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FCB VIPER Service Manual

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4. 1 Disconnect power from the unit Remove the access panel two 2 screws and the right side panel Turn off the CO2 source and then turn the Product valve 90 degrees to the off position 4 Relieve pressure in the barrel by opening the relief valve on the faceplate of both barrels 5 Disconnect the three 3 supply lines at the rear of the regulators using a small wrench Remove the two lock nuts from the mounting bracket in back of the regulators Remove the pressure switch wires from the regulators O 2008 2009 IMI Cornelius Inc 63 Publication Number 621260373SER Viper Service Manual CCGineliis Table 50 Step Action 8 Remove the assembly and replace the defective regulator 9 Reverse the procedure to install the regulator assembly 10 Check the system for leaks after repressurizing the system 11 Reset the regulator to the desired setting CONDENSER FAN MOTOR REPLACEMENT The fan motor is located on the top of the unit as shown in Figure 49 If the motor needs replacement perform the procedure in Table 51 to remove and reinstall a motor Locking Nuts Locking Nuts Figure 49 Condenser Fan Mounting Nuts Table 51 Step Action Disconnect power from the unit Disconnect the fan by unplugging the connector Remove the four locking nuts securing the fan to the top of the condenser Lift the fan and shroud off the unit
5. Mounting 5 Studs Ly o z z 4 2 Figure 56 View of Motor Board in E Box 71 Publication Number 621260373SER Viper Service Manual TROUBLESHOOTING THE SYSTEM TROUBLESHOOTING days Problem Probable Cause Remedy Unit will not run A Unit not plugged in A Plug in unit B Circuit breaker B Reset replace circuit breaker C No power at L1 or L2 on contac C Check voltage at outlet tor Check wiring to contactor D Low voltage at T1 or T2 D Replace the contactor Sleep display on bar A Sleep time set A Check sleep programming rel status menu B Clock incorrectly set B Check sleep programming C No wake time set C Check sleep programming Barrel status OFF A Not activated A Turn to ON DFRST or SPIN B Error has shut off motors B Correct error amp turn to ON DFRST or SPIN C Unit in Diagnostics C Exit diagnostics amp turn to ON DFRST or SPIN D Defective touch switch D Replace Low High voltage A Line Voltage out of SPEC specis A 1 Check line voltage ERROR 205 255 VAC for 60 Hz and 196 2 Check T1 T2 with Compressor 265 VAC for 50 Hz running B Error range 180 260 B Correct line voltage Frozen Barrel A Low Brix A Correct cause and reset Brix B Broken beater bar B Replace beater bar C Broken drive coupler C Replace the drive coupler D No defrost D Program defrosts in unit E Are defrosts programmed all E Reprogram
6. Note Do not lubricate the static side outer portion of the seal This could cause the seal to rotate in the bore and leak 6 Carefully slide the seal over the motor shaft and press it firmly until is fully seated against the spacer and the seal cannot be pushed any further 7 Run your finger around the perimeter of the seal to insure it is flush against the back of the barrel 8 Reinstall the blade assembly Rotate the assembly while inserting it to insure that it is fully seated on the motor shaft Figure 30 9 Lubricate the faceplate o ring 10 Re install the faceplate and replace the four 4 mounting nuts Hand tighten the nuts until the faceplate makes contact with the gasket then use a wrench to tighten the nuts an additional 1 4 turn Be careful not to overtighten the nuts or cracking of the faceplate may result 11 Clean the drip tray and tube using warm water 12 Perform the seal leak test in Table 44 Spacer N Figure 41 View of Motor Shaft with Spacer on Shaft 57 Publication Number 621260373SER Viper Service Manual Motor Seal Leak Test Figure 42 Side View of Seal and Spacer on Motor Shaft After replacing the motor seal it is advisable to test the seal under pressure before refilling the barrel with product Perform the procedure in Table 44 to ver ify that the seal is installed properly and not leaking When the seal passes the leak test perform the motor calibration routine on page 40
7. Solenoids sa Figure 47 View of Shutoff Solenoids w Access Panel Removed 2 Barrel Unit Table 49 Step Procedure 1 Disconnect power from the unit 2 Disconnect and bleed the water and syrup lines to remove pressure from the system Remove the rear cover and side panels Remove the water and syrup lines from the input to the valves Remove the Wye tube from the output top of the valves by loosening the nuts between the Wye and the check valves Tr Check Valves Wye Retaining Nuts Publication Number 621260373SER 62 O 2008 2009 IMI Cornelius Inc C Ginclius gt Viper Service Manual Table 49 Step Procedure 6 Remove the two 2 locknuts from the base of the assembly and remove it from the unit 7 Remove the check valve from the valve being replaced 8 Install the check valve on the new valve and solenoid 9 Remove the valve and solenoid from the mounting bracket and replace it 10 Reverse the procedure to reinstall the bracket into the unit 11 Reconnect power to the unit and test the system CO2 REGULATOR REPLACEMENT The CO2 regulators are located at the center of the unit in back of the access panel as shown in Figure 48 To replace the regulators perform the procedure in Table 50 CO2 Regulators A AS Figure 48 Front view of CO2 Regulators w Access Panel Removed 2 Barrel Unit Table 50 Step Action
8. If BRIX is not within the proper range adjust the syrup water mixture by opening or closing the syrup valve shown in Figure 32 and then retest 13 Clear hose When BRIX measurement is complete press the valve on the bottom of the appropriate water solenoid to flush out the hose before closing the valve at the end of the hose 14 Set product supply valve Turn product supply valve back to the BARREL position for the barrel you tested See Figure 31 15 Replace access panel Replace the hoses and the access panel Secure the panel with the two screws removed in Step 2 This completes the procedure BRIX 1 OFF SETUP 2 OFF 12 51P MAR 04 BACK BRIX STOP Splash Panel Retaining Screws Figure 30 Splash Panel Mounting Screws 38 2008 2009 IMI Cornelius Inc CGineliis Viper Service Manual fi hall Product oy SE Valve alve Barrel 1 Barrel 2 Flow Controls A Barrel 1 Barrel 2 Valves shown in BARREL position w Splash Panel Removed Figure 31 Product Control Valves 2 Barrel Unit Manual Manual Water Control Syrup Control Valve Valve Syrup Flow Control Water Flow Control Do Not Adjust Figure 32 Flow Controls Motor Setup Menu Motor setup is initially done at the factory and does not need to be changed unless a barrel motor or barrel components are replaced adjusted or removed and reinstalled This menu allows you to select diff
9. Select the CLOCK SETUP menu from the Select menu shown in Figure 19 This displays the Clock Setup menu shown in Figure 20 To set the time perform the procedure in Table 11 Table 11 Step Action Procedure 1 Set clock time Use up and down arrows on the right side of the con trol panel to highlight TIME display on screen 2 Select hour field Use the left and right arrows to select hour field 26 2008 2009 IMI Cornelius Inc Setting Daylight Sav ings Time O 2008 2009 IMI Cornelius Inc Viper Service Manual Table 11 Step Action Procedure 3 Set correct hour Use the or buttons at the bottom of the display to set the proper hour 4 Select minute field Use the left and right arrows to select minute field 5 Set correct minute Use the or buttons at the bottom of the display to set the proper minute 6 Select AM PM field If the 12 hour clock option is selected use the left and right arrows to select the AM PM field 7 Set AM PM Use the button at the bottom of the display to set the AM PM setting To set the date perform the procedure in Table 12 and refer to Figure 20 Table 12 Step Action Procedure 1 Set date Use up and down arrows on the right side of the con trol panel to highlight DATE display on screen 2 Select month field Use the left and right arrows to select month field 3 Set correct month Use the or butt
10. s 9T sc fe Na pang Dane Maan AT ng NA a L he en BT 19 Control Panel Buttons e See tarea rad es 19 Control Panel Menu Descriptions 25 dh eta saw RR fe ms CRISE ER RE RI a DS ANG rg e 21 System Mentus xcd epe ec A Sas pas Ae Sade edd dien 21 LISTER Ista rM P nr PA 21 Unt Data Menu asi iu a dos Bete icem sette A Si 22 Error Status Men uu se tones pb et es e X COE ER NAN an e Rep toe diet e eo us 23 Error bog MS ts voe Man ab dd A a ANS c iL errat Me Da BAR pa a a 25 SN A tee ater Deis Deer t oce e a Te d Erde tof pta e e i qd 25 Clock Setup Men usas ne RON el D PROS TERR wate DUIS qe CODES 26 Setting the Clock sese ants REI a pu axe ee rase AUS 26 Setting Daylight Savings TIME iu uta deat re Rome tin pate dale NG e 27 Events Setup Menu s nts aba Se eat ae gee Eque esu eq i wie ees 28 Setting Events casa a e A 29 Setting the Sleep and Wakeup Times 29 Setting Defr st Locko t aeir ta as ai a ta ER E T 30 Viscosity Setup Menu ae Rasa PS 31 Options Setup MONI daos a A e an dl EEN E 31 Setting the Temperature FONMAt lenn nen ee 32 Setting the TEE 32 Setting the Time Format cores ee EEN 32 Setting the POS Lighting s ia xis c ER HL oU etc o aa 32 Setting the Type of Syrup ss Rb RE RE NG kape eA a Eod 33 Maintenance Menus os cansas ERU FUE NT NER ie re RAM EUR p 903 Bele eek 33 Barrel Maintenance Menu i2 ren ade Rx deed veio An dees ee Ys 33 Purging a BSrtel siue e e PEE ERE Saw ase W
11. when viewed from the rear of the unit Access to the switch is obtained by removing the left side panel of the unit when viewed from the rear To replace the water pressure switch perform the procedure in Table 56 2008 2009 IMI Cornelius Inc 67 Publication Number 621260373SER Viper Service Manual Water Pressure Switch Figure 53 View of Water Pressure Switch Table 56 Action Disconnect power from the unit Remove the side panel from the unit Turn off the water supply to the unit Drain the water from the system Disconnect the wires from the switch Remove the switch using two wrenches Replace the switch with a new unit Reverse the procedure to install the new switch o o o ula a afon FF o Restore the water supply and check for leaks A o Check to ensure that the new switch is working properly DisPLAY BOARD REPLACEMENT Publication Number 621260373SER When replacing or testing electronic components be sure to wear a static strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The display board is located on the back of the control panel display It is mounted to the panel with four 4 phillips head screws shown in Figure 54 Mounting Mounting Screws Screws Figure 54 View of Display Board 68 O 2008 2009 IMI Corn
12. Remove the four screws and washers securing the fan to the shroud Replace the fan Reverse the procedure to install the new fan 0 TO O E wo P Reconnect power to the unit COMPRESSOR REPLACEMENT Caution should be used when working with refrigerants To replace a compres sor perform the procedure in Table 52 NOTE Be sure to reclaim refrigerant when replacing compressor Publication Number 621260373SER 64 O 2008 2009 IMI Cornelius Inc Ginelus 3 Viper Service Manual Table 52 Step Action Disconnect power to the unit Remove the rear cover and side panels Label and disconnect all wires from the compressor Remove the four 4 mounting nuts from the base of the compressor Remove all insulation from around fittings Unsweat the suction line from the compressor NIIAJ E oO Mm Cut the discharge line on top of the compressor Make sure line can be spliced back together 8 Remove the compressor and unsweat the discharge line 9 Reverse the procedure to install the new compressor 10 Replace the dryer 11 Evacuate the system and recharge it according to the Cornelius nameplate on the unit 12 Replace the side panels and rear cover 13 Reconnect power to the unit and test the unit Hor Gas SOLENOID REPLACEMENT The hot gas valves and solenoids shown in Figure 50 are located near the cen te
