Cornelius Viper E 2 Flavor Service Manual
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Cornelius Viper E 2 Flavor Service Manual

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See also: Installation Manual
VIPER (E) 2 FLAVOR, VIPER (E) 3 FLAVOR
& VIPER (E) 4 FLAVOR
Service Manual
Carbon model
Classic model
Release Date: November 06, 2008
Publication Number: 621260373SER
Revision Date: May 10, 2016
Revision: N
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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Summary of Contents for Cornelius Viper E 2 Flavor

  • Page 1 VIPER (E) 2 FLAVOR, VIPER (E) 3 FLAVOR & VIPER (E) 4 FLAVOR Service Manual Carbon model Classic model Release Date: November 06, 2008 Publication Number: 621260373SER Revision Date: May 10, 2016 Revision: N Visit the 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 Safety Instructions ............. . . 1 Read and Follow ALL Safety Instructions .
  • Page 4 Setting the Sleep and Wake up Times ........27 Setting Defrost Lockout .
  • Page 5 Cleaning the Water Filter ........... . . 50 Component Replacement .

  • Page 7: Safety Instructions

    • Keep your unit in proper working condition and do not allow unauthorized modifications to the unit. NOTE: The dispenser is not designed for a wash-down environment and MUST NOT be placed in an area where a water jet could be used. © 2008-2016, Cornelius Inc. - 1 - Publication Number: 621260373SER...

  • Page 8: Qualified Service Personnel

    The above listed mounting bolts must be installed and the wheels extended and locked in the outboard position prior to moving the unit. Failure to comply could result in serious injury, death or equipment damage. Publication Number: 621260373SER - 2 - © 2008-2016, Cornelius Inc.

  • Page 9: 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 © 2008-2016, Cornelius Inc. - 3 - Publication Number: 621260373SER...

  • Page 10: Dispensed Product Conditions

    Freezing causes approximately a 5-7 percent expansion in dispensed frozen carbonated drinks. 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 - 4 - © 2008-2016, Cornelius Inc.

  • Page 11: System Overview

    Figure 4. and the wiring diagram of the 4-Barrel Viper unit is shown in Figure 5.. These diagrams show the details of the electrical connections in the unit. © 2008-2016, Cornelius Inc. - 5 - Publication Number: 621260373SER...
  • Page 12 Viper Service Manual Figure 1. Viper System 2-Barrel Refrigeration Schematic Publication Number: 621260373SER - 6 - © 2008-2016, Cornelius Inc.
  • Page 13 Viper Service Manual Figure 2. Viper System 3-Barrel Refrigeration Schematic © 2008-2016, Cornelius Inc. - 7 - Publication Number: 621260373SER...
  • Page 14 Viper Service Manual Figure 3. Viper System 4-Barrel Refrigeration Schematic Publication Number: 621260373SER - 8 - © 2008-2016, Cornelius Inc.
  • Page 15 Viper Service Manual Figure 4. Viper 2-Barrel Wiring Diagram (W/Transducer) © 2008-2016, Cornelius Inc. - 9 - Publication Number: 621260373SER...
  • Page 16 Viper Service Manual Figure 5. Viper 3-Barrel Wiring Diagram Publication Number: 621260373SER - 10 - © 2008-2016, Cornelius Inc.
  • Page 17 Viper Service Manual Figure 6. Viper 4-Barrel Wiring Diagram © 2008-2016, Cornelius Inc. - 11 - Publication Number: 621260373SER...

  • Page 18: Co2 System

    3/8 to 1/4 Inch Fitting Reducer Water Filter 115 Psig 75 Psig BIB Syrup BIB Pump BIB Pump BIB Syrup BIB Syrup BIB Pump BIB Syrup BIB Pump Figure 7. Cylinder CO Connection Publication Number: 621260373SER - 12 - © 2008-2016, Cornelius Inc.
  • Page 19 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. © 2008-2016, Cornelius Inc. - 13 - Publication Number: 621260373SER...
  • Page 20 Viper Service Manual Figure 8. 2-Barrel System Schematic Publication Number: 621260373SER - 14 - © 2008-2016, Cornelius Inc.
  • Page 21 Viper Service Manual Figure 9. 3-Barrel System Schematic © 2008-2016, Cornelius Inc. - 15 - Publication Number: 621260373SER...
  • Page 22 Viper Service Manual Figure 10. 4-Barrel System Schematic Publication Number: 621260373SER - 16 - © 2008-2016, Cornelius Inc.

  • Page 23: Water System

    The control panel display has two main areas. The first area is the menu display area. This area presents information about the status and settings of the machine. It also displays menus of actions that are taken to modify the functioning of the machine. © 2008-2016, Cornelius Inc. - 17 - Publication Number: 621260373SER...

