz Continuous Dispense Rate at 75 F 24 C ambient 7 x 12 oz 355 ml Peak Dispense Rate for 2 hours at 75 F 24 C ambient 10 x 12 oz 355 ml Maximum Ambient Condition 104 F 40 C Unit 120 F 49 C Remote Condenser Ice bank Weight 110 lbs 50 kg Compressor size 2 HP 2 65 cu in 43 5...

Page 10: ...n in Figure 5 5 Remove the front access panel See Service Access on page 18 and turn on the compressor by moving the compressor switch on the master controller to the ON position as shown in Figure 7 The compressor should start and begin to cool after a 3 to 5 minute time delay 6 The unit will start to build an ice bank approx 2 5 hrs 75 F 7 Turn on the carbonator pump motors by moving the carbona...

Page 11: ...ize6 Service Manual 2012 IMI Cornelius Inc 7 Publication Number 621058457SER Figure 3 Figure 4 Figure 5 Figure 6 Water Fill Valve Fill Valve Top of Drain Pipe Main Controller Slave Controller Indicator Light ...

Page 12: ...ower Yellow ON CO2 Pressure Low Check Replace CO2 Supply Red ON or Blinks Slow Time Out Carbonator Water Supply Pressure Low Reset Power If it Remains On Call Service Check Replace Water Filter Blinks Fast Over Temp Motion Controller Check Reset Power Red Green Red Green Blinks Main Controller Call Service Compressor Recirculation Carbonator Tanks Not Used Recirculation Carbonator Tanks Master Con...

Page 13: ... 621058457SER Figure 8 Figure 9 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 Agitator Mounting Bracket Carbonator 2 Agitator Mounting Bracket Carbonator 1 Relief Valve ...

Page 14: ... Number 621058457SER 10 2012 IMI Cornelius Inc ENDING OPERATION To prevent loss or health hazard in the event of a leak the CO2 supply and water supply lines should be turned off when the system is not in use for a extended period of time ...

Page 15: ...ENT DAMAGE CLEANING AND SANITIZING Changing to a Dif ferent Flavor Clean and sanitize the syrup system as described in Cleaning and San itizing the Syrup System on page 15 DAILY Daily Inspection Check CO2 and water supply Visually check the beverage syrup lines for leaks If leaks are noted call a service technician Check overflow drain connection on the bottom of the unit and the floor drain WEEKL...

Page 16: ... Adjust the setting as needed Syrup Supply The syrup supplies should be inspected and cleaned using the procedure in Table 5 Table 4 Step Action 1 Remove all the quick disconnects from all the B I B containers 2 Fill a 1 gallon bucket with mild detergent solution 3 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 ...

Page 17: ...eds to be cleaned perform the procedure in Table 8 WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user 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 Table 6 Step Action 1 Verify a CO2 high pressure regulator setting of 100 psi 6 8 bar 2...

Page 18: ...bath the ice coils and the prod uct coils if dirty 8 Fill the bath with a 200ppm chlorinated sanitizing solution 9 Reconnect the electrical supply to the unit 10 Turn on the agitator and allow it to run for 10 minutes 11 Turn off the agitator 12 Drain all of the sanitizing solution from the water bath 13 Thoroughly rinse the bath the ice coils and the product coils with the same sprayer as used in...

Page 19: ...gs One 1 gallon pail minimum One 5 gallon pail minimum One nylon brush Cleaning Sanitizing the BIB Backroom Package Weekly cleaning and sanitizing is recommended for the BIB system Cleaning and Sanitiz ing the Quick Discon nect Fittings To clean and sanitize the BIB quick disconnect fittings perform the procedure in Table 10 Cover Attaching Screw Table 10 Step Action 1 Remove all the quick disconn...

Page 20: ...en each dispenser valve until the sanitizing solution is flowing from the valve 4 Allow sanitizer to remain in the lines for fifteen 15 minutes 5 Remove the nozzle and syrup diffuser from each valve if equipped and clean them in a mild detergent solution Rinse with clean water and reassemble the nozzle and syrup diffuser to the valve 6 Remove the sanitizing fittings from the B I B disconnects and ...

Page 21: ...Energize6 Service Manual 2012 IMI Cornelius Inc 17 Publication Number 621058457SER 9 Replace the cover on the unit 10 Turn on the electrical supply to the unit Table 12 Step Action ...

Page 22: ...n serious injury death or damage to the equipment CAUTION All of the threaded plumbing connections in the system contain a plastic gasket to ensure a proper seal when the connection is tightened MAKE SURE TO REPLACE THIS GASKET WHENEVER A CONNECTION IS OPENED FOR REPAIR SERVICE ACCESS The following procedures describes how to access portions of the unit under the main service panel Main Service Pa...

