Cornelius FRUITISTA 3 User Manual
FRUITISTA VIPER 3 FLAVOR
Service Manual
Release Date: September 9, 2010
Publication Number: 621360041TBSER
Revision Date: N/A
Revision: A
Visit the IMI Cornelius web site at www.cornelius.com
for all your Literature needs.
The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible
contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and
mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject
to all of the restrictions and limitations contained in the 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
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 persons
to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating,
cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100% compatible with
the Product) which use voids the entire warranty, (13) Product parts in contact with water or the product dispensed
which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2010, All rights reserved, IMI Cornelius Inc.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Different Types of Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dispensed Product Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overrun, as Applied to Carbonated Beverages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overrun Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overrun is a Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specific Product Ingredients Affect Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRIX Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Low Dispensing Volume Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Carbonation Level in Liquid Product Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Freezing Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CO2 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Syrup System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Panel Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Unit Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Error Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Error Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clock Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting Daylight Savings Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Events Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting the Sleep and Wakeup Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting Defrost Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Viscosity Setup Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CO2 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Option Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setting the Temperature Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the Date Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the Time Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the POS Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the Type of Syrup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Barrel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Barrel Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Purging a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Filling a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Run the Barrel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rinsing a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Manual Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Totals Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRIX Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motor Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Calibrating a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Maintaining Product Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dispensed Product Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Programmed Defrost Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Sleep Mode Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Viscosity Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CO2 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Monthly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cleaning Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Semi-Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspecting and Replacing Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cleaning the Syrup Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Servicing Motorman Dispensing Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Sanitizing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Emptying a Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flushing the System of Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sanitizing the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Flushing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cleaning the Water Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Barrel Motor Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removing the Existing Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing a New Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Motor Seal Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Barrel Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Motor Run Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Water Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CO2 Pulse Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Syrup and Water Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Condenser Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hot Gas Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Liquid Line Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Syrup Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Water Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Software Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Troubleshooting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Troubleshooting Product Not Cold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Viper Installation Manual
MANUAL OVERVIEW
INTRODUCTION
The organization of this manual allows the user to scan quickly to the subject of
interest along the left side of a page and to read the detail about the subject or
procedure on the right side of the page. The manual provides the detail needed for
newcomers to the industry while allowing experienced technicians to skip over the
details and move quickly through the material.
This manual is designed as a guide to the technician in maintaining and servicing
the Viper system. The Viper system is simple in design and has built-in features
and diagnostic controls to help the service technician quickly and accurately
service the machine.
The unit consists of multiple freeze barrels that each contain an internal beater
driven by a rear mounted electric motor, a refrigeration system, timer-controlled,
automatic hot gas defrost system and interconnecting tubing and controls
required to dispense the product.
Some of the system features and functions are listed below:
• 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
2
© 2010, IMI Cornelius Inc. - 1 - Publication Number: 621360041TBSER
Viper Installation Manual
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any
warning/caution labels on the unit (decals, labels or laminated cards).
• Read and understand ALL applicable OSHA (Occupational Safety and
Health Administration) safety regulations before operating this unit.
Recognition
Recognize Safety Alerts
!
Different Types of Alerts
SAFETY TIPS
This is the safety alert symbol. When you see it in this manual or on the unit, be
!
Indicates an immediate hazardous situation which if not avoided WILL result in
serious injury, death or equipment damage.
!
Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
!
Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
alert to the potential of personal injury or damage to the unit.
DANGER:
WARNING:
CAUTION:
• Carefully read and follow all safety messages in this manual and safety
signs on the unit.
• Keep safety signs in good condition and replace missing or damaged
items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appli-
ance is not intended for use by very young children or infirm persons
Publication Number: 621360041TBSER - 2 - © 2010, IMI Cornelius Inc.
Viper Installation Manual
without supervision. Young children should be supervised to ensure
that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthor-
ized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO
NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN
SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
SAFETY PRECAUTIONS
This unit has been specifically designed to provide protection against personal
injury. To ensure continued protection observe the following:
Disconnect power to the unit before servicing following all lock 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.
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
Before shipping, storing, or relocating the unit, the unit must be sanitized and all
sanitizing solution must be drained from the system. A freezing ambient
environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
!
WARNING:
!
CAUTION:
!
CAUTION:
CO2 (CARBON DIOXIDE) WARNING
© 2010, IMI Cornelius Inc. - 3 - Publication Number: 621360041TBSER
Viper Installation Manual
!
DANGER:
CO
2 displaces oxygen. Strict attention MUST be observed in the prevention of
CO
2 gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, IMMEDIATELY ventilate the contaminated
area before attempting to repair the leak. Personnel exposed to high
concentrations of CO
of consciousness and DEATH.