  • Page 24: Control Panel Buttons

    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 - 18 - © 2008-2016, Cornelius Inc.

  • Page 25: Control Panel Menu Descriptions

    The Barrel Status menu, shown in Figure 13., is the home screen for the unit. During normal operation, this screen is displayed on the control panel. © 2008-2016, Cornelius Inc. - 19 - Publication Number: 621260373SER...

  • Page 26: Main Menu

    Refer to Table 3, the Select menu, for button functions. Table 3. Button Description BACK Returns the display to the Barrel Status menu MAIN Highlighted to indicate current menu SETUP Opens the Setup menu Publication Number: 621260373SER - 20 - © 2008-2016, Cornelius Inc.

  • Page 27: Unit Data Menu

    Table 5. Table 5. Error Type Description A System error displays the same information across all barrels in the System unit. Barrel A Barrel error is limited to a specific barrel © 2008-2016, Cornelius Inc. - 21 - Publication Number: 621260373SER...
  • Page 28 Motor stalled. A two minute defrost and two retries are allowed, then the Barrel STALL message is displayed, METER FAIL Barrel Metering chip is nonresponsive. Barrel viscosity is too high. Motor cannot rotate. Automatic two minute Barrel RECOVER defrost to thaw barrel. Publication Number: 621260373SER - 22 - © 2008-2016, Cornelius Inc.

  • Page 29: Error Log Menu

    #3 COMM FAIL OCCUR: 2:44 PM 3/04/08 12:51P CLEAR: 2:52 PM MAR 04 3/04/08 BACK Figure 17. Error Log Screen Button Description BACK Returns the display to the Select menu © 2008-2016, Cornelius Inc. - 23 - Publication Number: 621260373SER...

  • Page 30: Setup Menu

    MAR 04 BACK CLOCK Figure 19. Clock Setup Screen Table 9. Button Description BACK Returns the display to the Select menu CLOCK Highlighted to indicate that the Clock menu is displayed Publication Number: 621260373SER - 24 - © 2008-2016, Cornelius Inc.

  • Page 31: Setting The Clock

    Figure 20. If daylight savings time is off, press the + button to activate it. The button functions are described in Table 12. To set daylight savings time, perform the procedure in Table 13. NOTE: Default daylight savings settings are for the U.S. © 2008-2016, Cornelius Inc. - 25 - Publication Number: 621260373SER...
  • Page 32 The choices are 1, 2, 3 or When the daylight savings settings are complete, press the BACK button to save the settings and return to the Select menu, shown in Figure 18. Publication Number: 621260373SER - 26 - © 2008-2016, Cornelius Inc.

  • Page 33: Events Setup Menu

    Step Action Procedure Set sleep and wake up Open the Events Setup menu, shown in Figure 21. by pressing the GO button. times Select DAY The DAY field is highlighted. © 2008-2016, Cornelius Inc. - 27 - Publication Number: 621260373SER...

  • Page 34: Setting Defrost Lockout

    Repeat Steps 2 through 10 for the DEFROST LOCK 3 time, if desired. When the defrost lockout settings are complete, press the BACK button to save the settings and return to the Select menu, shown in Figure 18. Publication Number: 621260373SER - 28 - © 2008-2016, Cornelius Inc.

  • Page 35: Viscosity Setup Menu

    Refer to Table 18 for a listing of the button functions for the various field selections. OPTION TEMP FORMAT DATE FORMAT SETUP TIME FORMAT 12 HR POS LIGHTING ALWAYS #1 SYRUP TYPE: 12:51P #2 SYRUP TYPE: MAR 04 BACK Figure 23. Option Setup Screen © 2008-2016, Cornelius Inc. - 29 - Publication Number: 621260373SER...

  • Page 36: Setting The Temperature Format

    The Maintenance menu is used for barrel maintenance, diagnostics, BRIX setup and system information. It allows the technician access to the unit during periodic maintenance or troubleshooting problems. It sometimes overrides the normal inputs from the system in order to perform this task. Publication Number: 621260373SER - 30 - © 2008-2016, Cornelius Inc.

  • Page 37: Barrel Maintenance Menu

    When the barrel is completely empty, close the dispensing valve and press Complete the proce- the STOP button at the bottom of the display to turn off the purge. Press the dure BACK button to return to the Select menu. © 2008-2016, Cornelius Inc. - 31 - Publication Number: 621260373SER...

  • Page 38: Filling A Barrel

    Override Water Sole- and fill the barrel with plain water. Use the relief noid valve on the faceplate of the barrel to relieve pres- sure and completely fill the barrel. Publication Number: 621260373SER - 32 - © 2008-2016, Cornelius Inc.