Page 23: ...and replace a recirculating pump perform the procedure in Table 14 Front Panel Screws Access Side Panel Screws Access Table 14 Step Action 1 Determine which carbonator pump is malfunctioning 2 Turn off the electrical supply to the unit 3 Remove the cover using the procedure in Removing the Unit Cover on page 14 4 Turn off the appropriate recirculating shutoff valves shown in Figure 15 ...

Page 24: ... motor and tighten the pump retaining collar 11 Reinstall the insulation around the pump and over the pump tubing 12 Check and replace the gasket inside the fittings shown in Figure 14 before reconnecting the pump 13 Reconnect the inlet and outlet plumbing to the pump using teflon tape to insure a proper seal 14 Turn the water supply on and make sure the water bath level is up to the notch in the ...

Page 25: ...vice Manual 2012 IMI Cornelius Inc 21 Publication Number 621058457SER Figure 16 Figure 17 Figure 18 Recirculating Pump Tubing Insulation Recirculating Pump Connections Insulation Recirculating Pump Retaining Collar ...

Page 26: ...trol board Then pull the wiring out of the unit and untie the string Use the string to fish the new wiring back through the unit to the control box 6 Remove the ground wire from the chassis shown in Figure 19 7 Remove the pump retaining collar shown in Figure 18 8 Remove the pump from the motor by pulling it away from the motor 9 Using the proper size wrench remove the pump mounting bolts shown in...

Page 27: ...ove the pressure sensors from the pump body 8 Remove the high and low pressure plumbing connectors from the pump shown in Figure 23 9 Loosen the retaining collar shown in Figure 25 10 Remove the recirculating pump assembly by pulling it away from the motor 11 Install the new recirculating pump assembly onto the motor and tighten the pump retaining collar 12 Check and replace the gasket inside the ...

Page 28: ...the recirculating shutoffs shown in Figure 22 18 Turn on the CO2 supply to the unit and check the system for leaks 19 Turn on the electrical supply to the unit 20 Replace the unit cover Table 16 Step Action Carbonator Shutoff Valves Low Pressure Pump Connection Carbonator High Pressure Pump Connection Carbonator ...

Page 29: ...ng in place TIP Once all tie wraps have been removed tie a length of string to the connector before pulling it out of the control board Then pull the wiring out of the unit and untie the string Use the string to fish the new wiring back through the unit to the control box 4 Remove the ground wire from the chassis as shown in Figure 19 on page 22 5 Remove the pump retaining collar shown in Figure 2...

Page 30: ...pply to the unit 2 Remove the cover using the procedure in Removing the Unit Cover on page 14 3 Drain the system pressure by opening a dispense valve 4 Turn off the carbonator shutoffs shown in Figure 22 5 Label and remove the pressure switch wires on the sensor being replaced shown in Figure 24 6 Remove the malfunctioning pressure switch 7 Insert the new pressure switch into the pump using teflon...

Page 31: ...olding the agitator bracket to the unit shown in Figure 27 6 Carefully slide the bracket and remove it 7 Place the bracket and pump assembly on a workbench or table and unscrew the impeller blade from the shaft shown in Figure 28 8 Remove the slinger off the end of the motor shaft 9 Remove the four screws and nuts holding the agitator motor to the mount ing bracket shown in Figure 29 10 Remove the...

Page 32: ...wiring in place TIP Once all tie wraps have been removed tie a length of string to the connector before pulling it out of the control board Then pull the wiring out of the unit and untie the string Use the string to fish the new wiring back through the unit to the control box 6 Unsnap the ice probe from the evaporator coil and lift the assembly up and out of the water bath shown in Figure 30 and F...

Page 33: ...o the unit 4 Turn off the CO2 supply to the unit 5 Remove the cover using the procedure in Removing the Unit Cover on page 14 6 Drain the bath by removing the overflow tube from the unit 7 Thaw the ice bank This can be accelerated by pouring warm water into the water bath 8 Drain the system pressure by opening a dispense valve 9 To gain access to the carbonator tank remove the agitator bracket fro...

Page 34: ...eplace the gasket inside the fittings shown in Figure 14 on page 20 before reconnecting the carbonator plumbing 19 Reinstall the plumbing connectors to the carbonator using teflon tape to insure a proper seal 20 Reconnect the connector and ground wire to the top of the carbonator 21 Reinstall the agitator bracket 22 Replace the overflow tube being careful to lubricate the O rings on the bot tom of...