13. SETUP TEMP FORMAT OF DATE FORMAT TIME FORMAT USA 12 HR POS LIGHTING ALWAYS 12 51P MAR 04 1 SYRUP TYPE 2 SYRUP TYPE FCB FCB BACK op 0G EBENEN aa Figure 24 Option Setup Screen Table 19 Option Button 2 Button 3 Button 4 Button 5 Temp Format F C Date Format USA EURO Time Format 12 HR 24 HR POS Lighting OFF ALWAYS SLEEP 1 SYRUP TYPE FCB FCB L FUB FUB L X SYRUP TYPE FCB FCB L FUB FUB L When all the options are set to the desired settings for the unit press the BACK button to store these settings and return to the Select menu shown in Figure 19 The temperature format displayed by the unit may be set to either Centigrade or Farenheit Press the F button to display readings in Farenheit and press the C button to display readings in Centigrade The date format can be displayed in either United States or European format To display U S date format press the USA button This displays the date in mm dd yy format Press the EURO button to display the date in dd mm yy format Time format can be displayed in either 12 or 24 hour format To display the clock settings in 12 hour format 1 08 P press the 12 HR button To display settings in 24 hour format 23 05 press the 24 HR button POS Lighting is controlled by the POS LIGHTING field on the Option Setup menu Figure 24 To turn off the merchandiser lighting press the OFF button 32 O 20
14. SETUP button to display the Setup menu shown in Figure 19 To set up the unit options use the Up and Down arrows on the right side of the control panel to highlight the choices on the display When the desired option is highlighted press the GO button to access that menu SELECT CLOCK SETUP EVENTS SETUP VISC SETUP OPTION SETUP 12 51P MAR 04 BACK MAIN SETUP MAINT GO EBENEN aa Figure 19 Setup Screen 25 Publication Number 621260373SER Viper Service Manual CG Clock Setup Menu Setting the Clock Publication Number 621260373SER Table 9 Button Description BACK Returns the display to the Select menu MAIN Opens the Main menu SETUP Highlighted to indicate that the Setup menu is displayed MAINT Displays button and opens Maintenance menu if security is off or accessed GO Opens the highlighted selection on the current menu Select the CLOCK SETUP menu from the Select menu shown in Figure 19 This displays the Clock Setup menu shown in Figure 20 Button functions are described in Table 10 TIME 11 00 AM DATE 01 01 00 ES coxa EBENEN cc Figure 20 Clock Setup Screen Table 10 Button Description BACK Returns the display to the Select menu CLOCK Highlighted to indicate that the Clock menu is displayed DST Opens the Daylight Savings Time menu Decrements the highlighted field Increments the highlighted field
15. a listing of the button functions for the various field selections SYSTEM 4 OF BARRELS 2 OF COMPRESSOR 1 SECURITY OFF NW CMP 1 SENSORS BOTH 12 51P CMP X SENSORS LOW MAR 04 8 VS nm lt Figure 34 System Screen 41 Publication Number 621260373SER Viper Service Manual Security Pressure Sensors Publication Number 621260373SER C Table 31 Display Description OF BARRELS This selection shows the number of barrels in the system and allows the user to change the quantity OF COMPRESSORS This selection shows the number of compressors in the sytem Currently this number is fixed at one and cannot be changed SECURITY This selection allows the user to turn security on or off CMP X SENSORS This selection allows the user to choose which pressure sensors are read for the compressor Table 32 Option Button 2 Button 3 Button 4 Button 5 of Barrels E of Compressors Security OFF ON Compressor Sensors NONE LOW HIGH BOTH System security is located on the System menu It allows a supervisor or service technician to keep unauthorized personnel from accessing the Maintenance menu This feature is activated on the System menu When security is turned on users can only access the Main and Setup menus The word LOCKED appears in the upper left corner of the display to inform users that security is enabled Pressing the extre
16. based on syrup type Table 18 Step Action Procedure 1 Set viscosity range From the Setup screen Figure 19 open the Viscos ity Setup screen shown in Figure 23 2 Select barrel pee us Up and Down arrows to highlight the desired arrel 3 Select range field Use Left and Right arrows to select range field 4 Set range Use the or buttons at the bottom of the display to set the desired range 5 Select barrel Repeat Steps 2 through 4 for all barrels To set all barrels in the system to the same viscosity setting perform Steps 1 through 4 in Table 18 and then press the ALL button at the bottom of the display while highlighting the viscosity setting you desire for all the barrels When the viscosity settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 19 The Option Setup menu allows the user to set the various options available in the system These options are listed in Table 19 The Option Setup menu is shown in Figure 24 The functions of the display buttons change depending on the highlighted selection on the Option Setup screen Refer to Table 19 for a listing of the button functions for the various field selections 31 Publication Number 621260373SER Viper Service Manual Setting the Temperature Format Setting the Date Format Setting the Time Format Setting the POS Light ing Publication Number 621260373SER OPTION
17. line valve and solenoid Replace the liquid line valve and solenoid and insulation Replace the filter dryer Evacuate the system o o ol oj lo 5 o m o Restore the proper refrigerant charge to the system and verify proper system operation Publication Number 621260373SER 66 O 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual SYRUP PRESSURE SWITCH REPLACEMENT The syrup pressure switches Sold Out Indicators are located along the left and right sides of the unit near the front There is one switch for each barrel in the system Figure 52 shows the syrup pressure switch on the left side of the unit To replace the syrup pressure switch perform the procedure in Table 55 Syrup Pressure Switch 5 Figure 52 View of Syrup Pressure Switch and Valve Table 55 Step Action Disconnect power to the unit Remove the appropriate side panel Turn off the syrup supply to the unit Drain the syrup from the system Disconnect the wires on the pressure switch Remove the switch using two wrenches Replace the switch with a new unit Reverse the procedure to install the new switch OO CO LO GG 60 P Restore the syrup supply and check for leaks o Check switch operation WATER PRESSURE SWITCH REPLACEMENT The water pressure switch shown in Figure 53 is located in back of the water filter
18. of scraper blades See Inspecting and Replacing Scraper Blades on page 49 12 Perform a leak test on the barrel See Motor Seal Leak Test on page 58 Sanitizing the Barrel Sanitize the syrup system and barrel by performing the procedure shown in Table 40 Table 40 Step Action 1 Use a clean 5 gallon pall filled with a sanitizing solution and water at a temper ature of 90 F to 110 F 32 C to 43 C The sanitizing solution must have 200 ppm available chlorine 2 Connect a sanitizing fitting p n cc 28688 to the BIB connector Put the con nector in the bucket of sanitizing solution 3 Make sure the Product BRIX valve in the BRIX position 4 Hold waste container under the BRIX tube to collect flush water from the syrup line and open the manual syrup flow valve to start filling the syrup line with sanitizing solution Continue to hold the syrup flow valve open until sanitizing solution starts coming out of the BRIX tube 5 Turn the Product BRIX valve in the Product position 6 Manually override open the syrup flow valve to fill the barrel with sanitizing solution 7 Fill the barrel with sanitizing solution by opening the faceplate relief valve until sanitizing solution comes out of the relief port 8 Hold a 16 oz cup under the dispense valve Hold the dispense valve fully open until the cup is full 9 Use the brush provided with the unit to clean the relief p
19. seconds then turn barrel OFF by pressing the OFF button To drain the water from the system turn the barrel OFF Place a container under the barrel dispensing valve Open the dispensing valve and dispense all rinse water from the barrel When the pressure in the barrel drops from the Barrel Maintenance menu press the PURGE button to re pressurize the barrel with CO2 As the wash water level lowers in the barrel partially close the valve to avoid spurting Remove the sanitizing fitting p n cc 28688 from the BIB connector and con nect a BIB containing syrup to the syrup line Rotate the Product BRIX valve to the BRIX position and open the valve at the end of the tube Hold a waste container under the BRIX tube to collect the sanitizing solution from the syrup line and open the manual syrup flow valve to start filling the syrup line with syrup Continue to hold open the syrup flow valve until syrup starts coming out of the BRIX tube Perform a BRIX setup See BRIX Setup Menu on page 37 10 Fill the barrel with product as described in Table 21 11 Perform motor calibration See Calibrating a Motor on page 40 Cleaning the Water Filter Publication Number 621260373SER The water filter screen in the rear of the unit should be removed and cleaned every six months during the preventative maintenance procedures To inspect and clean the filter screen perform the procedure in Table 4
20. situation which if not avoided MAY result in minor or moderate injury or eguipment damage Carefully read all safety messages in this manual and safety signs on the machine Keep safety signs in good condition and replace missing or damaged items Do not let anyone operate the machine 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 2 O 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual Keep your machine in proper working condition and do not allow unauthorized modifications to the machine QUALIFIED SERVICE PERSONNEL A CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES CO CARBON DIOXIDE WARNING A WARNING CO2 Displaces Oxygen Strict Attention must be observed in the prevention of CO 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 concentration of CO2 gas will experience tremors which are followed rapidly by loss of consciousness and death SHIPPING AND STORAGE A CAUTION Before shipping storing or relocating the Unit syrup systems must be sani
21. z m E E Een A e NUS A E 019v 1 029 i est M NOR e 898v 1029 r m pro ao Ein CES Lal SE a H HO SL8ri 029 S181079 E rigritoz9 4 NS lt lol 1 1 vi nga zr n Lr it 034 2 25 HAL VAP nnm Je 0S0EP0029 RH M M duvog 2021 lav Den Den Zen I18vi O0c9 vr ms a t a SNOLLNG zezsy ma ke Lol X98 3 lubog 1558 4 ei HSNd Fri baa F Bue tHe soe S aro Ka sE AV 1aS10 nag rer or HH 4OLIV INO oud jouod jouog jauog ofo ubauen liybiiydog liubiiyang ubr 1 gt 0g NuG 91121S029 j e112icoz9 911215029 941215020 XOg 4 9UD4 U0J4 nig Figure 6 Viper 4 Barrel Wiring Diagram 12 2008 2009 IMI Cornelius Inc Publication Number 621260373SER CGinelus 3 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 CO System A CO2 tank or bulk CO2 supply delivers carbon dioxide gas CO to an adjust able secondary CO2 regulator assembly that is attached to the tank as shown in Figure 7 and Figure 8 The CO2 system also supplies CO to the water boost pump the expansion tank regulator and the secondary CO2 tank regulators CO enters the expansion t
22. 08 2009 IMI Cornelius Inc Setting the Type of Syrup Maintenance Menu Barrel Maintenance Menu O 2008 2009 IMI Cornelius Inc Viper Service Manual while the POS LIGHTING field is highlighted To turn on the merchandiser lighting permanently press the ALWAYS button To turn the merchandiser lighting on and off with the Sleep settings press the SLEEP button Syrup type for each barrel may be selected by highlighting the desired barrel and pressing the appropriate button FCB FCB L FUB or FUB L FCB is for Frozen Carbonated Beverage FCB L is for Frozen Carbonated Beverages Light diet FUB is for Frozen Uncarbonated Beverages and FUB L is for Fro zen Uncarbonated Beverages Light diet Each of these settings provides the proper viscosity and temperature settings for the type of syrup being used The Maintenance menu shown in Figure 25 is only available to service person nel or other authorized users if security is enabled The Maintenance menu is used for barrel maintenance diagnostics BRIX setup and system information It allows the technician access to the unit during peri odic maintenance or troubleshooting problems It sometimes overrides the nor mal inputs from the system in order to perform this task SELECT BARREL MAINT MANUAL DIAG TOTALS BRIX SETUP MOTOR SETUP SYSTEM BACK ET man oo SEEGER Gx Figure 25 Select Screen The Barrel Maintenance menu shown in Figure 26 allows the serv
