IMI Cornelius, Inc. VIPER 4 FLAVOR Service Manual
VIPER 2 FLAVOR, VIPER 3 FLAVOR &
VIPER 4 FLAVOR
Service Manual
Release Date: October 28, 2008
Publication Number: 621260373SER
Revision Date: August 6, 2010
Revision: E
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cart Information and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dispensed Product Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overrun, as Applied to Carbonated Beverages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overrun Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overrun is a Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Product Ingredients Affect Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRIX Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Low Dispensing Volume Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Carbonation Level in Liquid Product Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Freezing Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CO2 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Syrup System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control Panel Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
System Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Error Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Error Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clock Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Events Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Setting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Setting the Sleep and Wakeup Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Viscosity Setup Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Barrel Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manual Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Totals Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
BRIX Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Motor Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pressure Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintaining Product Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dispensed Product Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Programmed Defrost Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sleep Mode Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Viscosity Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Monthly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Semi-Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inspecting and Replacing Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cleaning the Syrup Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Servicing Motorman Dispensing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Sanitizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emptying a Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sanitizing the Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flushing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cleaning the Water Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Barrel Motor Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removing the Existing Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installing a New Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Motor Seal Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Barrel Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor Run Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Water Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CO2 Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Syrup and Water Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CO2 Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Condenser Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hot Gas Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Liquid Line Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Syrup Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Water Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Control Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Backward/Forward Compatibility with Older Software Versions . . . . . . . . . . . . . . . . . . . . . . . . 71
Motor Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Troubleshooting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Troubleshooting Product Not Cold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Viper Service 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
© 2008-2009, IMI Cornelius Inc. - 1 - Publication Number: 621260373SER
Viper Service 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
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.
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in
serious injury, death or equipment damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
!
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and
safety signs on the unit.
Publication Number: 621260373SER - 2 - © 2008-2009, IMI Cornelius Inc.
Viper Service Manual
• 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.
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:
!
WARNING:
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.
!
CAUTION:
Always be sure to keep area around the unit clean and free of clutter. Failure to
keep this area clean may result in injury or equipment damage.
© 2008-2009, IMI Cornelius Inc. - 3 - Publication Number: 621260373SER
Viper Service Manual
SHIPPING AND STORAGE
!
CAUTION:
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
!
DANGER:
CO2 displaces oxygen. Strict attendtion MUST be observed in the prevention of
CO2 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.
2 gas experience tremors which are followed rapidly by loss
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 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.
CART INFORMATION AND MOUNTING
These carts are also designed with movable wheels that act as outriggers to
provice stability to the unit when it is being moved.
to insure adequate support for the unit. FAILURE
Publication Number: 621260373SER - 4 - © 2008-2009, IMI Cornelius Inc.
Viper Service Manual
!
WARNING:
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.
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
Specific Product Ingredients Affect Overrun
BRIX Affects Overrun
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.
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.
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.
© 2008-2009, IMI Cornelius Inc. - 5 - Publication Number: 621260373SER
Viper Service Manual
Low Dispensing Volume 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, CO2 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
peak-use periods.
Carbonation Level in Liquid Product Affects Overrun
Freezing 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 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”.
Publication Number: 621260373SER - 6 - © 2008-2009, IMI Cornelius Inc.
INTRODUCTION
Viper Service Manual
SYSTEM OVERVIEW
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.
© 2008-2010, IMI Cornelius Inc. - 7 - Publication Number: 621260373SER
Viper Service Manual
THEORY OF OPERATION
The refrigeration system schematic is shown in Figure 1. It provides the basic
configuration for the Viper refrigeration system.
The wiring diagram of the 2-Barrel Viper unit is shown in Figure 4, the wiring diagram of the 3-Barrel Viper unit is shown in Figure 5 and the wiring diagram of the
4-Barrel Viper unit is shown in Figure 6. These diagrams show the details of the
electrical connections in the unit.
Figure 1. Viper System 2-Barrel Refrigeration Schematic
Publication Number: 621260373SER - 8 - © 2008-2010, IMI Cornelius Inc.
Viper Service Manual
Figure 2. Viper System 3-Barrel Refrigeration Schematic
© 2008-2010, IMI Cornelius Inc. - 9 - Publication Number: 621260373SER
Viper Service Manual
Figure 3. Viper System 4-Barrel Refrigeration Schematic
Publication Number: 621260373SER - 10 - © 2008-2010, IMI Cornelius Inc.