Page 35: ...on 1 Determine which pressure switch is malfunctioning 2 Turn off the electrical supply to the unit 3 Turn off the CO2 supply to the unit 4 Remove the cover using the procedure in Removing the Unit Cover on page 14 5 Drain the system pressure by opening a dispense valve 6 Vent the carbonators by opening the relief valves shown in Figure 10 on page 9 7 Label and disconnect the wiring from the press...

Page 36: ...ulbs 5 Remove the expansion valve sensor bulb from the clamp holding it to the refrigerant line shown in Figure 36 6 Replace the expansion valve and re install the sensor bulb into the clamp 7 Replace the insulation around the bulb sensor 8 Replace the filter dryer located at the left rear of the unit as shown in Fig ure 37 9 Evacuate the system 10 Restore the proper refrigerant charge to the syst...

Page 37: ...ion 1 Turn off the electrical supply to the unit 2 Remove the access panel from the rear of the unit 3 Unplug the electrical connections from the high pressure switch to the con trol box and remove any tie wraps holding the wiring TIP Tie a length of string to the connector before pulling it out of the con trol board Then pull the wiring out of the unit and untie the string Use the string to fish ...

Page 38: ...noid Valve High Pressure Switch Reset Button Table 25 Step Action 1 Turn off the electrical supply to the unit 2 Remove the access panel from the rear of the unit 3 Remove the electrical connections to the solenoid shown in Figure 39 4 Pull the solenoid off of the valve stem 5 Replace the solenoid by pressing the new solenoid onto the valve stem as shown in Figure 40 6 Reconnect the wiring to the ...

Page 39: ...the access panel from the rear of the unit 3 Remove the solenoid coil from the valve body 4 Reclaim the refrigerant from the system 5 Replace the solenoid valve body 6 Replace the solenoid coil by pressing the it onto the valve stem as shown in Figure 40 7 Replace the filter dryer see Figure 37 on page 33 8 Evacuate the system 9 Restore the proper refrigerant charge to the system and verify proper...

Page 40: ...ly to the unit 2 Turn off the water supply to the unit 3 Remove the cover using the procedure in Removing the Unit Cover on page 14 4 Drain the system pressure by opening a dispense valve 5 Vent the carbonators by opening the relief valves shown in Figure 10 on page 9 6 Turn off the recirculation shutoffs shown in Figure 22 on page 24 7 Remove the high pressure plumbing connector from the pump sho...

Page 41: ...3 Remove the cover using the procedure in Removing the Unit Cover on page 14 4 Drain the system pressure by opening a dispense valve 5 Vent the carbonators by opening the relief valves shown in Figure 10 on page 9 6 Turn off the recirculation shutoffs shown in Figure 22 on page 24 7 Remove the high pressure plumbing connector from the pump shown in Figure 23 on page 24 8 Remove the check valve sho...

Page 42: ...1 Turn off the electrical supply to the unit 2 Remove the cover using the procedure in Removing the Unit Cover on page 14 3 Remove the service panel using the procedure in Service Access on page 14 4 Remove the cover from the malfunctioning control board shown in Figure 43 5 Unplug the connectors from the control board 6 Install the new control board 7 Reconnect all the connectors to the control b...

Page 43: ...arm Drinks Compressor Not Running Condenser Fan Motor Failure Start compressor and look if the fan motor starts as well 8 Warm Drinks Compressor Not Running Compressor internal cut out Power to compressor Check volt age to each leg 120V to ground 9 Warm Drinks Compressor Not Running Compressor Failure Check start relay and start capaci tor 10 Warm Drinks Compressor Not Running Main Controller Fail...

Page 44: ...nning Still Water Solenoid fails open Check if solenoid is closing if still water is being dispensed 5 Low Carbon ation Carbonator Pump Motor short cycling Low Water pressure Check red indicator flashing once per second 6 Low Carbon ation Carbonator Pump Motor short cycling Level control probe and connec tions Check probe location and connec tions 7 Low Carbon ation Carbonator Pump Motor short cyc...

Page 45: ...ter bath continues to overfill Water bath fill valve not shut off completely Check water bath fill valve 2 Water bath overflows Water bath continues to overfill Stainless steel cooling coil s rup tured Check coils and replace if neces sary 3 Water bath overflows Water bath continues to overfill Leaking crimped water line con nection Check crimped water line connec tions 1 No recircula tion Recircu...

Page 46: ...Energize6 Service Manual Publication Number 621058457SER 42 2012 IMI Cornelius Inc FLOW CHARTS AND CIRCUIT DIAGRAMS PLUMBING DIAGRAM ...

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Page 49: ...Energize6 Service Manual 2012 IMI Cornelius Inc 45 Publication Number 621058457SER WIRING DIAGRAM ...

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