23. 2 Refer to Figure 39 for water filter location Water Filter Figure 39 Water Filter Location 54 O 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual Table 42 Step Procedure 1 Disconnect power from the unit Turn off and disconnect the water supply to the unit Remove the rear cover of the unit Disassemble the water filter Use two wrenches if necessary Remove the filter and rinse it under running water to remove any debris Reassembe the filter Connect and turn on the water supply to the unit Check the filter for any leaks CO OPN OO oy wo N Replace the rear cover a o Reconnect power to the unit O 2008 2009 IMI Cornelius Inc 55 Publication Number 621260373SER Viper Service Manual C Ginelius gt COMPONENT REPLACEMENT The following are procedures for servicing the major components of the Viper system BARREL MOTOR SEAL REPLACEMENT The barrel motor seal is typically replaced during the semi annual preventative maintenance procedure The seal location is shown in Figure 40 Motor Shaft Motor Seal Figure 40 Front View Inside of Barrel w Faceplate off Removing the Existing Seal To remove the existing barrel seal perform the procedure in Table 42 Table 42 Step Action 1 Purge the barrel See Purging a Barrel on page 34 2 When purging is complete disconnect power from the
24. 40 WATER PumP REPLACEMENT The water pump is located just behind the water filter in the center of the unit It is mounted on a bracket facing the rear of the unit To replace the pump perform the procedure in Table 47 Water Pump Figure 45 Rear View of Water Pump Table 47 Step Action Disconnect power from the unit Remove the rear cover and the side panels Disconnect the CO2 supply from the unit Remove and drain the water supply from the unit oy B amp B ow rm Disconnect the quick disconnect input and output water lines from the bottom of the pump o Disconnect guick disconnect CO2 input from the bottom of the pump Remove the four 4 screws and locknuts holding the pump to the mounting bracket Publication Number 621260373SER 60 O 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual Table 47 Step Action 8 Replace the pump 9 Reverse the procedure to install the new pump CO2 SHUTOFF SOLENOID REPLACEMENT The CO2 shutoff valves and solenoids shown in Figure 46 are located near the center of the unit and are mounted on a bracket to the bottom of the chassis They control the injection of CO2 with the syrup water combination to provide the final mixture for the product There are one of these solenoids for each barrel in the system When working in this area care should be taken not to damage or mi
25. 8 eu NI dN4AS a 5 0 a 9ISd 8 440 LND ry DISd SS NI LAJ 0 0 sivman TI ANYAS CH RI 373344 ed 8z 440 IN Pr 8 0 OISd Z NI LNI 0 ZHINVL M 8 V NOISNVdX3 8 IMYA 0 i SUUS B L Z NI dNYAS 6 0 a 0 w 8 DISd 8t 440 102 gi DISASSNILNI d H yaivmanv 0 i A z 1IYYVO 3233Y3 DISd 8Z 440 1NI 0 SONNA L 0 0 DISd EZ NI LNI a 8 0 Vi MNVL 0 8 r NOISNYdX3 B H 0 3A1VA EN 0 0 yara 0 L NI dNYAS S 8 0 L a 0 0 0 d p 9Isa By 4430 no 4 Q Sen ONV g PISAssNIino B H ANYAS HET3HHVS 3Z33Hd 91Sd 8Z 440 INI 0 0 40 ONIXIW 0 SL DISd Z NI 102 0 0 0 S3AT1VA IIHI 9isd sp 440 1n9 did ANYAS ANY YILYM a 9ISd 92 NILNO YILYM 3A1VA TOULNODJ MOTA t MOSH ZO a e ee ee ee ee ee ee ee ee ee ee ee 0 b eme amp enrile amp eile amp enrile OISdSS 440 1NI 1 2014INO dies DISd PI NI 102 y solvi YOLVIN9IY LIEN 3unssaud c aunssaud YE fe HOLIMS 4 uanivis 7 4 S 4 5 t d DISd 9 3UNSSINA y T ee ee e e 00000 oc cw on oisdl 1 sZ Y 4 9ISd 001 9ISasz IV Alddns 8 1V AlddNs OILVWAHOS T388V8 v 12 d AIIA des Z0 ware YALYM Publication Number 621260373SER Figure 11 4 Barrel System Schematic ES be O 2008 2009 IMI Cornelius Inc Viper Service Manual C Geh Water System Syrup System CoNTROL PANEL Introduction Publication Number 621260373SER Incoming water flows to a water pressure regulator that is preset to 30 psig It flows throug
26. Clock Setting Every six months or when changing to or from daylight savings time Change caged o ring on models w Motorman Valves Every six months or when changing syrup types refrigeration technicians should service this unit ALL WIRING AND CAUTION Only trained and certified electrical plumbing and PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES 47 Publication Number 621260373SER Viper Service Manual Girulius 3 MONTHLY MAINTENANCE A general inspection of the machine for leaks and cleanliness should be done on a weekly basis Any abnormal conditions should be reported and corrected when noticed Cleaning Air Filter The air filter should be cleaned at least once a month more often in harsh envi ronments Perform the procedure in Table 34 to clean the air cleaner Table 34 Step Action 1 Open the merchandiser 2 Remove the filter shown in Figure 37 by grasping the two tabs and sliding it straight out the front of the unit 3 Wash the filter with clean water Shake out the excess water 4 Reinstall the air filter mesh side down 5 Close the merchandiser Tab Tab Figure 37 Air Filter Location Publication Number 621260373SER 48 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual SEMI ANNUAL MAINTENANCE There are several procedures that should be completed on a semi annual basis There procedures help
27. ENIGW ii EE 2 Eet Wa See PA ae S ge Oa BK a dep a a ues 2 Different Types of Alans ood toa o in ee EE EA 2 DanQer napagana os e 2 Wamnihg vs nuum e sa Ar NAT Walt a baa as COR A A T Ps one S 2 AU MON RE AA a L week ome aes L ka oua 2 Safety MPa ds ts dela t e ENG 2 Qualified Service Personnel EE 3 CO2 Carbon Dioxide WArnllit as cd ete zb qu Sabe ea poe A e eo 3 Shipping And Storage oss Sie decal dta m EE Sad E Vides dde Qus uid itat 3 Mounting or a Counter aaa 4 teow ee REC RA e pda Dae de vee ee ee So edes EA 3 Dispensed Product Conditions aa vr de oe me aie Be i a Rai Wee dee ee 4 Overrun as Applied to Carbonated Beverages ee en nan kn n ann konn 4 Overrun Dellr tlfe cu denen o dee ts Pe Rover epe RO teda S SS yard 4 Overrun is a Variable eer d acetic E NU ode pte Me 4 Specific Product Ingredients Affect Overrun 4 BRIX Affects Overrun ore EE 4 Low Dispensing Volume Affects Overrun lt 0c cee ee 5 Carbonation Level in Liquid Product Affects Overrun lt 5 Freezing Affects Overrun i oasis a Ree She la P 5 SYSTEM OVEWICW d 6 MAGO orb S a S a akay pao che adan Dn e o ads E ae EEN 6 TIHEOr Operation PC 7 COZ SYSTEM oe as rs A a Rte Adare a 13 Water SystelTi L i l bye eee Era erae bead es Eh dee Pa eee Rd qr DE Feed 18 SV MID System L a a arden REUS TQ EORR S urpis I PR n OR 18 Ono Dane Rus AS Yu eret S LK Eel O 18 lues PRICE ed ika eles a BA eae as heed se Shea NG 18 Control Panel Display
28. IA T ili D 518716029 v19r1 029 ER iii SNIVIS 041 SNIVIS 031 Es sa 1 i t 430N31X3 NIVW EI TT ee tO tle m 221 821 v2 311 811 vi ttn poea np sos e M E 000 000 ooze ooir sr zt vr zr nun e e E NY d e len lir AA llar Geer si YISNIONO e R E E 699v 1 029 a A ar ar fat GYvOog O yaaa er 2911024802 Es Thy d CH m SLLZISO pel IEA MOSS IUAMOD vm Up npn qm Ai 021L92029 CH Ga H 140d NOISNVdX3 321809 ipp stie En ELLE EMT ma 30 90 i erm el 33 an ILLZISOZI ILLZISOZI Z 9UD4 9UD4 l1H91I 149V8 1H9I D2V8 1 lav 118718029 ee e lim ayvog 021 SNOLING zezs xog 3 Fung JD9Y HSNd Cr me ba WM d 3d DV nus ee 34 SUB Jes pubuo4Jos AV TdS ee S 8012v1N02 ef ES No efe MN me n me Louws Xog 3 9UDJ 1U04J4 Figure 4 Viper 2 Barrel Wiring Diagram 2008 2009 IMI Cornelius Inc 10 621260373SER Publication Number Viper Service Manual V Add 8v82v00d9 TYNOILdO 3NV 1 Q3 H8VW SWILI ILON YOY X194 ne 3
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30. SLEEP WAKEUP SUN 10 00 PM 08 00 AM DEFROST LOCK 1 05 15 PM 12 51P DEFROST LOCK 2 09 30 AM MAR 04 DEFROST LOCK 3 BACK CLEAR BEBE cc Figure 22 Event Setup Screen 28 2008 2009 IMI Cornelius Inc Viper Service Manual Setting Events Setting the Sleep and Wakeup Times O 2008 2009 IMI Cornelius Inc Table 15 Button Description BACK Returns the display to the Select menu and saves current settings CLEAR Clears the highlighted field on the menu Decrements the highlighted field Increments the highlighted field When the sleep and wakeup settings and the defrost lockout settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 19 Events setup allows the user to set sleep periods for the unit and to lock out the defrost cycle during peak busy times Sleep periods and defrost lockouts may be programmed for individual days of the week or for all days of the week depending on location requirements Sleep and wakeup times are set on the Event Setup menu shown in Figure 22 To set the sleep and wakeup times perform the procedure in Table 16 When the unit goes into a sleep period the barrel automatically defrosts for four minutes Also if a barrel is off when the sleep cycle starts the barrel continues to be in the off state when the sleep cycle ends If a barrel is running when the sleep cycle
31. SS2Md SI GRLVINSNN Ge Deeg E YOSSINAMOD G3LVINSND XH ANN NOLLONS OL dinon asanannan i j sani SS3008Yd YISNIGNOD MOVd WO ias HOO 331002 ANS Stauyve SHOLVHOdVA3 e omo d o ET ss em mmm mmm DeL S 1 s 3 a U 1 a 1 4 1 LU L t L U LUOd SSHOOV HLM MAI SILVIW3HOS NOLLVH39 H AZ AE Figure 2 Viper System 3 Barrel Refrigeration Schematic O 2008 2009 IMI Cornelius Inc Publication Number 621260373SER Viper Service Manual XP YOLSINYAHL XP 021 bel QBLVINSND SVO dTI o e axivinsND adinbnd111 o GINO dH LT o eee SVO dH LH exem HOSS3HdWO2 gana SS390Yd aaivinsND cendi OL amori ma NOvd Wvod G3ivinsNi uoivinwnoov s1auuva SNOLV3OdVA3 3an SSIDOYd Moes JUNSSIVA SI PELO EE Om lo d d d dh ls M GELVINSND xv Aay 3 1 D T P O3LVINSND XH 4 annmNouons 1MOdSS322V HLAM H3SAISOSH NHSN3ONOO gt LAV SILVINSHOS NOLLVIJOIY 418 AP d Figure 3 Viper System 4 Barrel Refrigeration Schematic Publication Number 621260373SER O 2008 2009 IMI Cornelius Inc Viper Service Manual
32. STOP button at the bottom of the display to stop the motor Press the BACK button to return to the Select menu Rinsing a Barrel NOTE When RUN button is pressed it changes to a STOP button When rinsing a barrel the Barrel Maintenance menu cannot be used The pro cedure must be done manually as described in Table 23 Step Action Table 23 Procedure 1 Empty a barrel If the barrel has liquid in it use the Purge procedure in Table 20 to empty the barrel Rinse a barrel Go to the Barrel Status menu Figure 12 Select the barrel Use the Up and Down arrows to highlight the desired barrel Turn off the barrel Press the OFF button at the bottom of the display to turn off the barrel Override Water Solenoid Press the manual bypass on the water solenoid and fill the barrel with plain water Use the relief valve on the faceplate of the barrel to relieve pressure and com pletely fill the barrel Run the barrel motor Use the procedure in Table 22 to rinse the barrel Complete the procedure popoa the Purge procedure in Table 20 to empty the arrel Manual Diagnostic Menu The Manual Diagnostic menu shown in Figure 27 is used for troubleshooting and testing the system on a component basis It allows the service technician to turn individual components of the system on and off for troubleshooting pur poses Pressing the BACK button returns the display to
33. Table 44 Step Action 1 Turn the 3 way Product Supply valve behind the splash panel see Figure 31 to the Off horizontal position 2 From the Maintenance menu press the FILL button for the barrel This pres surizes the barrel with CO2 Observe the water and syrup fill solenoids If there are NO seal leaks these solenoids cycle off within a minute and remain off 5 If the solenoids cycle off and remain off the barrel seal is not leaking and the barrel is ready to be filled with product 6 If the solenoids do not cycle off or cycle off and on the seal is leaking and the seal installation process described in Table 42 and Table 43 must be rea peated 7 If there are no leaks turn the 3 way Product Supply valve to the BRIX posi tion BARREL MoToR REPLACEMENT Publication Number 621260373SER The barrel motor does not require any special alignment when being replaced It mounts on four 4 bolts These bolts are screwed into threaded bosses in the foam pack barrel assembly as shown in Figure 43 To replace a barrel motor perform the procedure in Table 45 58 O 2008 2009 IMI Cornelius Inc CC Ginelus 3 Viper Service Manual Barrel Motor Mounting Bolts Foam D Pack Figure 43 Side View of Motor Showing Two of the Four Mounting Bolts Table 45 Step Action 1 Perform the procedure in Steps 1 through 8 of Table 42 2 Disconnect the motor from the ci