MOUNTING IN OR ON A COUNTER
!
WARNING:
When installing the unit in or on a counter top, the counter must be able to support
a weight in excess of 450 lbs. to insure adequate support for the unit. FAILURE
TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT
DAMAGE.
Note:
Many units incorporate the use of additional equipment such as icemakers.
When any addition equipment is used you must check with the equipment
manufacturer to determine the additional weight the counter will need to
support to ensure a safe installation.
2 gas experience tremors which are followed rapidly by loss
DISPENSED PRODUCT CONDITIONS
Overrun, as Applied to Carbonated Beverages
Overrun Definition
Overrun is defined as product expansion that takes place in the frozen carbonated
drink. It is caused primarily by CO2 gas breakout and secondarily by freezing.
Overrun is a Variable
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
factors hav been considered, desired viscosity (product consistency) adjustment
may be made on the unit. The viscosity adjustment adjusts product texture from
very wet to light.
Specific Product Ingredients Affect Overrun
Each syrup has its own specific formulation of makeup. Fruit flavors contain citric
acids that colas do not. Colas also differ in ingredients from one brand to another.
Publication Number: 621360041TBSER - 4 - © 2010, IMI Cornelius Inc.
BRIX Affects Overrun
Viper Installation Manual
Each product formulation has its own peculiarities regarding the way the product
absorbs carbonation and the way it releases carbonation.
Sugar in carbonated drinks is like anti-freeze in water. The higher the BRIX, the
greater the resistance of the product to freezing. Conversly, in products with lower
BRIX, freezing takes place at higher termperatures than for high-BRIX products.
Thus, BRIX affects overrun because the amount of sugar in a drink has a direct
bearing on the product’s freezing characteristics.
Low Dispensing Volume Affects Overrun
Carbonation Level in Liquid Product Affects Overrun
Freezing Affects Overrun
When a unit sits idle fo a period of time with no drinks being dispensed, CO2 gas
in the system takes a “set”. When the first few drinks are drawn off after an idle
period, CO
2 gas has less tendancy to break out as the drink is dispensed. The
result is that these first drinks hav less overrun than drinks dispensed during peakuse periods.
The higher the specific carbonation level in a given product, the greater the
potential for carbonation breakout in frozen carbonated form of that drink. 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
2 gas.
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”.
© 2010, IMI Cornelius Inc. - 5 - Publication Number: 621360041TBSER
Viper Service Manual
SYSTEM OVERVIEW
INTRODUCTION
The Viper unit consists of the following systems and hardware:
Multiple freeze barrels, each containing an internal scraper bar driven by an AC
motor.
A refrigeration system and an intelligent, hot gas defrost system.
The components are enclosed in a powder-coated steel frame to prevent corrosion. It is covered with ventilated cladding panels and a lighted merchandiser.
The cladding is easily removable to facilitate installation, service and maintenance.
Each barrel has a transparent faceplate, with an integral relief valve and a
removable, self-closing dispensing valve mounted on the front. A removable drip
tray, with cup rest is located directly below the dispensing valves.
A programmable control system with a control panel that controls operational
and diagnostic functions and settings is located behind the merchandiser.
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Viper Service Manual
THEORY OF OPERATION
The refrigeration system schematic is shown in Figure 1. It shows the basic configuration for the Viper refrigeration system.
The wiring diagram of the 3-Barrel Viper unit is shown in Figure 2. This diagram
shows the details of the electrical connections in the unit.
Figure 1. Fruitista Viper System 3-Barrel Refrigeration Schematic
© 2010, IMI Cornelius Inc. - 7 - Publication Number: 621360041TBSER
Viper Service Manual
Figure 2. Fruitista Viper 3-Barrel Wiring Diagram
Publication Number: 621360041TBSER - 8 - © 2010, IMI Cornelius Inc.
CO2 System
Viper Service Manual
An overall schematic of the three delivery systems contained in the unit are
shown in Figure 5. The CO
and the syrup system is at the bottom of the diagram. The CO
2 system is on top, the water system is in the middle
2 system interacts
with both the water and syrup systems. It provides pressure and carbonation for
the syrup/water product mix.
A CO2 tank or bulk CO2 supply delivers carbon dioxide gas (CO2) to an adjustable secondary CO
Figure 3 and Figure 4. The CO
pump, the expansion tank regulator and the secondary CO
CO
2 enters the expansion tank regulator and is reduced to approximately 30
2 regulator assembly that is attached to the tank as shown in
2 system also supplies CO2 to the water boost
2 tank regulators.
psig to feed holding pressure on the expansion tank. This provides a force to
work against the barrel pressure when the product freezes and expands.
