Cornelius VIPER, VIPER E Service Manual

VIPER (E) 3 FLAVOR

LOW OVERRUN

Service Manual

Release Date: May 10, 2016

Publication Number: 621360241LOEWSE

Revision: A

Visit the 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 Warranty 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.

This document contains the original instructions for the unit described.

CORNELIUS INC

101 Regency Drive

Glendale Heights, IL

Tel: + 1 800-238-3600

Printed in U.S.A.

TABLE OF CONTENTS

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(Carbon Dioxide) Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Manual Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Low Dispensing Volume Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Carbonation Level in Liquid Product Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Freezing Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Syrup System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control Panel Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Unit Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Error Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Error Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Clock Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting Daylight Savings Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Events Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Setting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Setting the Sleep and Wakeup Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Setting Defrost Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Viscosity Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Option Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Temperature Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Date Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setting the Time Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setting the POS Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setting the Type of Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Barrel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Barrel Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Purging a Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Filling a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Run the Barrel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Rinsing a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Manual Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Totals Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

BRIX Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motor Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Calibrating a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

System Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Maintaining Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dispensed Product Throughput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Programmed Defrost Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Sleep Mode Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Viscosity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Starting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cleaning Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Semi-Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Inspecting and Replacing Scraper Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cleaning the Syrup Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Servicing Motorman Dispensing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Sanitizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Emptying a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Flushing the System of Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Sanitizing the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Barrel Motor Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Removing the Existing Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing a New Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Motor Seal Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Barrel Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Motor Run Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Pulse Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Syrup and Water Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Condenser Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Hot Gas Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Liquid Line Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Syrup Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Water Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Software Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Motor Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting Product Not Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SAFETY INSTRUCTIONS

DANGER:

WARNING:

CAUTION:

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

This is the safety alert symbol. When you see it in this manual or on the unit, be

alert to the potential of personal injury or damage to the unit.

Viper Low overrun Service Manual

Different Types of Alerts

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.

SAFETY TIPS

• 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 appliance is not intended for use by very young children or infirm persons 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 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 water jet could be used.

Viper Low overrun Service Manual

WARNING:

CAUTION:

WARNING:

CAUTION:

DANGER:

WARNING:

QUALIFIED SERVICE PERSONNEL

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.

IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER, ITS SERVICE AGENT OR SIMILARLY QUALIFIED PERSONS IN ORDER TO AVOID A HAZARD.

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

Do not use dispense spigot to lift or move unit as this could result in personal injury.

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.

CO2 (CARBON DIOXIDE) WARNING

CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and soft drink system. If a CO 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.

2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the

2 gas

MOUNTING IN OR ON A COUNTER

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 damage to the equipment.

NOTE: Many units incorporate the use of additional equipment such as ice makers. 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.

THE APPLIANCE HAS TO BE PLACED IN A HORIZONTAL POSITION.

Viper Low overrun Service Manual

INTRODUCTION

MANUAL OVERVIEW

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

Viper Low overrun Service Manual

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 CO

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 have 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. Each product formulation has its own peculiarities regarding the way the product absorbs carbonation and the way it releases carbonation.

BRIX Affects Overrun

Sugar in carbonated drinks is like anti-freeze in water. The higher the BRIX, the greater the resistance of the product to freezing. Conversely, in products with lower BRIX, freezing takes place at higher temperatures 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.

Figure 1.

Low Dispensing Volume Affects Overrun

When a unit sits idle for 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 dispensed. The result is that these first drinks have less overrun than drinks dispensed during peak-use periods.

2 gas has less tendency to break out as the drink is

Carbonation Level in Liquid Product Affects Overrun

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 gas breakout in frozen carbonated form and more overrun than drinks that contain 2.0 volumes of CO

2 gas.

Freezing Affects Overrun

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”.

Viper Low overrun 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.

THEORY OF OPERATION

The refrigeration system schematic is shown in Figure 2. It shows the basic configuration for the Viper refrigeration system.

The wiring diagram of the 3-Barrel Viper unit is shown in Figure 3. This diagram shows the details of the electrical connections in the unit.