34. a Eth FP PA REIP Fal 34 Hinga Barrelo cts ost tut na eta seque ds itte bh ns Es 34 Run the Barrel Motor ek ses crede ue te Beales es PIGA NP a RES ate 35 Rinsing CUO ES S06 e DL ee o E baga kn Au eme ans k Kri DA d ME clan auk 35 Manual Diagnostic Meri 2 is m ks ka SEA verte Paw 35 TotalS MENU oou eR nd A Es 36 BRIX Setup CN bo aeos o EE e aeo sire ita e tac iste M A d 37 Motor Setup Mentis sins 5 carat she Race ir eene bee i ia ad 39 Calibrating Motol s Dieser e We ue ed xS RE A eere d 40 System Men oue edu de eie chop da boy dta ix oro ada lena KAWAL 41 leg M Tc ad 42 Pressure Sensors ue aot pul Bu EDO E Nr rae ra B LA DO RD es NN 42 Operativa iS ceci eir S INE EIAS ai 44 Maintaining Product Quality pnpa a pet emere LAE E ed i acx de a 44 Dispensed Product Throughput se 4a xe na eR ce AY uU ORO Oe las 44 Programmed Defrost Scheduling e sans i da Y XR t 45 Sleep Mode Recommendations eee res 45 MISCOSIW SOU NON Deseos os e ak ae eu dien atop ai eue T 45 Star ng this Units s ava av kwa lE Rede BA LALA LAKAN PARADA AERE ts xod tpud 45 Preventative Maintenance we ketai sk EE Roe t e Ree VOR a E AUR ob e PNTA ue OE 47 SUMMANY2 so cover e ER Mee MANG RENE e pe oe sii M Ea eu had mau Su rad 47 Monthly Maintenance ume a RR EE eee ee ee Rada me RS 48 OSA APS AA dad kn Say a E Coe 48 Semi Annual Maintenance 2 aaa a a a 49 Inspecting and Replacing Scraper Blades eee nn nn nn an
35. an nna nan 49 Cleaning the Syrup Connections sakes 40 e ak i NG ee mox S eee ee ee ee Paw 49 Servicing Motorman Dispensing Valves eee lee 50 Sanitizing the System 43 oe doe eet e e PIDEN Bae way ee Rae AA EB QU RENS 51 Emptying a Barrel tiki ett PE a RI A E o 52 Flushing the System of Syrup cur osos Ocak oa mp rele RUN Sew mi d Ek 52 Sanitizing Me Barrel 2545 ead bestiae Dala EE 53 El shina he System s x eroi NAN ce QR Ee egeo RR Dc o A Bele 53 Cleaning the Water Filters serre xn rx KUER Eo EU UR RES ras 54 Component Replacement ule pe or ir EE NE EE 56 Barrel Motor Seal Replacement nen 56 Removing the Existing SO Al conira RIDERE sa iue raa ee e ea 56 Installirig 8 New Sal eun Sac eec a ie 57 Motor Seal Leak Test iss seeks EE a Ree nee aes Bele be Re ee 58 Barrel Motor Replacement a atsi eR per hoe EXE E RA TAL RR E ER ROSE RUE PAG eed eels 58 Motor Run Capacitor Replacement nen 59 Water Pump Replacement 23 L ass RR a A dare RR A S 60 CO2 Shutoff Solenoid Replacement ree 61 Syrup and Water Shutoff Solenoid Replacement 62 602 Regulator Replacements Las o shoes IN A 63 Condenser Fan Motor Replacement e rl seh 64 Compressor Replacement EE 64 Hot Gas Solenoid Peplacerienb epe reso go E BANA RR cata d Up dA 65 Liquid Line Solenoid Replacement 2a a thas REY meer e e A ERE EG 66 Syrup Pressure Switch Replacement lere 67 Water Press
36. ank 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 CO 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 flows into the product line Secondary CO2 Regulator Assemblies 65 70 psig A 9 A Q Q 75 1psig N To Viper e Unit Bulk a Cylinder A 110 200 psig Bag in Box A fwen Figure 7 Typical Bulk Cylinder CO2 Connection O 2008 2009 IMI Cornelius Inc 13 Publication Number 621260373SER Viper Service Manual 75 1psig CO2 Cylinder Il Secondary CO2 Regulator To Viper Unit u ge mem ec Th 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 B Syrup Type Type Set Viscosity Pressure Expansion FCB Syrup
37. barrel or on the beater bar 2 Defrost the barrel Select DFRST on the Barrel Status menu Figure 14 It is very important that calibration be performed on a fully defrosted barrel outlet temperature must be 41 F or barrel must be purged and refilled with new product 3 Select Motor Setup Use the Up and Down arrows to highlight MOTOR SETUP on the Maintenance menu 4 Select the barrel Use the Up and Down arrows to highlight the desired barrel 5 Start calibration Press the CAL button at the bottom of the Motor Setup menu to start the calibration process 6 The calibration cycle continues for five 5 minutes to allow the gearbox to stabalize at temperature and ensure correct callibration At that time the motor stops and it is calibrated 7 Complete the procedure Press the BACK button at the bottom of the display to return to the Maintenance menu The System menu is used during production to set up the unit It also allows the technician to view and change the number of barrels the number of compres sors and the number of pressure sensors present in the sytem as shown in Fig ure 34 The description of these items is shown in Table 31 NOTE Changing these values to a number that doesn t match the physical number of items in the system generates errors or turns off some of the equipment present in the system When the individual fields are highlighted the display buttons change Refer to Table 32 for
38. c ep ep ep ep ep ep ep ep ep ep ep ep ep ep ep e iJ y Yo nu 91sd 0 A 8 H a st NI dA t ANVL H pda S NOISNVdX3 9 pi YILVM anv dnYAS CH TIYAVABIZIIAYI TI 40 ONIXIW DISd 87 440 LND DISd EZ NI LNJ EE YILVM ONY il m 0 EH dfiHAS Zi 13V 323384 Nn do epo DISd 82 440 LND L ANVL NOISNVdX3 DISd EZ NI LI AE otsa ep 440 INO TT DISd SS NI LAJ T NI dNYAS 9ISd 8r 440 LND DISd SS NI LANJ Vt NI dNYAS ii T SISd 87 440 LND bi mn 8 osassNi no 0 YALVMONV 0 L mung 3Z3334 rT D 8 dNYAS 0 S ISA 8Z 340 ID y 0 40 SNIXIW 8 ie TONES SSNTVA JI93H9 0 OISd SE 340 ID dWNd M H SISd 92 NI 102 YILVM 104LNO2 MO14 INIVA 323H9 Z02 i an kasi H gt P ep ep ep eg P ep ep ep e ee e ee 3013140 DISASS 440 Im 8 A ouod DISd PI NILNO g d Bs uoivinoaau YOLVINIFY R Houms 9 muang Ug aunssaud AS C olsa 9 3UNSSIYd Y LI t t Li OLLWNJFKODS TFAAYAVE 13 d YAdIA Aadns 200 dee YALM Figure 10 3 Barrel System Schematic 16 O 2008 2009 IMI Cornelius Inc Publication Number 621260373SER Viper Service Manual 0 Yo OISd 0 0 Wl 3ATVA 0 8 9 NOISNVdX3 0 VA NI ANYAS 9ISd 87 440 LND y 9ISd SS NI LND 6 e H ON 0 ANYAS v IFJAAVA 323383 9154 8Z 440 INI JO ONIXIW 0 8 DISd Z NI 1NO e e d 8 i MNVL 0 0 INIYA 0 NOISNVdX3 0 8 Fanvs 0 Y 8
39. 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 18 O 2008 2009 IMI Cornelius Inc Control Panel Display Control Panel Buttons O 2008 2009 IMI Cornelius Inc Viper Service Manual 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 13 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 12 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 lt also displays menus of actions that are taken to modify the function ing of the machine BARREL 1 FREEZE 87 Menu STATUS 2 FREEZE 68 Display 12 51P alge MAR 04 AN MENU ON OFF DFRST SPIN BEBE ae Menu Buttons Figure 12 Control System Display The second area are the buttons and arrows
40. d Defrost Scheduling Sleep Mode Recom mendations Viscosity Setting The control system in the Viper system includes a function to automatically defrost product in the barrel at programmed intervals based on the viscosity of the product Programmed defrosts are scheduled frequently to ensure that product quality within the barrel is maintained Failure to defrost regularly during periods of low throughput allow increased ice crystal size with a possible decrease in product quality Regular throughput of dispensed product replenishs the barrel frequently with liquid and reduces the requirements for programmed defrosts The unit automatically senses the lack of throughput and maintains the product quality by defrosting the barrels more frequently when throughput is slow Cornelius recommends programming a sleep period for the machine during any amount of time over 3 hours that the unit is not used This increases the life of the machine and reduces energy consumption A wakeup time must be programmed after the sleep period to return the unit to nor mal operation Cornelius recommends programming the wakeup time for approxi mately 20 minutes before the product is needed This is the time recommended if the ambient temperature is at 75 F The times will vary depending on the ambient temperature a higher ambient temperature requires more time for the product to cool The control system includes a function to select the desired product viscosit
41. d down arrows to highlight WAKEUP and repeat Steps 5 through 7 to set the WAKEUP times When the sleep and wakeup settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 19 Setting Defrost Lockout From the Barrel Status menu shown in Figure 14 press the MENU button and then press the SETUP button to display the Setup menu Use the up and down arrows on the right of the control to highlight the Events Setup menu then press GO to enter the menu Figure 22 The lockout can also be set day by day or for all days with up to three lockout periods of three hours each per day These lockout periods may be overlapped to provide from three to nine hours of defrost lockout if desired When the periods are overlapped it is recommended that the defrost lockouts for sequential lockout periods be overlapped by 15 minutes The defrost lockout affects all barrels in the unit To set the defrost lockouts perform the procedure in Table 17 Table 17 Step Action Procedure 1 Set defrost lockout Open Events Setup menu shown in Figure 22 2 Select DAY The DAY field is highlighted 3 Set DAY Use the and buttons at the bottom of the display to set the desired day or all days 4 Select DEFROST LOCK Use the up and down arrows to highlight 1 DEFROST LOCK 1 5 Set hour field Use left and right arrows to select hour field 6 Use the and buttons at
42. e merchandiser Close the merchandiser In approximately 20 minutes product is ready to serve Publication Number 621260373SER 46 2008 2009 IMI Cornelius Inc PREVENTATIVE MAINTENANCE Viper Service Manual SUMMARY O 2008 2009 IMI Cornelius Inc There are no daily maintenance procedures required on the Viper unit other than normal cleanup of spills or overspray and emptying the drip tray Normal equip ment maintenance intervals are listed in Table 33 It is recommended that a pre ventative maintenance procedure be performed every six 6 months This procedure should include all of the maintenance items described in Table 33 and the following sections Table 33 Preventative Maintenance Summary Maintenance Procedure Frequency of Maintenance Clean Air Filter Monthly or more often as necessary See Table 34 Check BRIX Every six months or when changing syrup types See BRIX Setup Menu on page 37 Seal Change Every six months Clean Condenser Coil Every six months or as necessary Sanitize Unit Every six months or when changing syrup types Check Water Filter Every six months or if water pressure in the system is low Change or Rotate Scraper Blades Every six months Check for Leaks Every six months Clean BIB Connectors 8 check opera tion of syrup sold out switches Every six months or when changing syrup types Check
43. e the faceplate from the barrel 50 O 2008 2009 IMI Cornelius Inc Sanitizing the System O 2008 2009 IMI Cornelius Inc Viper Service Manual Table 37 Step Action 4 Carefully remove the large o ring from the faceplate 5 Unscrew the relief valve from the faceplate 6 Disassemble the dispensing valve see Figure 38 7 Remove the two screws and hold down plates securing the spring housing to the dispensing valve body then remove the housing 8 Remove the torsion spring from the dispensing valve 9 Remove the knob spring sleeve and lever from the dispensing valve 10 Remove spring fitting from dispensing valve 11 Press the valve with the caged O ring down and out of the dispensing valve body 12 Carefully remove the caged O ring from the valve 13 Wash all the parts in warm water Remove all traces of syrup and lubricant especially from the faceplate o rings and dispensing valve If parts are excessively coated wipe clean with a paper towel to remove excess syrup and lubricant especially from caged o ring and dispensing valve Use a brush provided with the unit to clean the faceplate relief valve passages 14 Submerge all the parts in a 4 percent solution of approved sanitizing agent for the amount of time recommended by the sanitizer manufacturer 15 Remove the parts from the sanitizing solution and place them on clean paper towels 16 A