CO
2 also enters the secondary regulators. These regulators are used to adjust
barrel overrun/expansion for various products. The pressure settings for various
types of syrup are shown in Table 1. Overrun CO
2 pressure is applied to the CO2
control solenoids through preset orifices and on to the in-line check valves.
From the in-line check valve, the CO
2 flows into the product line.
Figure 3. Typical Bulk Cylinder CO2 Connection
© 2010, IMI Cornelius Inc. - 9 - Publication Number: 621360041TBSER
Viper Service Manual
Table 1 provides guidelines for machine settings based on general syrup type.
Several factors, including syrup formulation, level of citric acids, etc, will impact
settings. These settings are to provide initial adjustments to achieve product
overruns in the 80-120% range.
Figure 4. Typical Tank CO2 Connection
Table 1
Settings
Nominal Settings FCB 3 50% 7 PSIG
NOTE: For citric syrups, adjust the CO
the above to compensate for the lower CO
Syrup
Type Set
Viscosity CO
2 pressures down by 2-4 PSIG from
2 Setting Expansion
2 adsorption.
Publication Number: 621360041TBSER - 10 - © 2010, IMI Cornelius Inc.
Viper Service Manual
Figure 5. 3-Barrel System Schematic
© 2010, IMI Cornelius Inc. - 11 - Publication Number: 621360041TBSER
Viper Service Manual
Water System
Incoming water flows to a water pressure regulator that is preset to 30 psig. It
flows through the water booster pump, to the regulator and through a sold-out
switch.
Once through the boost pump, the water supply is split to each barrel and is fed
to the water flow controls. From the flow rate control, the water passes through a
single ball check valve and mixes with the syrup in a wye fitting for injection into
the freeze barrel.
Syrup System
Syrup enters the unit through a sold-out switch. It enters a similar flow control to
the water system, passes through a single-ball check valve and into the wye fitting where it meets the water for injection into the freeze barrel.
CONTROL PANEL
Introduction
The Viper unit uses a microprocessor based control system that monitors and
controls all of the major systems and components of the machine. Temperatures
and pressures are monitored, along with pumps, valves and the refrigeration
system. They are managed by the control system to provide a consistently high
quality product with optimal efficiency.
The control system is set up by the service provider to perform the tasks necessary to keep the Viper unit operating correctly. In addition to controlling the unit,
the control system keeps track of the diagnostic information used when adjusting and/or repairing the machine.
The control system needs to be accessed in the following situations:
• Installing the Viper
• Modifying Operating Characteristics
• Checking Performance
• Servicing/Repairing the Machine
• Checking for Error Messages
The control system is accessed using the control panel located behind the
lighted merchandiser. The control panel contains an LCD display and buttons
shown in Figure 6.
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
can be secured (locked out) so that an operator does not have access to them.
Publication Number: 621360041TBSER - 12 - © 2010, IMI Cornelius Inc.
Viper Service Manual
Control Panel Display
The control panel has a structured organization of menus. The outline of this
structure is shown in Figure 7. The Maintenance sub-menu is not visible when
the security feature is on.
The first menu that is displayed after the unit is powered up and stabilized is the
BARREL STATUS or HOME menu, shown in Figure 6. This menu is displayed
when the unit is running in normal operation.
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.
Control Panel Buttons
Menu
BARREL
STATUS
#1 FREEZE 87
#2 FREEZE 68
Display
Area
12:51P
MAR 04
MENU ON OFF DFRST SPIN
Menu Buttons
Figure 6. Control System Display
The second area are the buttons and arrows located across the bottom and on
the right side of the control panel. There are up to five buttons and four directional arrows that may be used on a screen to activate and control various the
functions of the system. Each button that is active for a given menu has a label
directly above it. The label describes what that button controls. For example,
from the Barrel Status menu, pressing button 1 (labeled MENU) displays the
Select menu with more options — pressing button 3 (labeled OFF) turns off the
highlighted barrel.
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.
© 2010, IMI Cornelius Inc. - 13 - Publication Number: 621360041TBSER
Viper Service Manual
Initialization
Main
Sub-Menus
Screens
Unit Data
Barrel Data
Barrel
Status
(Home Screen)
Setup
Sub-Menus
Clock Setup
Event Setup
Option Setup
Maintenance
Sub-Menus
Barrel Maint.
Manual Diag
Totals
Error Status
Error Log
Unit Data
Software Ver.