  • Page 39: Manual Diagnostic Menu

    To move between one set of barrel parameters to the next, press the Right or Left arrow keys. This moves the highlight to the first entry of the second barrel, etc. © 2008-2016, Cornelius Inc. - 33 - Publication Number: 621260373SER...

  • Page 40: Totals Menu

    BRIX comparison can be made between samples. To perform a BRIX test, perform the procedure in Table 25. Table 25. Step Action Procedure Set status of barrels Make sure the status of all barrels is OFF on the control display. Publication Number: 621260373SER - 34 - © 2008-2016, Cornelius Inc.
  • Page 41 Replace the hoses and the access panel. Secure the panel with the two Replace access panel screws removed in Step 2. This completes the procedure. #1 OFF BRIX #2 OFF SETUP 12:51P MAR 04 BACK BRIX STOP Figure 28. BRIX Setup Screen © 2008-2016, Cornelius Inc. - 35 - Publication Number: 621260373SER...
  • Page 42 Supply Supply Valve Valve Barrel 1 Barrel 2 Flow Flow Controls Controls Barrel 1 Barrel 2 Valves shown in BARREL position w/ Splash Panel Removed Figure 31. Product Control Valves Publication Number: 621260373SER - 36 - © 2008-2016, Cornelius Inc.

  • Page 43: Motor Setup Menu

    Table 26. Model Motor Type All 60 Hz All 50 Hz MOTOR #1 MOTOR TYPE 1 #2 MOTOR TYPE 2 SETUP 12:51P MAR 04 BACK Figure 33. Motor Setup Screen © 2008-2016, Cornelius Inc. - 37 - Publication Number: 621260373SER...

  • Page 44: Calibrating A Motor

    At that time the motor stops and it is cali- brated. Complete the proce- Press the BACK button at the bottom of the display to return to the Maintenance dure menu. Publication Number: 621260373SER - 38 - © 2008-2016, Cornelius Inc.

  • Page 45: System Menu

    Main menu, security is re-activated and the Maintenance menu is not accessible. To disable security, access the System menu, highlight Security and press the OFF button. © 2008-2016, Cornelius Inc. - 39 - Publication Number: 621260373SER...

  • Page 46: Pressure Sensors

    NOTE: If a pressure sensor is open, the pressure reading is 386 PSIG. UNIT LINE VOLTAGE: LINE FREQUENCY: 60 DATA LOW PSIG #1: HIGH PSIG #1: 12:51P MAR 04 BACK UNIT Figure 36. Unit Data Screen Publication Number: 621260373SER - 40 - © 2008-2016, Cornelius Inc.

  • Page 47: Operation

    Sleep Mode Recommendations Cornelius recommends programming a sleep period for the machine during any amount of time over 3 hours that the unit is not used. This increases the life of the machine and reduces energy consumption.

  • Page 48: Viscosity Setting

    Viper Service Manual A wake up time must be programmed after the sleep period to return the unit to normal operation. Cornelius rec- ommends programming the wake up time for approximately 20 minutes before the product is needed. This is the time recommended if the ambient temperature is at 75°F.

  • Page 49: Preventative Maintenance

    Cleaning Air Filter The air filter should be cleaned at least once a month (more often in harsh environments). Perform the procedure in Table 34. to clean the air cleaner. © 2008-2015, Cornelius Inc. - 43 - Publication Number: 621260373SER...

  • Page 50: Semi-Annual Maintenance

    Remove the four (4) 3/4 in. nuts from the faceplate and slowly remove the faceplate from the unit. Slowly pull the blade assembly out of the barrel. Rinse and inspect the blade assembly for signs of wear. Publication Number: 621260373SER - 44 - © 2008-2015, Cornelius Inc.

  • Page 51: Cleaning The Syrup Connections

    Caged O-rings should be replaced every 12 months. Refer to Figure 38 and perform the procedure in Table 37. to lubricate or change the caged o-rings in each dis- pensing valve on the unit. © 2008-2015, Cornelius Inc. - 45 - Publication Number: 621260373SER...
  • Page 52 Submerge all the parts in a 4-percent solution of approved sanitizing agent for the amount of time recom- mended by the sanitizer manufacturer. Remove the parts from the sanitizing solution and place them on clean paper towels. Assemble the dispensing valve. Publication Number: 621260373SER - 46 - © 2008-2015, Cornelius Inc.

  • Page 53: Sanitizing The System

    Flushing the System of Syrup After emptying the barrel, the barrel should be flushed of product before proceeding with the sanitizing procedure. Perform the procedure in Table 39. © 2008-2015, Cornelius Inc. - 47 - Publication Number: 621260373SER...