44. egree BRIX position for the barrel you are testing See Figure 31 2008 2009 IMI Cornelius Inc 37 Publication Number 621260373SER Viper Service Manual Publication Number 621260373SER CG Table 26 Step Action Procedure Access BRIX menu Press MENU Then press the SETUP button Set barrel for BRIX From the Setup screen Figure 19 open the BRIX Setup screen shown in Figure 29 Use the Up and Down arrows to highlight BRIX SETUP Press the GO button at the bottom of the display Select barrel Use the Up and Down arrows to highlight the desired barrel for BRIXing Perform BRIX procedure Locate the appropriate barrel sample tube and hold a cup under it Open the valve at the end of the sample tube Press the BRIX button and wait 3 5 seconds The product pump pumps product for approximately 3 seconds After the sample is dispensed Press BRIX twice more to dispense product two more times Discard all three of these samples 10 Press the BRIX button a fourth time Collect this sample in a cup and close the valve at end of the sample tube 11 Measure BRIX Place adequate amount of the product on a refracto meter and read the BRIX value A target BRIX read ing of 13 0 1 0 is normally desired for sugar based syrups Lower values for some diet syrups can be specified Check with the syrup manufacturer if you are not sure 12 Adjust BRIX
45. elius Inc Viper Service Manual Table 57 Step Action Disconnect power from the unit Connect a static strap to your wrist and any convenient chassis ground on the unit Unplug the two 2 connectors from the display board Remove the four 4 screws from the corners of the board oj aj A Replace the board with a new board Reverse the procedure to install the new board CONTROL BOARD REPLACEMENT O 2008 2009 IMI Cornelius Inc When replacing or testing electronic components be sure to wear a static strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The control board is located in the E Box It is mounted to the panel on four 4 plastic mounting studs shown in Figure 55 Table 58 Step Action 1 Disconnect power from the unit 2 Connect a static strap to your wrist and any convenient chassis ground on the unit 3 Unplug the eight 8 connectors from the control board 4 Squeeze each of the mounting studs at the corners of the board while care fully lifting the board 5 Replace the board with a new board 6 Reverse the procedure to install the new board Mounting Studs lt H a nnn P T YT Figure 55 View of Control Board in E Box 69 Publication Number 621260373SER C Gne Viper Service Manual Backward Forward Compatibility
46. er 621260373SER C Geh To empty the barrel perform the procedure in Table 38 Table 38 Step Action 1 From the Barrel Status menu press the DFRST button 2 When the barrel is defrosted go to the Maintenance menu If the security fea ture is active access the Maintenance menu by by pressing and holding the far left and right buttons simultaneously for approximately five seconds 3 Remove the splash panel See BRIX Setup Menu on page 37 Turn the Product BRIX valve 90 degrees clockwise to shutoff product to the barrel 5 Place a large waste container under the dispense valve and drain as much product as possible from the barrel 6 When the pressure in the barrel drops from the Barrel Maintenance menu press the PURGE button to repressurize the barrel with CO2 As product level lowers in the barrel partially close the valve to avoid spurting 7 Disconnect the BIB from the unit NOTE The unit should be sanitized every 180 days by a qualified service technician following the sanitizer manufacturer s recom mendations After emptying the barrel the barrel should be flushed of product before pro ceeding with the sanitizing procedure Perform the procedure in Table 39 Table 39 Step Action 1 Fill a clean 5 gallon pail with plain water 2 Connect a sanitizing fitting p n cc 28688 to the BIB connector Put the con nector in the bucket of water 3 Make
47. erent motor types for each barrel in the unit and run the calibration procedure on that motor This procedure correlates the actual viscosity of the barrel and its contents with the electrical characteristics of O 2008 2009 IMI Cornelius Inc 39 Publication Number 621260373SER Viper Service Manual Calibrating a Motor Publication Number 621260373SER CG the motor These characteristics are stored by the control system and are accessed at the time of calibration for each particular motor Because of the differences between motor characteristics from different motor suppliers the Motor menu shown in Figure 33 is used to adjust the unit settings to match the motor type being installed It provides the correct table of electrical characteristics from imbedded settings located in non volatile memory Perform the procedure described in Table 29 to change the motor type setting Insure that the motor type matches the settings listed in Table 27 based on model NOTE If the Motor Type shown is DEFAULT it indicates that the EEPROM is not installed or is faulty Table 27 Model Motor Type All 60 Hz 1 All 50 Hz 2 MOTOR 1 MOTOR TYPE 1 SETUP 2 MOTOR TYPE 2 Figure 33 Motor Setup Screen Table 28 Button Description BACK Returns the display to the Select menu CAL Verifies the motor settings of a new motor Decrements the highlighted field Increments the highli
48. figuration for the Viper refrigeration system The wiring diagram of the 2 Barrel Viper unit is shown in Figure 4 the wiring dia gram 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 S EG e sg o 2 lt n o a Se B SS 8 E a98 5 n 33 m 3 lt og 2 io e o 0330 Xs ul ul a a an t om E od oF E H oh 82 E Zb ge g gt GALVINSND wo zu x 255 ui azi 2 382 a 2952 z 2x 8 T X a Sa o 3 SE P qu ka 2 o ii a wb p SE a i i iu a o 5 dE gr o o 3 o Ck EM ty ga puce ee ee eee ee enam x a z g EE d i E a H O 8 uo aspen 1 jo H S k a H 1 mi a ul gt 3 o S TTC 5 1 3 m bi n 1 L 8 M 3 LI 3 gt H a mp D 1 A m mp p e IX s stauuva 12 2 SMOLVHOdVAI ta H E 1 iK a H 19 SE H H 1 S 23 H gt a 4 a S 2 H m 3 E we o 3 1 o 4 K a H LE d o 4 e EH 3 o n k g d a 8g BS lt as 1 1 2 Ae o e op op e em ee eememeeomemeemeeg HS PRESSURE SENSOR Figure 1 Viper System 2 Barrel Refrigeration Schematic O 2008 2009 IMI Cornelius Inc 7 Publication Number 621260373SER Viper Service Manual XE NOLSIWYIHL XE OOL del GALVINSNI SVO ASILI men aaivinsN AINO ATLI o e OD dH L1 e aa1vinsND YOLYINANSOV SVO dH LH O maca 398N1 SS320Hd MOSN3S DUN
49. ghted field Table 29 Step Action Procedure 1 Set barrel for Motor Type From the Maintenance menu Figure 25 open the Motor Setup menu shown in Figure 33 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select the proper motor Press the or buttons at the bottom of the display to type select the proper motor type 4 Complete the procedure Press the BACK button at the bottom of the display to save the settings and return to the Setup menu Calibration of motors is typically required when a motor or any associated barrel components i e scrapper blades seal faceplate etc is removed or replaced Calibration establishes a new baseline for the motor assembly This allows the system to determine proper viscosity settings for the new motor When a new 40 2008 2009 IMI Cornelius Inc Viper Service Manual System Menu O 2008 2009 IMI Cornelius Inc motor is installed in the unit or any of the barrel components are changed or adjusted the motor should be calibrated by performing the procedure described in Table 30 CAUTION Calibration must be performed when the product in the barrel is completely liquid There must not be any ice on the scraper blade Table 30 Step Action Procedure 1 Re assemble barrel Itis VERY IMPROTANT that calibration be performed when the product in the barrel is in a 100 liquid state There can be no ice in the
50. h 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 fit ting where it meets the water for injection into the freeze barrel 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 neces sary to keep the Viper unit operating correctly In addition to controlling the unit the control system keeps track of the diagnostic information used when adjust ing 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
51. ice techni cian to clean rinse and sanitize the system on a barrel by barrel basis The bar rel must be OFF in order to perform the barrel maintenance functions As a warning to the technician the Do Not Drink status indicators are illuminated on the barrels when entering the Barrel Maintenance menu The procedure for purging a barrel is shown in Table 20 The procedure for filling a barrel is shown in Table 21 The procedure for running the scraper blade only on a barrel is shown in Table 22 and the procedure for waking up a barrel is shown in Table 24 33 Publication Number 621260373SER Viper Service Manual CG Purging a Barrel Filling a Barrel Publication Number 621260373SER BARREL 1 PURGE MAINT 2 OFF 12 51P MAR 04 BACK PURGE FILL SPIN L iii cc Figure 26 Barrel Maintenance Screen Table 20 Step Action Procedure 1 Purge a barrel From the Select menu Figure 25 open the Barrel Maintenance menu shown in Figure 26 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select Purge function Press the PURGE button at the bottom of the display to select purge for the highlighted barrel 4 Empty the barrel Place a container under the barrel dispensing valve open the dispensing valve and dispense all the prod uct from the barrel As the product level lowers in the barrel partially close the valve to avoid sp
52. ids 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 DRAWING 1 DRAWING 2 DRAWING 3 4 O 2008 2009 IMI Cornelius Inc Low Dispensing Volume Affects Overrun Carbonation Level in Liq uid Product Affects Over run Freezing Affects Overrun O 2008 2009 IMI Cornelius Inc Viper Service Manual 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 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 overru
53. l Ee Figure 35 System Screen When the pressure sensors selection is highlighted pressing the NONE button removes the pressure readings from the Unit Data screen shown in Figure 36 If LOW is selected only the low pressure reading is displayed If HIGH is selected only the high pressure reading is displayed NOTE If a pressure sensor is open the pressure reading is 386 PSIG UNIT LINE VOLTAGE 229 DATA LINE FREQUENCY 60 LOW PSIG 1 60 HIGH PSIG 1 174 12 51P MAR 04 BACK BRL un VER EBENEN GC Figure 36 Unit Data Screen 2008 2009 IMI Cornelius Inc 43 Publication Number 621260373SER Viper Service Manual CCineliis OPERATION MAINTAINING PRODUCT QUALITY It has been determined that the following factors can affect the rate at which product quality diminishes as indicated by a change in product appearance 1 Dispensed Product Throughput 2 Programmed Defrost Scheduling 3 Viscosity Setting Cornelius recommends the following instructions be read and followed relative to operating and establishing settings for the FCB equipment Cornelius equipment service manuals contain instructions on how to program settings within the control system Operators who have not been trained on servicing Cornelius FCB equip ment should not attempt to modify equipment settings but should contact an accred ited service provider Cornelius makes the following recommendations to help assure maximum
54. located across the bottom and on the right side of the control panel There are up to five buttons and four direc tional 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 19 Publication Number 621260373SER Viper Service Manual Cines 3 e ine Barrel Initialization Screens Status Home Screen Main Setup Maintenance Sub Menus Sub Menus Sub Menus Clock Setup Barrel Maint Event Setup Manual Diag Barrel Data Option Setup Totals Viscosity Setup Brix Setup Software Ver Motor Setup System Setup Error Log Figure 13 Software Structure Publication Number 621260373SER 20 O 2008 2009 IMI Cornelius Inc CGinetius D 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 struct
55. me Left and Right buttons Buttons 1 and 5 on the bottom of the display simultaneously and holding them for approximately five 5 seconds unlocks the Security menu If security is left ON on the System menu when the system times out or when the user goes back to the Main menu security is re activated and the Maintenance menu is not accessable To disable security access the System menu highlight Security and press the OFF button Pressure sensors allow the technician to view the high and low side pressures in the refrigeration system without having to connect external gauges to the sys tem To view this information go to the Unit Data screen shown in Figure 16 and press the UNIT button The System screen shown in Figure 35 is displayed The number and type of sensors in the unit are typically set at the factory and should not be changed Data is only available on the sensors installed If a sen sor that is not installed in the unit is activated incorrect data is displayed It is possible to install sensors in the field but it is not recommended because sys tem refrigerant charge may be lost The low side pressure sensor is used to monitor compressor reversal If it is not installed on the unit the unit may not operate properly 42 O 2008 2009 IMI Cornelius Inc CC Ginelus 3 Viper Service Manual SYSTEM OF BARRELS 2 OF COMPRESSOR 1 SECURITY OFF CMP 1 SENSORS BOTH 12 51P MAR 04 BACK NONE LOW HIGH BOTH u