Figure 7. Software Structure
Viscosity Setup
CO2 Setup
Barrel Maint.
Brix Setup
Motor Setup
System Setup
Publication Number: 621360041TBSER - 14 - © 2010, IMI Cornelius Inc.
Viper Service Manual
CONTROL PANEL MENU DESCRIPTIONS
The following section describes the information displayed on each control panel
menu and the interactions and settings that are controlled by that menu.
System Menus
The system menu structure allows the user to control the unit through the control
panel. Operational settings, optional parameters, troubleshooting and error
information are controlled through this menu system.
The Barrel Status menu, shown in Figure 8, is the home screen for the unit.
During normal operation, this screen is displayed on the control panel.
BARREL
STATUS
12:51P
MAR 04
MENU ON OFF DFRST SPIN
#1 FREEZE 87
#2 FREEZE 68
Figure 8. Main Screen
Table 2
Button Description
MENU Displays the Main menu
ON Turns on the highlighted barrel
OFF Turns off the highlighted barrel
DFRST Initiates a manual defrost on the highlighted barrel. Manual defrost is lim-
SPIN Turns off refrigeration, if on and mixes the product in the barrel.
ited to a two minute cycle. If the barrel is off, this selection initiates a full
defrost cycle.
Main Menu
To access the menus for the system from the Barrel Status menu, press the
MENU button. This displays the Select menu, shown in Figure 9. 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.
© 2010, IMI Cornelius Inc. - 15 - Publication Number: 621360041TBSER
Viper Service Manual
SELECT
12:51P
MAR 04
BACK MAIN SETUP MAINT GO
UNIT DATA
ERROR STATUS
ERROR LOG
Figure 9. Select Screen
When the Select menu is displayed, the Unit Data is highlighted. To access the
Unit Data menu, press the GO button. 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
MAINT Displays and opens Maintenance menu, if security is off or accessed
GO Opens the highlighted selection on the current menu
Unit Data Menu
The Unit Data screen, shown in Figure 10, provides information about the
individual barrels in the system. When DATA is highlighted and the GO button is
pressed on the Select menu, the display shows the first barrel in the system and
some of its parameters. To view the next barrel, press the Down arrow on the
right side of the display. Continue pressing the Down arrow to view the data on
all barrels in the system. Refer to Table 4 for button functions.
UNIT
DATA
12:51P
MAR 04
BACK BRL UNIT VER
#1 FREEZE
OUTLET TEMP 33
VISCOSITY: 9
REFRIGERATION: ON
AV OZ/HR/3 HR: 80
DEFROST TIMER: 2:50:23
o
F
Figure 10. Unit Data Screen
Table 4
Button Description
BACK Returns the display to the Select menu
BRL Displays the data for a single barrel, including Outlet Temperature, Vis-
cosity, if Refrigeration is On or Off, Average Ounces of product dispensed
per hour for the last three hours and Defrost Lock Time until next defrost
Publication Number: 621360041TBSER - 16 - © 2010, IMI Cornelius Inc.
Error Status Menu
Viper Service Manual
Table 4
Button Description
UNIT Displays the real time input voltage and frequency being supplied to the
unit and the low, high or both refrigeration pressures for the unit, depending on the settings of the compressor sensors in the Unit Data screen, as
shown in Figure 31.
VER Displays the version number of the UI, I/O, Motor and Status boards
installed in the unit
The Error Status menu, shown in Figure 11, displays any current errors contained in the Error Messages List.
There are three types of errors that can be generated by the system. These
error types and a description of their meaning are listed in Table 5.
Table 5
Error Type Description
System A System error displays the same information across all barrels in the unit.
Barrel A Barrel error is limited to a specific barrel
Limp A Limp error is an error that doesn’t prevent the unit from operating, but limits
functionality.
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
STATUS
12:51P
MAR 04
BACK
#1 MOTOR PWR
COMP HIGH
Figure 11. Error Status Screen
Table 6
Displayed
Message
HOT GAS Off System Occurs when the barrel outlet temperature exceeds
HOT BARREL Off System Occurs when the barrel outlet temperature exceeds
MTR CTL FAIL System The motor controller reported a fault, triacs are
TCO OPEN System TCO (Temperature Cut Off) has occurred on the
Action Type Description
o
F for more than one minute and the compres-
115
sor is on.
o
115
F for more than one minute and the compres-
sor is off.
shorted and there is a loss of motor on/off functionality.
refrigeration oulet of a barrel or the 24VAC power
has failed.
© 2010, IMI Cornelius Inc. - 17 - Publication Number: 621360041TBSER
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