Viper Low overrun Service Manual

Figure 2. Low overrun Viper System 3-Barrel Refrigeration Schematic

Viper Low overrun Service Manual

Figure 3. Low overrun Viper 3-Barrel Wiring Diagram

Viper Low overrun Service Manual

FCB Unit

ylppuS2O

BIB Syrup

BIB Pump

Water Filter

Connections

Tubing

1/2 Inch Beverage Tubing

3/8 Inch Beverage Tubing

1/4 Inch Beverage Tubing

3/8 Inch Tygon Tubing

1/2 Inch Hose Barb to 3/4 NPT

1/4 Inch Female Flare Nut and Barb (1/4)

Direct Connection to Syrup Outlet on Syrup Pump

Direct Connection to CO2 Inlet on Syrup Pump

Direct Connection to Syrup Inlet on Syrup Pump

1/2 to 3/8 Inch Fitting Reducer

Water Inlet

Syrup Line 1

Syrup Line 2

CO2 Inlet

BIB Syrup

BIB Syrup BIB Pump

BIB Pump

Syrup Line 3

Syrup Line 4

¼ Inch Cross Barb

CO2 Regulator

3/8 Inch TEE Barb

3/8 Inch Flare Nut and Barb (3/8)

3/8 to 1/4 Inch Fitting Reducer

Max 3 Feet

3 Feet Typical

115 Psig

75 Psig

An overall schematic of the three delivery systems contained in the unit are shown in Figure 5. The CO2 system is on top, the water system is in the middle and the syrup system is at the bottom of the diagram. The CO

2 system

interacts with both the water and syrup systems. It provides pressure and carbonation for the syrup/water product mix.

CO2 System

A CO2 tank or bulk CO2 supply delivers carbon dioxide gas (CO2) to an adjustable secondary CO2 regulator assembly that is attached to the tank as shown in Figure 4 The CO pump, the expansion tank regulator and the secondary CO

2 enters the expansion tank regulator and is reduced to approximately 30 psig to feed holding pressure on the

2 tank regulators.

expansion tank. This provides a force to work against the barrel pressure when the product freezes and expands.

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 the CO

From the in-line check valve, the CO

2 control solenoids through preset orifices and on to the in-line check valves.

2 flows into the product line.

2 system also supplies CO2 to the water boost

2 pressure is applied to

Figure 4. Cylinder CO2 Connection

Viper Low overrun 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.

Table 1.

Settings

Nominal Settings FCB 3 50% 7 PSIG

Syrup Type

Set

NOTE: For citric syrups, adjust the CO

the lower CO

2 adsorption.

Viscosity CO2 Setting Expansion

2 pressures down by 2-4 PSIG from the above to compensate for

Viper Low overrun Service Manual

Figure 5. 3-Barrel System Schematic

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.

Viper Low overrun Service Manual

Menu Buttons

Area

Display

BARREL STATUS

12:51P MAR 04

#1 FREEZE 87 #2 FREEZE 68

MENU ON OFF DFRST SPIN

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. 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.

Control Panel Display

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.

Figure 6. Control System Display

Viper Low overrun Service Manual

Initialization

Screens

Barrel

Status

(Home Screen)

Error Status

Unit Data

Error Log

Clock Setup

Event Setup

Option Setup

Viscosity Setup

Brix Setup

Motor Setup

Barrel Maint.

Manual Diag

Totals

Barrel Data

Unit Data

Software Ver.

Setup

Sub-Menus

Main

Sub-Menus

Maintenance

Sub-Menus

System Setup

CO2 Setup

Barrel Maint.

Control Panel Buttons

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.

Figure 7. Software Structure

Viper Low overrun Service Manual

BARREL STATUS

12:51P MAR 04

#1 FREEZE 87 #2 FREEZE 68

MENU ON OFF DFRST SPIN

BACK MAIN SETUP MAINT GO

SELECT

12:51P MAR 04

UNIT DATA ERROR STATUS ERROR LOG

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. Refer to Table 2 for button functions.

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

Initiates a manual defrost on the highlighted barrel. Manual defrost is

DFRST

SPIN Turns off refrigeration, if on and mixes the product in the barrel.

limited 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.

Figure 9. Select Screen

Viper Low overrun Service Manual

UNIT DATA

12:51P MAR 04

#1 FREEZE OUTLET TEMP 33

F VISCOSITY: 9 REFRIGERATION: ON

DEFROST TIMER: 2:50:23

BACK BRL UNIT VER

AV OZ/HR/3 HR: 80

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 toTable 4 for button functions.

Figure 10. Unit Data Screen

Table 4.

Button Description

BACK Returns the display to the Select menu

Displays the data for a single barrel, including Outlet Temperature, Vis-

BRL

UNIT

VER

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

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.

Displays the version number of the UI, I/O, Motor and Status boards installed in the unit

Error Status Menu

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.

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

Table 5.

+ 46 hidden pages

Cornelius VIPER, VIPER E Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual