Table of Contents
Related Manuals for Cornelius VIPER 2 FLAVOR
Summary of Contents for Cornelius VIPER 2 FLAVOR
- Page 1 VIPER 2 FLAVOR, VIPER 3 FLAVOR & VIPER 4 FLAVOR Service Manual Release Date: October 28, 2008 Publication Number: 621260373SER Revision Date: May 14, 2012 Revision: H Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
-
Page 2: Contact Information
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
TABLE OF CONTENTS Introduction ..............1 Manual Overview . - Page 4 Setup Menu ..............27 Clock Setup Menu .
- Page 5 Preventative Maintenance ............50 Summary .
-
Page 6: Introduction
• Simple User Interface LCD Display • Real Time Clock • Incoming Line Voltage Sensing • Pressure Sensing of Incoming Water, Syrup and CO • System Error Handling • Error Log • Viscosity Control © 2008-2012, IMI Cornelius Inc. - 1 - Publication Number: 621260373SER... -
Page 7: Safety Instructions
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit. Publication Number: 621260373SER - 2 - © 2008-2012, IMI Cornelius Inc. -
Page 8: Qualified Service Personnel
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. © 2008-2012, IMI Cornelius Inc. - 3 - Publication Number: 621260373SER... -
Page 9: Mounting In Or On A Counter
The percentage or degree of overrun depends on a number of factors. The specific syrup, BRIX, low dispensing volume, carbonation level in the liquid product and freezing of the product. These items all affect overrun. After these Publication Number: 621260373SER - 4 - © 2008-2012, IMI Cornelius Inc. -
Page 10: Specific Product Ingredients Affect Overrun
For example, drinks with 3.0 volume of carbonation have more gass breakout in frozen carbonated form and more overrun than drinks that contain 2.0 volumes of CO gas. © 2008-2012, IMI Cornelius Inc. - 5 - Publication Number: 621260373SER... -
Page 11: Freezing Affects Overrun
The degree of freezing is limited because the finished drink is intended to be sipped through a straw. This is not possible if the product is too “solid”. Publication Number: 621260373SER - 6 - © 2008-2012, IMI Cornelius Inc. -
Page 12: System Overview
3-Barrel Viper unit is shown in Figure 5 and the wiring diagram of the 4-Barrel Viper unit is shown in Figure 6. These diagrams show the details of the electrical connections in the unit. © 2008-2012, IMI Cornelius Inc. - 7 - Publication Number: 621260373SER... - Page 13 Viper Service Manual Figure 1. Viper System 2-Barrel Refrigeration Schematic Publication Number: 621260373SER - 8 - © 2008-2012, IMI Cornelius Inc.
- Page 14 Viper Service Manual Figure 2. Viper System 3-Barrel Refrigeration Schematic © 2008-2012, IMI Cornelius Inc. - 9 - Publication Number: 621260373SER...
- Page 15 Viper Service Manual Figure 3. Viper System 4-Barrel Refrigeration Schematic Publication Number: 621260373SER - 10 - © 2008-2012, IMI Cornelius Inc.
- Page 16 Viper Service Manual Figure 4. Viper 2-Barrel Wiring Diagram © 2008-2012, IMI Cornelius Inc. - 11 - Publication Number: 621260373SER...
- Page 17 Viper Service Manual Figure 5. Viper 3-Barrel Wiring Diagram Publication Number: 621260373SER - 12 - © 2008-2012, IMI Cornelius Inc.
- Page 18 Viper Service Manual Figure 6. Viper 4-Barrel Wiring Diagram © 2008-2012, IMI Cornelius Inc. - 13 - Publication Number: 621260373SER...
-
Page 19: Co 2 System
From the in-line check valve, the CO flows into the product line. Figure 7. Typical Bulk Cylinder CO Connection Publication Number: 621260373SER - 14 - © 2008-2012, IMI Cornelius Inc. - Page 20 Foaming Agent FCB Syrup w/o 32-36 PSIG Foaming Agent NOTE:For citric syrups, adjust the CO pressures down by 2-4 PSIG from the above to compensate for the lower CO adsorption. © 2008-2012, IMI Cornelius Inc. - 15 - Publication Number: 621260373SER...
- Page 21 Viper Service Manual Figure 9. 2-Barrel System Schematic Publication Number: 621260373SER - 16 - © 2008-2012, IMI Cornelius Inc.
- Page 22 Viper Service Manual Figure 10. 3-Barrel System Schematic © 2008-2012, IMI Cornelius Inc. - 17 - Publication Number: 621260373SER...
- Page 23 Viper Service Manual Figure 11. 4-Barrel System Schematic Publication Number: 621260373SER - 18 - © 2008-2012, IMI Cornelius Inc.
-
Page 24: Water System
There are 2 levels of access to the control panel: The first level can be accessed by the operator for normal operation and the second level is used by qualified service technicians for installation and service functions. The service functions © 2008-2012, IMI Cornelius Inc. - 19 - Publication Number: 621260373SER... -
Page 25: Control Panel Display
On each menu below the Select menu, there is a button (labeled BACK) to save any settings and return to the previous menu. There is another button (GO) to advance to the highlighted menu. Publication Number: 621260373SER - 20 - © 2008-2012, IMI Cornelius Inc. - Page 26 Viper Service Manual Figure 13. Software Structure © 2008-2012, IMI Cornelius Inc. - 21 - Publication Number: 621260373SER...
-
Page 27: Control Panel Menu Descriptions
MENU button. This displays the Select menu, shown in Figure 15. The Setup and Maintenance menus are accessed through the buttons shown at the bottom of the display. NOTE:If security is turned on, the MAINT button is not displayed. Publication Number: 621260373SER - 22 - © 2008-2012, IMI Cornelius Inc. -
Page 28: Unit Data Menu
Continue pressing the Down arrow to view the data on all barrels in the system. Refer to Table 4 for button functions. UNIT #1 FREEZE DATA OUTLET TEMP 33 VISCOSITY: 9 REFRIGERATION: ON 12:51P AV OZ/HR/3 HR: 80 MAR 04 DEFROST TIMER: 2:50:23 BACK BRL UNIT VER Figure 16. Unit Data Screen © 2008-2012, IMI Cornelius Inc. - 23 - Publication Number: 621260373SER... -
Page 29: Error Status Menu
The possible messages from the control system and a description of the errors are shown in Table 6. The button functions are described in Table 7. ERROR #1 MOTOR PWR COMP HIGH STATUS 12:51P MAR 04 BACK Figure 17. Error Status Screen Publication Number: 621260373SER - 24 - © 2008-2012, IMI Cornelius Inc. - Page 30 This error occurs when the H O sensor O OUT System reports no or low water pressure for more than one second. Error is cleared 10 sec. after restoral. © 2008-2012, IMI Cornelius Inc. - 25 - Publication Number: 621260373SER...
-
Page 31: Error Log Menu
Table 8. ERROR NUMBER 2 ERROR #3 COMM FAIL OCCUR: 2:44 PM 3/04/08 12:51P CLEAR: 2:52 PM MAR 04 3/04/08 BACK Figure 18. Error Log Screen Table 8 Button Description BACK Returns the display to the Select menu Publication Number: 621260373SER - 26 - © 2008-2012, IMI Cornelius Inc. -
Page 32: Setup Menu
Select the CLOCK SETUP menu from the Select menu, shown in Figure 19. This displays the Clock Setup menu, shown in Figure 20. Button functions are described in Table 10. © 2008-2012, IMI Cornelius Inc. - 27 - Publication Number: 621260373SER... -
Page 33: Setting The Clock
Use the + button at the bottom of the display to set Set AM/PM the AM/PM setting. To set the date, perform the procedure in Table 12 and refer to Figure 20. Publication Number: 621260373SER - 28 - © 2008-2012, IMI Cornelius Inc. -
Page 34: Setting Daylight Savings Time
Returns the display to the Select menu CLOCK Opens the Clock menu Highlighted to indicate DST menu Decrements the highlighted field by one increment Increments the highlighted field by one increment © 2008-2012, IMI Cornelius Inc. - 29 - Publication Number: 621260373SER... -
Page 35: Events Setup Menu
Button functions are described in Table 15. DAY SUN EVENT SLEEP 10:00 PM SETUP WAKEUP 08:00 AM DEFROST LOCK 1: 05:15 PM 12:51P DEFROST LOCK 2: 09:30 AM MAR 04 DEFROST LOCK 3: ‐‐‐‐‐‐‐‐‐‐‐‐ BACK CLEAR ‐ + Figure 22. Event Setup Screen Publication Number: 621260373SER - 30 - © 2008-2012, IMI Cornelius Inc. -