  • Page 54: Sanitizing The Barrel

    Fill the barrel with sanitizing solution by opening the faceplate relief valve until sanitizing solution comes out of the relief port. Hold a 16 oz. cup under the dispense valve. Hold the dispense valve fully open until the cup is full. Publication Number: 621260373SER - 48 - © 2008-2015, Cornelius Inc.

  • Page 55: Flushing The System

    Perform a BRIX setup. See “BRIX Setup Menu” on page 34. Fill the barrel with product as described in Table 20. Perform motor calibration. See “Calibrating a Motor” on page 38. © 2008-2015, Cornelius Inc. - 49 - Publication Number: 621260373SER...

  • Page 56: Cleaning The Water Filter

    Remove the filter and rinse it under running water to remove any debris. Reassemble 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. Publication Number: 621260373SER - 50 - © 2008-2015, Cornelius Inc.

  • Page 57: Component Replacement

    Installing a New Seal Perform the procedure in Table 44., Figure 41 and Figure 42 to replace the barrel seal with a new seal. © 2008-2016, Cornelius Inc. - 51 - Publication Number: 621260373SER...
  • Page 58 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 - 52 - © 2008-2016, Cornelius Inc.

  • Page 59: Motor Seal Leak Test

    The barrel motor does not require any special alignment when being replaced. It mounts on four (4) bolts. These bolts are screwed into threaded bosses in the foam pack barrel assembly, as shown in Figure 43. To replace a barrel motor, perform the procedure in Table 46. © 2008-2016, Cornelius Inc. - 53 - Publication Number: 621260373SER...

  • Page 60: Motor Run Capacitor 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 procedure in Table 47. Motor Run Motor Run Capacitor Capacitor Figure 44. View of Motor Run Capacitors Publication Number: 621260373SER - 54 - © 2008-2016, Cornelius Inc.

  • Page 61: Water Pump Replacement

    Remove the four (4) screws and locknuts holding the pump to the mounting bracket. Replace the pump. Reverse the procedure to install the new pump. © 2008-2016, Cornelius Inc. - 55 - Publication Number: 621260373SER...

  • Page 62: Co2 Shutoff Solenoid Replacement

    The syrup and water shutoff valves and solenoids are mounted on a single bracket, as shown in Figure 47. Per- form the procedure in Table 50. to replace the valves. Publication Number: 621260373SER - 56 - © 2008-2016, Cornelius Inc.

  • Page 63: Co2 Regulator Replacement

    Figure 48. To replace the regulators, perform the procedure in Table 51. © 2008-2016, Cornelius Inc. - 57 - Publication Number: 621260373SER...

  • Page 64: 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. Locking Locking Nuts Nuts Figure 49. Condenser Fan Mounting Nuts Publication Number: 621260373SER - 58 - © 2008-2016, Cornelius Inc.

  • Page 65: Compressor Replacement

    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 66: 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 - 60 - © 2008-2016, Cornelius Inc.

  • Page 67: 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 Figure 53. View of Water Pressure Switch © 2008-2016, Cornelius Inc. - 61 - Publication Number: 621260373SER...

  • Page 68: Display Board Replacement

    This protects the electronic components from any static charge while working on the unit. The control board is located in the E-Box. It is mounted to the panel on four (4) plastic mounting studs, shown in Figure 55. Publication Number: 621260373SER - 62 - © 2008-2016, Cornelius Inc.

  • Page 69: Backward/Forward Compatibility With Older Software Versions

    “H20 OUT” will be displayed followed 30 seconds later with “X BRL TEMP OUT”. If either of these messages is displayed after changing a control board check the software version. The current software ver- © 2008-2016, Cornelius Inc. - 63 -...

  • Page 70: Motor Board Replacement

    Squeeze each of the mounting studs at the corners of the board while care- fully lifting the board. Replace the board with a new board. Reverse the procedure to install the new board. Publication Number: 621260373SER - 64 - © 2008-2016, Cornelius Inc.
  • Page 71 Viper Service Manual Mounting Studs Figure 56. View of Motor Board in E-Box © 2008-2016, Cornelius Inc. - 65 - Publication Number: 621260373SER...

  • Page 72: Troubleshooting

    “open”. windings and check incoming line voltage. E. Open or shorted compressor wind- E. Check resistance of compressor ings. windings. F. Bad control board. F. Troubleshoot, replace if necessary. Publication Number: 621260373SER - 66 - © 2008-2016, Cornelius Inc.
  • Page 73 Sensors 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. © 2008-2016, Cornelius Inc. - 67 - Publication Number: 621260373SER...
  • Page 75 Cornelius Inc. www.cornelius.com...

This manual is also suitable for:

Viper e 4 flavorViper e 3 flavor

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