56. mer 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 CO2 System Error Handling Error Log Viscosity Control 1 Publication Number 621260373SER Viper Service Manual SAFETY SAFETY INSTRUCTIONS Read and Follow ALL Safety Instructions Safety Overview Recognition Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning caution labels on the machine decals labels or laminated cards Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety regulations before operating this machine Recognize Safety Alerts A This is the safety alert symbol When you see it in this manual or on the machine be alert to the potential of personal injury or damage to the machine Different Types of Alerts Danger Warning Caution SAFETY TiPS Publication Number 621260373SER A Danger Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or eguipment damage WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or eguipment damage CAUTION Indicates a potentially hazardous
57. n run ning since the last reset COMP CYCLES 1 HHHH H Shows the number of compressor cycles since the last reset BARREL REFG 1 HHHHH MM Shows how long the barrel has been in refrigera tion mode MOTOR ON 1 HHHHH MM Shows how long the motor has been running on a specific barrel MOTOR SEAL 1 HHHHH MM Shows how long it has been since the motor seal was inserted on a specific barrel DEFROST 1 HHHHH MM Shows how long the barrel has been in defrost mode FILL CYCLES 1 HHHHHHHE Shows the number of times the barrel has filled with product SYRUP RUN 1 HH MM SS Shows how long the syrup solenoid has been open SYRUP OUT 1 HHHHH MM Shows how long the syrup has been out ERROR 1 HHHHH MM Shows how long the barrel has had an error BRIX Setup Menu BRIX is important to the quality of the final product The BRIX menu facilitates the extraction of a sample of product from the unit for BRIX measurement There is an automatic three second dispense of product that produces a constant volume so that a BRIX comparison can be made between samples To perform a BRIX test perform the procedure in Table 26 Table 26 Step Action Procedure 1 Set status of barrels Make sure the status of all barrels is OFF on the con trol display 2 Remove drip tray access Remove the drip tray loosen the two screws holding panel the access panel and remove it Figure 30 3 Set product supply valve Turn product supply valve to the 180 d
58. n than drinks that contain 2 0 volumes of CO2 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 5 Publication Number 621260373SER Viper Service Manual INTRODUCTION Publication Number 621260373SER 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 corro sion It is covered with ventilated cladding panels and a lighted merchandiser The cladding is easily removable to facilitate installation service and mainte nance 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 6 2008 2009 IMI Cornelius Inc Ginelus D Viper Service Manual THEORY OF OPERATION The refrigeration system schematic is shown in Figure 1 It provides the basic con
59. ndent Part numbers for software version 3 0 chips have the base number of 629096931 followed by an alpha suffix designating the language type The motor control boards and the main status board will still operate with either version 2 x or 3 x software of Ul and IO board When ordering replacement service parts for any unit check the software version of the Ul and lO boards and be sure to order the correct board as listed in Table 59 MoTOR BOARD REPLACEMENT When replacing or testing electronic components be sure to wear a static strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The motor board is located in the E Box to the right of the control board It is mounted to the panel on three 3 plastic mounting studs and a threaded stand off shown in Figure 55 Table 60 Step Action 1 Disconnect power from the unit 2 Connect a static strap to your wrist and any convenient chassis ground on the unit Publication Number 621260373SER 70 2008 2009 IMI Cornelius Inc Viper Service Manual O 2008 2009 IMI Cornelius Inc Table 60 Step Action 3 Unplug the eight 8 connectors from the control board 4 Squeeze each of the mounting studs at the corners of the board while care fully lifting the board 5 Replace the board with a new board 6 Reverse the procedure to install the new board
60. oard C Replace No Low Refrigerant A Leak A Repair and weigh in new charge Sensors A Bad connection A Correct wiring B Bad sensor B Replace sensor C Sensor out of position C Reposition sensor and clip D Defective product delivery board D Replace O 2008 2009 IMI Cornelius Inc 73 Publication Number 621260373SER IMI Cornelius Inc www cornelius com
61. ons at the bottom of the display to set the correct month 4 Select day field Use the left and right arrows to select day field 5 Set correct day Use the or buttons at the bottom of the display to set the correct day 6 Select year field Use the left and right arrows to select year field 7 Set correct year Use the or buttons at the bottom of the display to set the correct year Once the date and time are set properly daylight savings time settings can be done The Daylight Savings Time menu is shown in Figure 21 If daylight savings time is off press the button to activate it The button functions are described in Table 13 To set daylight savings time perform the procedure in Table 14 NOTE Default daylight savings settings are for the U S CLOCK SETUP 12 51P MAR 04 S ON SPRING MONTH MAR SPRING WEEK 1 FALL MONTH OCT FALL WEEK L BACK CLOCK OST E EBENEN aa Figure 21 Daylight Savings Setup Screen 27 Publication Number 621260373SER Viper Service Manual Events Setup Menu Publication Number 621260373SER AC Table 13 Button Description BACK Returns the display to the Select menu CLOCK Opens the Clock menu DST Highlighted to indicate DST menu Decrements the highlighted field by one increment Increments the highlighted field by one increment Table 14 Step Action Procedure Set daylight savings time Press DST button a
62. ort and clean the out let of the dispense valve with sanitizing solution 10 From the Barrel Status menu press the SPIN button while highlighting the appropriate barrel This starts the scraper blade Allow blade to operate for minimum of 10 but no more than 15 minutes Turn the scrapper blade off by pressing the OFF button 11 Place a large container under the dispense valve and drain as much sanitizing solution as possible from the barrel 12 When the pressure in the barrel drops from the Barrel Maintenance menu press the PURGE button to re pressurize the barrel with CO2 As sanitizing solution level lowers in the barrel partially close the valve to avoid spurting Flushing the System Flush the wash water from the system by performing the procedure in Table 41 CAUTION Flush the system thoroughly residual sani A tizing solution left in the system may create a health haz ard O 2008 2009 IMI Cornelius Inc 53 Publication Number 621260373SER Viper Service Manual C Ge gt Table 41 Step Action Turn the Product BRIX valve to the Product position Manually open the manual water flow valve to start filling the barrel with wash water At the same time open the faceplate relief valve until water comes out From the Barrel Status menu press the SPIN button while highlighting the appropriate barrel This starts the scraper blade Allow the blade to operate for fifteen
63. per 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 depend ing on the settings of the compressor sensors in the Unit Data screen as shown in Figure 36 VER 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 17 displays any current errors con tained 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 1 MOTOR PWR STATUS COMP HIGH 12 51P MAR 04 BACK EBENE ae Figure 17 Error Status Screen Table 6 Displ kt splayed Action Type Description Message HOT GAS Off System Occurs when the barrel outlet temperature exceeds 115 F for more than one minute and
64. product quality Dispensed Product Throughput FCB equipment is designed to provide a high throughput of frozen carbonated prod uct to meet peak draw demands Where low product throughput is experienced there is the potential for product quality to diminish The information shown in Table 33 outlines the minimum throughput per barrel that must be dispensed on a 24 hour basis Table 33 Viper Viscosity 4 Viscosity 4 Volume of dispensed product per barrel per 48 oz 60 oz 24 hours required to maintain product quality NOTE Cornelius recommends that in conditions where the FCB machine is operational and the minimum throughput as described in Table 33 is not met on a per barrel basis product should be dispensed and dis carded to increase throughput and help assure that product quality is maintained NOTE Data in Table 33 assumes equipment has been correctly installed commissioned and calibrated as per directions contained in all techni cal literature published by Cornelius and the recommendations con tained in this document have been followed Cornelius recommends that in conditions where the FCB machine is operational and the minimum throughput is not met on a per barrel basis product should be dis pensed and discarded to increase throughput and help assure that product quality is maintained Publication Number 621260373SER 44 2008 2009 IMI Cornelius Inc Viper Service Manual Programme
65. r of the unit on the right and left sides Whenever a hot gas valve and solenoid is replaced the dryer should be replaced at the same time Hot Gas Solenoid T a gt Figure 50 Hot Gas Solenoid 1 per barrel Table 53 Step Action Disconnect power from the unit Remove the side panels Reclaim refrigerant from the system Carefully remove the insulation and remove the hot gas valve and solenoid Replace the hot gas valve and solenoid o o E 6 pm Replace the insulation around the valve and solenoid O 2008 2009 IMI Cornelius Inc 65 Publication Number 621260373SER Viper Service Manual CCineliis Table 53 Step Action 7 Replace the filter dryer 8 Evacuate the system 9 Restore the proper refrigerant charge to the system and verify proper system operation Liquip LINE SOLENOID REPLACEMENT The liquid line valves and solenoids shown in Figure 51 are located near the center of the unit on the right and left sides Whenever a liquid line valve and solenoid is replaced the dryer should be replaced at the same time Liquid Line Solenoid WW Figure 51 Liquid Line Solenoid 1 per barrel Table 54 Action Disconnect power from the unit Remove the side panels Reclaim refrigerant from the system Carefully unwrap the foam insulation from around the valve and solenoid Remove the liquid
66. rcuit by unplugging the connector 3 Remove the motor by removing the four 4 bolts holding the motor to the bar rel assembly 4 Install the replacement motor and connect the connector 5 Replace the motor seal scraper blade assembly onto the motor shaft in the barrel as described in Table 42 6 Reconnect power to the unit 7 Refill the barrel with product See Filling a Barrel on page 34 8 When barrel fill is complete perform a motor calibration See Calibrating a Motor on page 40 MoTOR RUN CAPACITOR REPLACEMENT The motor run capacitors shown in Figure 44 are mounted at the rear of the unit between the barrel motors To replace a run capacitor perform the proce dure in Table 46 Motor Run Capacitor Motor Run Capacitor Figure 44 View of Motor Run Capacitors O 2008 2009 IMI Cornelius Inc 59 Publication Number 621260373SER Viper Service Manual Table 46 Step Action Disconnect power from the unit Remove the rear cover Disconnect the spade clips from the defective capacitor Remove the mounting screw from the base of the capacitor Replace the capacitor Reverse the procedure to install the new capacitor Reconnect power to the unit Refill the barrel with product See Filling a Barrel on page 34 jo LO oO AJOJN When barrel fill is complete perform a motor calibration See Calibrating a Motor on page