Page 36: Setting Events
Use the up and down arrows to highlight Select SLEEP SLEEP. Use the left and right arrows to select the hour Set hour field field and press the + or - buttons to change the hour. © 2008-2012, IMI Cornelius Inc. - 31 - Publication Number: 621260373SER... -
Page 37: Setting Defrost Lockout
Use the + button at the bottom of the display to set the AM/PM field. Select DEFROST Repeat Steps 2 through 10 for the DEFROST LOCK 2 LOCK 2 time, if desired. Publication Number: 621260373SER - 32 - © 2008-2012, IMI Cornelius Inc. -
Page 38: Viscosity Setup Menu
When the viscosity settings are complete, press the BACK button to save the settings and return to the Select menu, shown in Figure 19. © 2008-2012, IMI Cornelius Inc. - 33 - Publication Number: 621260373SER... -
Page 39: Options Setup Menu
The date format can be displayed in either United States or European format. To display U.S. date format, press the USA button. This displays the date in mm/dd/ yy format. Press the EURO button to display the date in dd/mm/yy format. Publication Number: 621260373SER - 34 - © 2008-2012, IMI Cornelius Inc. -
Page 40: Setting The Time Format
It sometimes overrides the normal inputs from the system in order to perform this task. BARREL MAINT SELECT MANUAL DIAG TOTALS BRIX SETUP 12:51P MOTOR SETUP MAR 04 SYSTEM BACK MAIN SETUP MAINT GO Figure 25. Select Screen © 2008-2012, IMI Cornelius Inc. - 35 - Publication Number: 621260373SER... -
Page 41: Barrel Maintenance Menu
Press the BACK button to return to the Select menu. NOTE: When the PURGE button is pressed, it changes to a STOP button. Publication Number: 621260373SER - 36 - © 2008-2012, IMI Cornelius Inc. -
Page 42: Filling A Barrel
Use the Up and Down arrows to highlight the Select the barrel desired barrel Press the OFF button at the bottom of the display Turn off the barrel to turn off the barrel. © 2008-2012, IMI Cornelius Inc. - 37 - Publication Number: 621260373SER... -
Page 43: Manual Diagnostic Menu
This selection opens and closes the product solenoids and PRODUCT SOL #1 valves for barrel 1 This selection opens and closes the CO solenoic and valve CO2 VALVE #1 for barrel 1 Publication Number: 621260373SER - 38 - © 2008-2012, IMI Cornelius Inc. -
Page 44: Totals Menu
Shows how long the barrel has been in BARREL REFG #1 HHHHH:MM refrigeration mode Shows how long the motor has been run- MOTOR ON #1 HHHHH:MM ning on a specific barrel © 2008-2012, IMI Cornelius Inc. - 39 - Publication Number: 621260373SER... -
Page 45: Brix Setup Menu
Discard all three of these samples. Press the BRIX button a fourth time. Collect this sample in a cup and close the valve at end of the sample tube. Publication Number: 621260373SER - 40 - © 2008-2012, IMI Cornelius Inc. - Page 46 Secure the panel with the two screws removed in Step 2. This completes the procedure. BRIX #1 OFF #2 OFF SETUP 12:51P MAR 04 BACK BRIX STOP Figure 29. BRIX Setup Screen Splash Panel Retaining Screws Figure 30. Splash Panel Mounting Screws © 2008-2012, IMI Cornelius Inc. - 41 - Publication Number: 621260373SER...
-
Page 47: Motor Setup Menu
This menu allows you to select different motor types for each barrel in the unit and Publication Number: 621260373SER - 42 - © 2008-2012, IMI Cornelius Inc. - Page 48 Complete the proce- Press the BACK button at the bottom of the display dure to save the settings and return to the Setup menu. © 2008-2012, IMI Cornelius Inc. - 43 - Publication Number: 621260373SER...