Viper Service Manual
J3
J4
BACKLIGHT
1
+
1
J3
PUSH
BUTTONS
BACKLIGHT
Merchandiser Panel
J6
DISPLAY
Front Panel E-Box
BRN
BRN
T1 L1
T2 L2
BLU
BRN
CONTACTOR
BRN
BRN
BLU
T3 L3
LCD BOARD
J5
RS232
BLU
BLU
BLU
1314
A1A2
620314871
1
J4
RED
Panel 2
620512776
Panel 1
620512776
RED
J
J
J
24VAC
1
+
2
DC-DC
Convertor
1
+
4
1
+
2
J7
J3
1
18
YLW
YLW
DownLight
620512775
620607120
1
1
DownLight
620512775
Motor
620314868
1
1
J8
EXPANSION PORT
1
J2J1
1
1
J3
J2
J8
(Logic)
Expansion
(Power)
Expansion
J7
Controller
J6
1
1
J9
J10
I/O BOARD
620314869
1
RED
RED
RED/WHITE
L2CL2A L2B
EXTENDER
620314875
LED STATUS
L1CL1A L1B
MAIN
620314874
LED STATUS
Run
Capacitor
M2
1
1
Run
Capacitor
M1
1
1
B1
Sensor
Pressure
#1
B2
Sensor
Pressure
J200
J100
BRN\ WH
BLU\ WH
1
BRN
BLU
1
J5
Syrup Soldout B1
Syrup Soldout B2
Barrel Pressure B1
Barrel Pressure B2
H2O Sold-Out
CO2 Sold-Out
B1
TCO
Outlet Temp B1
Outlet Temp B2
HGS B1
LLS B1
LLS B2
HGS B2
H20 B2
SYRUP B2
C02 B2
C02 B1
H20 B1
SYRUP B1
11
J2
RED
9
BLK
1
BLU
BLK
BLU
RED
BLK
1
ORG
5
BLK/WH
ORG/WH
BRN
7
BLK
ORG
1
BRN/WH
ORG/WH
YEL
BLU
BRN
10
BLK
1
ORG
BLK
YEL
BLU
BRN/WH
ORG/WH
J2J11 J4 J5 J6
YEL/WH
BLU/WH
1
VIO
BLK
RED
RED
B2
TCO
NOTE: #1 IS OPTIONAL PRESSURE SENSOR
RED
block
Terminal
(60Hz)
Or
(50Hz)
EMI Filter
CAP1
Rear Panel E-Box
CAP2
BLK
YEL
GRN/YEL
SRC
BRN
COMPRESSOR
BLK
BLU
GRN/YEL
FAN
CONDENSER
LEGEND
Indicates Splice that
happens in Connector
Indicates Connector
Cresent - Female
Pressure Switch Shown
with no pressures applied
24VAC Solenoid
Temperature
Thermistor
Cut-Off Switch
L2L1PE
620410577 REV B
Figure 4. Viper 2-Barrel Wiring Diagram
© 2008-2010, IMI Cornelius Inc. - 11 - Publication Number: 621260373SER
Viper Service Manual
J2
1
620314875
LED Status
1
J1
1
620314875
LED Status
1
1
1
620314874
LED Status
1
J7
J3
1
EXPANSION PORT
18
Expander
Expander
Main
1
620314868
J9
L3CL3A L3B
L2CL2A L2B
L1CL1A L1B
Motor
620314873
J8
Expansion
Motor Controller
1
J8
620314869
J3
DownLiht
Panel
Backliht
620512776
Panel
Backliht
620512776
Panel
Backliht
620512776
620512775
J3
DownLiht
620512775
J3
DownLiht
620512775
PUSH
BUTTONS
J6
LCD BOARD
DISPLAY
620314871
1
J4
J5
RS232
Front Panel E-Box
BLU
BRN
620043050
AC-DC Converter
LEGEND
Indicates Splice that
Indicates Connector
Cresent - Female
Merchandiser Panel
J200
BRN/BLK
BLU/BLK
J100
Expander
(Loic)
(Power)
Expansion
J7
1
J6
1
J10
I/O BOARD
BRN\ WH
BLU\ WH
J200
BRN
BLU
J100
BLU
BRN
J5
J2
1
1
BRN
7
ORG
BRN/WH
J4
ORG/WH
YEL
BLU
BLK
1
RED
9
BLK
BLU
WH
RED
J6
BLK
1
ORG
BLK/WH
ORG/WH
BLK
J5
ORG/BLK
RED
1
RED
YEL
YEL
J11
BLK
1
BRN
BLK
ORG
YEL
BLU
BRN/WH
J2
ORG/WH
YEL/WH
BLU/WH
BLK
VIO
BLK
11
GRY
BLK
BRN/BLK
BLK
ORG/BLK
YEL/BLK
BLU/BLK
Pressure Switch
happens in Connector
Shown with no
24VAC Solenoid
Run
Capacitor
Run
Capacitor
Run
Capacitor
Sensor CMP1
Hi-Side Press.