67. reis FCB VIPER Service Manual Release Date October 28 2008 Publication Number 621260373SER Revision Date July 13 2009 Revision D Visit the IMI Cornelius web site at www cornelius com for all your Literature needs CONTACT INFORMATION The products technical information and instructions contained in this manual are subject to change with out 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 Appropriate safety precautions should be followed and all local safety and construction requirements should be met To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact WWW cornelius com 800 238 3600 This document contains proprietary information and it may not be reproduced in any way without permis sion from Cornelius Printed in U S A Copyright O 2008 2009 All Rights Reserved IMI Cornelius Inc IntroductON ge iai ini bash Rane two edd r aed bier S eo eed 1 Manual e EE EE EO AE ada 1 GEELEN 2 Safety Instructions ege E pe a Men EE e 2 Read and Follow ALL Safety Instructions eee ken eten eee 2 Safety OOV
68. rrel parameters to the next press the Right or Left arrow keys This moves the highlight to the first entry of the second barrel etc Totals Menu The Totals menu Figure 28 shows the cumulative run time of the system a component of the system or an error Some individual items may be reset where available by highlighting the item and pressing the RESET button The RESET button is only displayed for items that may be reset such as hours since the motor seal was changed or the number of compressor cycles Pressing the BACK button returns to the Choose menu and saves the changes The descrip tion of each item in the Totals list is shown in Table 25 To move between one set of barrel parameters and the next press the Right or Left arrow keys This highlights the first entry of the second barrel etc Publication Number 621260373SER 36 O 2008 2009 IMI Cornelius Inc CC Ginelus 3 Viper Service Manual TOTALS POWER ON 00079 34 SLEEP 00034 21 SYSTEM ERROR 00003 45 COMP RUN 1 00006 53 12 51P COMP CYCLES 1 0000012 MAR 04 BARREL REFG 1 00006 54 BACK Figure 28 Totals Screen Table 25 Display Value Description POWER ON HHHHH MM Shows how long the machine has been powered up SLEEP HHHHH MM Shows how long the machine has been in sleep mode SYSTEM ERROR HHHHH MM Shows how long the machine has had a system error COMP RUN 1 HHHHH MM Shows how long the compressor has bee
69. s cleared 10 sec after restoral CLOCK System The real time system clock is not functioning MTR CTL System Motor control EEPROM is bad or missing EEPROM Table 7 Button Description BACK Returns the display to the Select menu RESET Allows the user to reset the highlighted error This button only appears on certain manually resettable errors 24 O 2008 2009 IMI Cornelius Inc Enti Error Log Menu Setup Menu O 2008 2009 IMI Cornelius Inc Viper Service Manual The Error Log screen displays information about any errors generated by the unit as shown in Figure 18 If no errors have been detected the right side of the display is blank To view more than one error press the Up or Down arrows on the right side of the display to scroll through the error log Button functions are described in Table 8 ERROR ERROR NUMBER 2 LOG 43 COMM FAIL OCCUR 2 44 PM l 3 04 08 1251P CLEAR 2 52 PM MAR 04 3 04 08 BACK BEBE ae Figure 18 Error Log Screen Table 8 Button Description BACK Returns the display to the Select menu The Setup menu provides the means to change various settings to local preferences such as time date and temperature formats It also allows the user to adjust the unit for the type of syrup being served in each barrel To access the Setup menu from the Barrel Status menu press the MENU button This displays the Select menu shown in Figure 15 Press the
70. salign the CO2 metering orfice To replace one of these solenoids perform the procedure in Table 48 CO2 Metering Orfice CO2 Shutoff CO2 Valve Shutoff Solenoid i EM Figure 46 Side View of CO2 Shutoff Solenoid 2 Barrel Unit Table 48 Step Action Disconnect power from the unit Disconnect the CO2 supply from the unit Remove the rear cover and side panels alo mn Carefully remove the tubing from the right angle fitting at the rear of the valve Be sure not to damage the CO2 metering orfice located above the fitting Fig ure 46 Remove the tubing from the front of the valve o O Remove the two 2 locknuts mounting the valve and solenoid to the base Remove the two 2 mounting screws from the bottom of the mounting bracket Replace the valve and solenoid Reverse the procedure to reinstall the valve and solenoid into the unit 10 Test the unit for CO2 leaks O 2008 2009 IMI Cornelius Inc 61 Publication Number 621260373SER Viper Service Manual Cines 3 Table 48 Step Action 11 Replace the rear and side panels 12 Reconnect power to the unit SYRUP AND WATER SHUTOFF SOLENOID REPLACEMENT The syrup and water shutoff valves and solenoids are mounted on a single bracket as shown in Figure 47 Perform the procedure in Table 49 to replace the valves Valves amp Solenoids Syrup Shutoff Valves amp
71. ssemble the dispensing valve 17 Lubricate the caged o ring Carefully install the caged o ring onto the valve from the straight end opposite tapered end Lubricate the grooves that the o ring rides to fill in all void areas around the o ring 18 Carefully install the valve with the caged o ring in the dispensing valve body 19 Install the spring fitting knob and lever parts torsion spring and spring hous ing assembly by reversing the removal procedure Do not tighten down the hold down plates securing the spring housing at this time 20 After re installing the faceplate turn the dispensing valve spring housing to the left counterclockwise to put tension on the tension spring Apply just enough tension so that the dispense valve shaft returns to the closed position after release Do not overtighten Overtightening results in a high activation force on the valve NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant to lubricate the o rings The syrup systems should be sanitized every 180 days by a qualified service technician following the sanitizer manufacturer s recommendations or when changing syrup types The sanitizing process consists of emptying the barrel washing the lines and barrel cleaning the BIB connectors rinsing and refilling the system 51 Publication Number 621260373SER Viper Service Manual Emptying a Barrel Flushing the System of Syrup Publication Numb
72. starts the barrel starts back up when the sleep cycle ends Wakeup should be scheduled for approximately one hour before product is required NOTE Setting the sleep time after midnight requires you to set it during the next day i e Saturday night at 1am must be set as 1am on Sunday etc If this type of setting is required you cannot set another sleep cycle during that following day i e Sunday Table 16 Step Action Procedure 1 Set sleep and wakeup Open the Events Setup menu shown in Figure 22 times by pressing the GO button 2 Select DAY The DAY field is highlighted 3 Set DAY Use the or buttons at the bottom of the display to set the desired day or all days 4 Select SLEEP Use the up and down arrows to highlight SLEEP 5 Set hour field Use the left and right arrows to select the hour field and press the or buttons to change the hour 6 Set minute field Use the left and right arrows to select the minute field and press the or buttons to change the minutes 15 min increments 29 Publication Number 621260373SER Viper Service Manual CCineliis Table 16 Step Action Procedure 7 Select AM PM field Ifthe 12 hour clock option is selected use the left and right arrows to select the AM PM field Then press the or buttons to change between AM and PM 8 Select DAY for Wakeup Repeat Steps 2 and 3 as needed 9 Select WAKEUP Use the up an
73. sure the Product BRIX valve is in the BRIX position 4 Hold a waste container under the brix tube to collect syrup from the syrup line and open the manual syrup flow valve see Figure 32 to start filling the syrup line with plain water Continue to hold the manual syrup flow valve open until clean water starts coming out of the BRIX tube 5 Release the manual syrup flow valve and turn the Product BRIX valve to the Product position 6 Open the manual water flow valve see Figure 32 to start filling the barrel with water At the same time open the faceplate relief valve until water comes out 7 When the barrel is full press the SPIN button on the Barrel Status menu while highlighting the appropriate barrel This starts the scraper blade Allow blade to operate for fifteen seconds 8 Turn barrel OFF by pressing the OFF button 9 Place a waste container under the barrel dispensing valve Open the dispens ing valve and dispense all wash water from the barrel When the pressure in the barrel drops from the Barrel Maintenance menu press the PURGE button to re pressurize the barrel with CO2 As the wash water level lowers in the bar rel partially close the valve to avoid spurting 52 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual Table 39 Step Action 10 Perform rear barrel seal replacement See Barrel Motor Seal Replacement on page 56 11 Perform inspection and replacement
74. syrup types are changed Perform the procedure in Table 36 to clean the BIB connec tors O 2008 2009 IMI Cornelius Inc 49 Publication Number 621260373SER Viper Service Manual Enti Table 36 Step Action 1 Open the merchandiser and select OFF for the barrel to be cleaned Remove the quick disconnect from the BIB container Fill a suitable pail or bucket with soap solution Pe oe N Submerge the disconnect in the soap solution and then clean it using a nylon bristle brush Do not use a wire brush Rinse with clean water and dry Servicing Motorman Dispensing Valves Publication Number 621260373SER NOTE Dispensing valves with caged o rings should be serviced lubri cated every six months and o rings should be replaced once a year Refer to Figure 39 and perform the procedure in Table 37 to lubricate or change the caged o rings in each dispensing valve on the unit ded RETAINING SPRING HOUSING SCREW 2 TORSION SPRING at d HOLD DOWN SPRING FITTING PLATE 2 Wi DISPENSING o VALVE BODY CAGED O RING NG VALVE F s KNOB vr Figure 38 Self Closing Dispensing Valve Table 37 Step Action 1 Defrost freeze cylinders shut unit down disconnect electrical power from Unit 2 Perform the procedure in Table 38 to empty the barrels 3 Remove the hex nuts and flat washers securing the faceplate to the freeze barrel then remov
75. t min or max value for 30 sec without changing MOTOR STALL Barrel Motor stalled A two minute defrost and two retries are allowed then the message is displayed METER FAIL Barrel Metering chip is nonresponsive BRL RECOVER Barrel Barrel viscosity is too high Motor cannot rotate Automatic two minute defrost to thaw barrel COM ERR STAT Limp Communications error the system continues to run HIGH VOLTAGE System The unit is experiencing voltage greater than 260VAC System is enabled when line voltage drops below 260VAC for two minutes LOW VOLTAGE System The unit is experiencing voltage less than 200VAC System is enabled when line voltage rises above 200VAC for two minutes NO MOTOR Barrel The motor is reporting no current draw when acti vated Motor is unplugged or thermal cutoff has tripped FILL ERROR Barrel Barrel has not filled properly within 2 min H20 OUT System Water pressure is too low for proper operation This error occurs when the H20 sensor reports no or low water pressure for more than one second Error is cleared 10 sec after restoral CO2 OUT System CO2 pressure is below required operating pressure This error occurs when the CO2 sensor reports no or low CO2 pressure for more than one second Error is cleared 10 sec after restoral SYRUP OUT Barrel Syrup pressure is below required operating pres sure This error occurs when the syrup sensor reports no or low syrup pressure for more than one second Error i