-
Page 49: Calibrating A Motor
When the individual fields are highlighted, the display buttons change. Refer to Table 32 for a listing of the button functions for the various field selections. Publication Number: 621260373SER - 44 - © 2008-2012, IMI Cornelius Inc. -
Page 50: Security
Main menu, security is re- activated and the Maintenance menu is not accessable. To disable security, access the System menu, highlight Security and press the OFF button. © 2008-2012, IMI Cornelius Inc. - 45 - Publication Number: 621260373SER... -
Page 51: Pressure Sensors
NOTE: If a pressure sensor is open, the pressure reading is 386 PSIG. UNIT LINE VOLTAGE: 229 LINE FREQUENCY: 60 DATA LOW PSIG #1: 60 HIGH PSIG #1: 174 12:51P MAR 04 BACK BRL UNIT VER Figure 36. Unit Data Screen Publication Number: 621260373SER - 46 - © 2008-2012, IMI Cornelius Inc. -
Page 52: Operation
FCB equipment. Cornelius equipment service manuals contain instructions on how to program settings within the control system. Operators who have not been trained on servicing Cornelius FCB equip- ment should not attempt to modify equipment settings but should contact an accred- ited service provider. -
Page 53: Programmed Defrost Scheduling
Cornelius recommends that the viscosity settings be set at the lowest possible set- ting to achieve the desired drink quality. In most typical installations using a sugar- based syrup, acceptable drink quality can be achieved by programmed viscosity set- tings in the range of 3-5 for Viper. -
Page 54: Starting The Unit
Turn all barrels on by pressing the buttons labeled ON Turn on the barrels to start the normal refrigeration process. Close the merchandiser. In approximately 20 minutes, Close the merchandiser. product is ready to serve. © 2008-2012, IMI Cornelius Inc. - 49 - Publication Number: 621260373SER... -
Page 55: Preventative Maintenance
Motorman Valves. types. CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. © 2008-201, IMI Cornelius Inc. - 50 - Publication Number: 621260373SER... -
Page 56: Monthly Maintenance
Wash the filter with clean water. Shake out the excess water. Reinstall the air filter, mesh side down. Close the merchandiser. Figure 37. Air Filter Location © 2008-201, IMI Cornelius Inc. - 51 - Publication Number: 621260373SER... -
Page 57: Semi-Annual Maintenance
Cleaning the Syrup Connections Syrup connections should be cleaned at least every six months, or when syrup types are changed. Perform the procedure in Table 36. to clean the BIB connec- tors. © 2008-201, IMI Cornelius Inc. - 52 - Publication Number: 621260373SER... -
Page 58: Servicing Motorman Dispensing Valves
Figure 38. Self-Closing Dispensing Valve Table 37. Step Action Defrost freeze cylinders, shut unit down, disconnect electrical power from Unit. Perform the procedure in Table 38. to empty the barrels. © 2008-201, IMI Cornelius Inc. - 53 - Publication Number: 621260373SER... - Page 59 Do not overtighten. Overtightening results in a high activation force on the valve. NOTE: Use Dow-Corning DC-111 (P/N 321471000) light grade silicone lubri- cant to lubricate the o-rings. © 2008-201, IMI Cornelius Inc. - 54 - Publication Number: 621260373SER...
-
Page 60: Sanitizing The System
Connect a sanitizing fitting (p/n cc 28688) to the BIB connector. Put the con- nector in the bucket of water. Make sure the Product/BRIX valve is in the BRIX position. © 2008-201, IMI Cornelius Inc. - 55 - Publication Number: 621260373SER... -
Page 61: Sanitizing The Barrel
BRIX tube. Turn the Product/BRIX valve in the Product position. Manually override (open) the syrup flow valve to fill the barrel with sanitizing solution. © 2008-201, IMI Cornelius Inc. - 56 - Publication Number: 621260373SER... -
Page 62: Flushing The System
Perform a BRIX setup. See “BRIX Setup Menu” on page 40. Fill the barrel with product as described in Table 21. Perform motor calibration. See “Calibrating a Motor” on page 44. © 2008-201, IMI Cornelius Inc. - 57 - Publication Number: 621260373SER... -
Page 63: Cleaning The Water Filter
Remove the filter and rinse it under running water to remove any debris. Reassembe the filter. Connect and turn on the water supply to the unit. Check the filter for any leaks. Replace the rear cover. Reconnect power to the unit. © 2008-201, IMI Cornelius Inc. - 58 - Publication Number: 621260373SER... -
Page 64: Component Replacement
Remove the seal and spacer from the rear of barrel. When old seal and spacer are removed, use a clean soft cloth to clean between the motor shaft and the barrel to remove any remaining product. © 2008-2012, IMI Cornelius Inc. - 61 - Publication Number: 621260373SER... -
Page 65: Installing A New Seal
Clean the drip tray and tube using warm water. Perform the seal leak test in Table 45.. Spacer (Note Orientation) Motor Shaft Figure 41. View of Motor Shaft with Spacer on Shaft Publication Number: 621260373SER - 62 - © 2008-2012, IMI Cornelius Inc. -
Page 66: Motor Seal Leak Test
Table 43. and Table 44. must be rea- peated. If there are no leaks, turn the 3-way Product Supply valve to the BRIX position. © 2008-2012, IMI Cornelius Inc. - 63 - Publication Number: 621260373SER... -
Page 67: Barrel Motor Replacement
The motor run capacitors, shown in Figure 44, are mounted at the rear of the unit between the barrel motors. To replace a run capacitor, perform the proce- dure in Table 47.. Publication Number: 621260373SER - 64 - © 2008-2012, IMI Cornelius Inc. -
Page 68: Water Pump Replacement
To replace the pump, perform the procedure in Table 48.. Water Pump Figure 45. Rear View of Water Pump © 2008-2012, IMI Cornelius Inc. - 65 - Publication Number: 621260373SER... -
Page 69: Co Shutoff Solenoid Replacement
To replace one of these solenoids, perform the procedure in Table 49.. Metering Orfice Shutoff Valve Shutoff Solenoid Figure 46. Side View of CO Shutoff Solenoid (2 Barrel Unit) Publication Number: 621260373SER - 66 - © 2008-2012, IMI Cornelius Inc. -
Page 70: Syrup And Water Shutoff Solenoid Replacement
Figure 47. Perform the procedure in Table 50. to replace the valves. Water Shutoff Valves & Solenoids Syrup Shutoff Valves & Solenoids Figure 47. View of Shutoff Solenoids w/ Access Panel Removed (2 Barrel Unit) © 2008-2012, IMI Cornelius Inc. - 67 - Publication Number: 621260373SER... -
Page 71: Co Regulator Replacement
Figure 48. To replace the regulators, perform the procedure in Table 51.. Publication Number: 621260373SER - 68 - © 2008-2012, IMI Cornelius Inc. -
Page 72: Condenser Fan Motor Replacement
The fan motor is located on the top of the unit, as shown in Figure 49. If the motor needs replacement, perform the procedure in Table 52. to remove and reinstall a motor. © 2008-2012, IMI Cornelius Inc. - 69 - Publication Number: 621260373SER... -
Page 73: Compressor Replacement
Unsweat the suction line from the compressor. Cut the discharge line on top of the compressor (Make sure line can be spliced back together.) Remove the compressor and unsweat the discharge line. Publication Number: 621260373SER - 70 - © 2008-2012, IMI Cornelius Inc. -
Page 74: Hot Gas Solenoid Replacement
Action Reverse the procedure to install the new compressor. Replace the dryer. Evacuate the system and recharge it according to the Cornelius nameplate on the unit. Replace the side panels and rear cover. Reconnect power to the unit and test the unit. -
Page 75: Liquid Line Solenoid Replacement
There is one switch for each barrel in the system. Figure 52 shows the syrup pressure switch on the left side of the unit. To replace the syrup pressure switch, perform the procedure in Table 56.. Publication Number: 621260373SER - 72 - © 2008-2012, IMI Cornelius Inc. -
Page 76: Water Pressure Switch Replacement
Access to the switch is obtained by removing the left side panel of the unit, when viewed from the rear. To replace the water pressure switch, perform the procedure in Table 57.. Water Pressure Switch © 2008-2012, IMI Cornelius Inc. - 73 - Publication Number: 621260373SER... -
Page 77: Display Board Replacement
Unplug the two (2) connectors from the display board. Remove the four (4) screws from the corners of the board. Replace the board with a new board. Reverse the procedure to install the new board. Publication Number: 621260373SER - 74 - © 2008-2012, IMI Cornelius Inc. -
Page 78: Control Board Replacement
With version 3.0 software release several of the boards used to control the equipment will not be backward compatible with boards containing version 2.x of the software. Please refer to the table below for compatibility. © 2008-2012, IMI Cornelius Inc. - 75 - Publication Number: 621260373SER... -
Page 79: Motor Board Replacement
Disconnect power from the unit. Connect a static strap to your wrist and any convenient chassis ground on the unit. Unplug the eight (8) connectors from the control board. Publication Number: 621260373SER - 76 - © 2008-2012, IMI Cornelius Inc. - Page 80 Replace the board with a new board. Reverse the procedure to install the new board. Mounting Studs Figure 56. View of Motor Board in E-Box © 2008-2012, IMI Cornelius Inc. - 77 - Publication Number: 621260373SER...
-
Page 81: Troubleshooting
B. Replace beater bar. C. Broken drive coupler. C. Replace the drive coupler. D. No defrost. D. Program defrosts in unit. E. Are defrosts programmed all E. Reprogram to all days. days? © 2008-2012, IMI Cornelius Inc. - 72 - Publication Number: 621260373SER... -
Page 82: Troubleshooting Product Not Cold
A. Bad connection. A. Correct wiring. B. Bad sensor. B. Replace sensor. C. Sensor out of position. C. Reposition sensor and clip. D. Defective product delivery board. D. Replace. Publication Number: 621260373SER - 73 - © 2008-2012, IMI Cornelius Inc. - Page 83 Viper Service Manual © 2008-2012, IMI Cornelius Inc. - 74 - Publication Number: 621260373SER...
- Page 85 IMI Cornelius Inc. www.cornelius.com...