Sensor CMP1
Lo-Side Press.
Thermistor
pressures applied
M3
1
1
M2
1
1
M1
1
1
Syrup Soldout B1
Syrup Soldout B2
Fill Switch B1
Fill Switch B2
H2O Soldout
CO2 Soldout
#1
Temperature Cut-Off
Switch
Outlet Temp B1
Outlet Temp B2
Outlet Temp B3
HGS B1
LLS B1
HGS B2
LLS B2
H20 B1
SYRUP B1
C02 B1
C02 B2
H20 B2
SYRUP B2
NOTE: ITEMS MARKED #1 ARE OPTIONAL
BLK
BLK
BLK
HGS B3
LLS B3
BLK
H20 B3
SYRUP B3
C02 B3
BLK
BRN
BLU
Or
(60Hz)
(50Hz)
EMI Filter
Terminal block
BRN
T1 L1
CONTACTOR
T2 L2
BRN
BRN
BLU
BLU
BLU
1314
A2A1
T3 L3
Rear Panel E-Box
GRN/YEL
RED
RED
RED
RED
FAN
CONDENSER
RED/WHITE
BRN/BLK
ORG/BLK
B1
TCO
B2
TCO
B3
B3
TCO
TCO
620314870
I/O Expander
24VAC
YLW
YLW
RED
RED
24VAC
YLW
YLW
RED
CAP1
BLK
YEL
GRN/YEL
SRC
GRY
BLK
CAP2
BLK
BRN
BLU
COMPRESSOR
Syrup Soldout B3
Fill Switch B3
620042848 REV A
Figure 5. Viper 3-Barrel Wiring Diagram
Publication Number: 621260373SER - 12 - © 2008-2010, IMI Cornelius Inc.
Viper Service Manual
J3
620512775
DownLight
Panel
620512776
Backlight
J3
620512775
DownLight
Panel
620512776
Backlight
J3
620512775
DownLight
Panel
620512776
Backlight
J3
620512775
DownLight
Panel
620512776
Backlight
PUSH
BUTTONS
J6
DISPLAY
Front Panel E-Box
BRN
BLU
BRN
T1 L1
CONTACTOR
LCD BOARD
620314871
1
J4
J5
RS232
BLU
BRN
BLU
BLU
BRN
BLU
BRN
1314
A2A1
T2 L2
T3 L3
620043050
AC-DC Converter
24VAC
24VAC
J2
J1
J2
J1
1
1
J7
1
18
YLW
YLW
RED
RED
YLW
YLW
1
Expander
620314875
LED Status
1
1
Expander
620314875
LED Status
1
1
Expander
620314875
LED Status
1
1
Main
620314874
LED Status
1
J3
EXPANSION PORT
L4CL4A L4B
L3CL3A L3B
LEGEND
L2CL2A L2B
Merchandiser Panel
L1CL1A L1B
Motor
Expander
620314873
J8
(Loic)
(Power)
Expansion
Expansion
J7
620314868
1
Motor Controller
J6
1
1
J8
J10
I/O BOARD
620314869
620314870
I/O Expander
GRY
BLK
1
7
J4
9
J6
J5
J11
J2
11
RED
RED
RED
RED
J9
Indicates Splice that
happens in Connector
Indicates Connector
Cresent - Female
BRN/GRY
BLU/GRY
J200
BRN/BLK
BLU/BLK
J100
BRN\ WH
BLU\ WH
J200
BRN
BLU
J100
BLU
BRN
J5
J2
1
BRN
ORG
BRN/WH
ORG/WH
YEL
BLU
BLK
1
RED
BLK
BLU
WH
RED
BLK
1
ORG
BLK/WH
ORG/WH
BLK
ORG/BLK
BLK/GRY
ORG/GRY
RED
1
RED
YEL
YEL
BLK
1
BRN
BLK
ORG
YEL
BLU
BRN/WH
ORG/WH
YEL/WH
BLU/WH
BLK
VIO
BLK
GRY
BLK
BRN/BLK
BLK
ORG/BLK
YEL/BLK
BLU/BLK
BRN/GRY
ORG/GRY
YEL/GRY
BLU/GRY
BLK
BRN/BLK
ORG/BLK
BRN/GRY
ORG/GRY
RED/WHITE
24VAC Solenoid
Pressure Switch
Shown with no
pressures applied
Run
Capacitor
1
Run
Capacitor
1
Run
Capacitor
1
Run
Capacitor
1
Sensor CMP1
Hi-Side Press.
#1
Sensor CMP1
Lo-Side Press.
B1
TCO
Temperature Cut-Off
Thermistor
M4
1
M3
1
M2
1
M1
1
Syrup Soldout B1
Syrup Soldout B2
Fill Switch B1
Fill Switch B2
H2O Soldout
CO2 Soldout
Outlet Temp B1
Outlet Temp B2
Outlet Temp B3
Outlet Temp B4
B2
TCO
Switch
HGS B1
LLS B1
HGS B2
LLS B2
H20 B1
SYRUP B1
C02 B1
C02 B2
H20 B2
SYRUP B2
TCOB3TCO
NOTE: ITEM MARKED #1 ARE OPTIONAL
BLK
BLK
B4
HGS B3
LLS B3
LLS B4
HGS B4
H20 B3
SYRUP B3
C02 B3
C02 B4
H20 B4
SYRUP B4
Syrup Soldout B3
Fill Switch B3
Syrup Soldout B4
Fill Switch B4
BLK
BLK
RED
CAP2
BLK
YEL
GRN/YEL
SRC
COMPRESSOR
GRN/YEL
BLK
BRN
BLU
FAN
CONDENSER
620046599 REV A
Or
(60Hz)
(50Hz)
EMI Filter
Terminal block
CAP1
Rear Panel E-Box
Figure 6. Viper 4-Barrel Wiring Diagram
© 2008-2010, IMI Cornelius Inc. - 13 - Publication Number: 621260373SER
Viper Service Manual
An overall schematic of the three delivery systems contained in the unit are
shown in Figure 9, Figure 10 and Figure 11. 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 CO2 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 7 and Figure 8. The CO2 system also supplies CO2 to the water boost
pump, the expansion tank regulator and the secondary CO2 tank regulators.
CO2 enters the expansion tank regulator and is reduced to approximately 30
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.
CO2 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 CO2 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
Figure 7. Typical Bulk Cylinder CO2 Connection
2 flows into the product line.
Publication Number: 621260373SER - 14 - © 2008-2010, IMI Cornelius Inc.
Viper Service Manual
Figure 8. Typical Tank CO2 Connection
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
Syrup Type
FCB Syrup w/
Foaming Agent
FCB Syrup w/o
Foaming Agent
FUB FUB 7 N/A 30
NOTE: For citric syrups, adjust the CO
Syrup
Type Set
FCB 4 34-36 PSIG 30
FCB 4 32-36 PSIG 30
Viscosity Pressure Expansion
2 pressures down by 2-4 PSIG from
the above to compensate for the lower CO2 adsorption.
© 2008-2010, IMI Cornelius Inc. - 15 - Publication Number: 621260373SER
Viper Service Manual
Figure 9. 2-Barrel System Schematic
Publication Number: 621260373SER - 16 - © 2008-2010, IMI Cornelius Inc.
Viper Service Manual
Figure 10. 3-Barrel System Schematic
© 2008-2010, IMI Cornelius Inc. - 17 - Publication Number: 621260373SER
Viper Service Manual
Figure 11. 4-Barrel System Schematic
Publication Number: 621260373SER - 18 - © 2008-2010, IMI Cornelius Inc.
Water System
Syrup System
Viper Service Manual
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 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 12.
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
© 2008-2010, IMI Cornelius Inc. - 19 - Publication Number: 621260373SER
Loading...