76. t the bottom of display to open day light savings time display shown in Figure 21 2 Select DST Use the up and down arrows to select DST 3 Set DST on Use the button to turn on daylight savings time 4 Select SPRING MONTH Use up and down arrows to select SPRING MONTH 5 Set SPRING MONTH Use the or buttons at the bottom of the display to set the correct month 6 Select SPRING WEEK Use up and down arrows to select SPRING WEEK 7 Set SPRING WEEK Use the or buttons at the bottom of the display to set the correct week The choices are 1 2 3 or L 8 Select FALL MONTH Use the up and down arrows to select FALL MONTH 9 Set FALL MONTH Use the or buttons at the bottom of the display to set the correct month 10 Select FALL WEEK Use up and down arrows to select FALL WEEK 11 Set FALL WEEK Use the or buttons at the bottom of the display to set the correct week The choices are 1 2 3 or L When the daylight savings settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 19 The Events Setup menu shown in Figure 22 allows the user to set sleep periods for the unit and to lock out the defrost cycle during peak busy times Sleep periods and defrost lockouts may be programmed for any day of the week or for all days of the week depending on business requirements Button functions are described in Table 15 EVENT DAY SETUP
77. 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 16 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 1 FREEZE DATA OUTLET TEMP 33 F VISCOSITY 9 REFRIGERATION ON 12 51P AV OZ HR 3 HR 80 MAR 04 DEFROST TIMER 2 50 23 eM BRL IN EBENE cc Figure 16 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 621260373SER 22 O 2008 2009 IMI Cornelius Inc Ginelus D Vi
78. the Main menu and turns off all the active loads This screen should only be used by qualified technicians to troubleshoot the system 2008 2009 IMI Cornelius Inc 35 Publication Number 621260373SER Viper Service Manual CCineliis MANUAL POS LIGHTING COMPRESSOR 1 HOT GAS SOL 1 PRODUCT SOL 1 CO2 VALVE 1 LLS VALVE 1 BACK ON OFF EBENEN lt gt Figure 27 Manual Diagnostic Screen The items shown in Table 24 are for the first barrel in the unit only The list includes additional components with their related barrel number i e Hot Gas Sol 2 etc CAUTION The compressor can suffer damage if it is allowed to run without either a hot gas defrost or liquid line solenoid open The software is designed to turn on the hot gas sole noid for a barrel to prevent damage from occurring Table 24 Display Description POS LIGHTING This selection turns the Point Of Sale lighting on and off COMPRESSOR 1 This selection turns the compressor on and off HOT GAS SOL 1 This selection opens and closes the hot gas solenoid for barrel 1 PRODUCT SOL 1 This selection opens and closes the product solenoids and valves for barrel 1 CO2 VALVE 1 This selection opens and closes the CO2 solenoic and valve for barrel 1 LLS VALVE 1 This selection opens and closes the Liquid Line solenoid and valve for barrel 1 BRL MOTOR 1 This selection turns the barrel 1 motor on and off To move between one set of ba
79. the bottom of the display to set the desired hour 7 Set minute field Use left and right arrows to select minute field 8 Use the and buttons at the bottom of the display to set the desired minute in 15 min increments 9 Select AM PM field If the 12 hour clock option is selected use the left and right arrows to select the AM PM field 10 Use the button at the bottom of the display to set the AM PM field 11 Select DEFROST LOCK Repeat Steps 2 through 10 for the DEFROST 2 LOCK 2 time if desired 12 Select DEFROST LOCK Repeat Steps 2 through 10 for the DEFROST 3 LOCK 3 time if desired When the defrost lockout settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 19 Publication Number 621260373SER 30 O 2008 2009 IMI Cornelius Inc CE Viscosity Setup Menu Options Setup Menu 2008 2009 IMI Cornelius Inc Viper Service Manual The viscosity maintained in the freeze barrels depends on the type of product being served Some products are served best at a higher viscosity while others require a lower viscosity for best quality The Viscosity menu shown in Figure 23 allows the user to adjust the viscosity in each barrel to the optimum setting for each type of syrup 1 VISC RANGE 6 48 110 2 VISC RANGE 6 48 110 ate BACK ALL n lt gt Figure 23 Viscosity Setup Screen Refer to the Installation manual for the recommended settings
80. the compres Sor is on HOT BARREL Off System Occurs when the barrel outlet temperature exceeds 115 F for more than one minute and the compres sor is off MTR CTL FAIL System The motor controller reported a fault triacs are shorted and there is a loss of motor on off function ality TCO OPEN System TCO Temperature Cut Off has occurred on the refrigeration oulet of a barrel or the 24VAC power has failed O 2008 2009 IMI Cornelius Inc 23 Publication Number 621260373SER Viper Service Manual Publication Number 621260373SER C Ges Table 6 Displ A aos splayed Action Type Description Message COMM ERR IO System A communications error occurred between the lO board and the Ul board COMM ERR System UI board cannot communitcate with the motor MTR board BARREL Barrel Compressor has been on for more than 45 minutes REFRG and the viscosity of the barrel is not satisfied with no draws MTR CAL ERR Barrel Occurs if a calibration initiated from the Motor Setup menu fails This indicates that the power draw of the motor is outside the allowable calibra tion range CMP HI PRESS System This error is generated if the low side pressure is greater than 55 psi for greater than 30 sec Only checked when barrels are in freeze mode and com pressor is running more than two minutes BRL TEMP OUT Barrel Indicates thermistor reading is a
81. tized and all sanitizing solution must be purged from the syrup systems All liguids after sanitizing must be purged from the unit A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components MOUNTING ON A COUNTER A WARNING When installing the unit on a counter top the counter must be able to support a weight in excess of 450 Ibs to insure adequate support for the unit O 2008 2009 IMI Cornelius Inc 3 Publication Number 621260373SER Viper Service Manual DisPENSED PRODUCT CONDITIONS Overrun as Applied to Carbonated Beverages Overrun Definition Overrun is a Variable Specific Product Ingredi ents Affect Overrun BRIX Affects Overrun Publication Number 621260373SER 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 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 ac
82. to all days Publication Number 621260373SER 72 2008 2009 IMI Cornelius Inc CGinelus 3 Viper Service Manual Troubleshooting Product Not Cold Problem Probable Cause Remedy Compressor not Run A Barrel not in ON mode A Turn barrel to ON ning B No voltage to compressor B Check power at contactor L1 L2 T1 T2 C Bad start components C Check components and wiring D Compressor s thermal overload D Check resistance of compressor protector open windings and check incoming line voltage E Open or shorted compressor wind E Check resistance of compressor ings windings F Badcontrol board F Troubleshoot replace if necessary Compressor Running A Low refrigerant A Repair leak and weigh in new but not Cooling charge B Restricted condenser filter B Clean or repair C Condenser fan motor blade defec C Repair or replace tive D Hot gas valve leaking or open D Replace E Defective compressor E Repair or replace Restricted Air Flow A Dirty filter A Clean filter B Dirty condenser B Clean condenser C Damaged fins C Repair replace if necessary D Not enough clearance around D Ensure proper spacing around unit unit Fan Motor A Bad connection A Check connect B Bad motor B Replace motor C Cracked or bent fan blade C Replace fan blade Hot Gas Valve A Miswired A Correct wiring B Defective coil B Replace coil C Defective product delivery b
83. to insure proper operation of the system on a long term basis Refer to Table 33 for a listing of the semi annual maintenance items Inspecting and Replacing Scraper Blades Scraper blades should be inspected for wear during the semi annual mainte nance check To inspect the blades perform the procedure in Table 35 Table 35 Step Action 1 See Purging a Barrel on page 34 2 When purging is complete remove power from the unit 3 Remove the four 4 3 4 in nuts from the faceplate and slowly remove the faceplate from the unit 4 Slowly pull the blade assembly out of the barrel 5 Rinse and inspect the blade assembly for signs of wear 6 If there is significant wear on the blades Reverse or replace them depending on the wear pattern 7 Replace the blade assembly and bushings PN 2392 onto the motor shaft in the barrel 8 Re install the faceplate and replace the four 4 mounting nuts Hand tighten the nuts untill the faceplate makes contact with the gasket then use a wrech to tighten the nuts an additional 1 4 turn Be careful not to over tighten the nuts or cracking of the faceplate may result 9 Refill the barrel with product See Filling a Barrel on page 34 10 When barrel fill is complete perform a motor calibration See Calibrating a Motor on page 40 Cleaning the Syrup Connections Syrup connections should be cleaned at least every six months or when
84. unit 3 Open the relief valve on the front of the barrel to ensure that pressure is eer CAUTION Barrel pressure MUST be relieved before removing the aceplate 4 Remove the four 4 3 4 in nuts from the faceplate and slowly remove the faceplate from the unit 5 Carefully pull the blade assembly out of the barrel 6 Remove any remaining product from the barrel 7 Rinse and inspect the blade assembly and barrel for signs of wear Replace if necessary 8 Remove the seal and spacer from the rear of barrel 9 When old seal and spacer are removed use a clean soft cloth to clean between the motor shaft and the barrel to remove any remaining product Publication Number 621260373SER 56 O 2008 2009 IMI Cornelius Inc CE Viper Service Manual Installing a New Seal Perform the procedure in Table 43 Figure 41 and Figure 42 to replace the barrel seal with a new seal When installing a new seal NEVER use oil or silicon based lubricants This can cause the new seal to rotate and LEAK Note Orientation Motor Shaft 2008 2009 IMI Cornelius Inc Table 43 Step Action 1 Remove the old seal and the spacer see Table 42 2 Remove the new seal from its packaging 3 Clean the spacer 4 Slide the spacer with slots toward the motor housing over the motor shaft 5 Lubricate the inside of the seal using Dow Corning 111 Lubricant and Sealant
85. ure Switch Replacement Ile l ene 67 Display Board Replacement 1 uice a Coe NPA ae RORIS dob HD SR PLE P dada 68 Control Board Replacement aaa wa BRA Seeded dew eeu xe x Fe edd Re 69 Backward Forward Compatibility with Older Software Versions 70 Motor Board Replacements 1064 Re EE REESE EPI RENE AA 70 Troubleshooting osos ees rr EE EROR HEROS HER ROCA S S REOR eased D ARA 72 Troubleshooting the System oo rra OR en OUT RR KAG KE ee Ree eke Sede eee ee MN 72 Troubleshooting Product Not Cold s Lange ER nis a ra ow UR SRE pace RR 73 MANUAL OVERVIEW O 2008 2009 IMI Cornelius Inc Viper Service Manual 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 ti
86. ure 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 14 is the home screen for the unit During normal operation this screen is displayed on the control panel BARREL 1 FREEZE 87 STATUS 2 FREEZE 68 12 51P MAR 04 AN MENU ON OFF DFRST SPIN EBENE ae Figure 14 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 ited to a four minute cycle SPIN Turns off refrigeration if on and mixes the product in the barrel 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 15 The Setup and Maintenance menus are accessed through the buttons shown at the bottom of the display NOTE If security is turned on the MAINT button is not displayed O 2008 2009 IMI Cornelius Inc 21 Publication Number 621260373SER Viper Service Manual Cines 3 SELECT UNIT DATA ERROR STATUS ERROR LOG 12 51P MAR 04 NG MAIN SETUP MAINT GO Figure 15 Select Screen When the Select menu is displayed the Unit Data is highlighted To access the Unit Data menu press
87. urting 5 Complete the procedure When the barrel is completely empty close the dis pensing valve and press the STOP button at the bot tom of the display to turn off the purge Press the BACK button to return to the Select menu NOTE When the PURGE button is pressed it changes to a STOP button Table 21 Step Action Procedure 1 Fill a barrel From the Select menu Figure 25 open the Barrel Maintenance menu shown in Figure 26 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select Fill function Press the FILL button at the bottom of the display to fill the highlighted barrel 4 Finish filling the barrel When the fill completes intermittently open and close the relief valve to bleed CO2 from the barrel 5 Complete the procedure Press the STOP button at the bottom of the display to stop the fill Press the BACK button to return to the Select menu NOTE When FILL button is pressed it changes to a STOP button 34 O 2008 2009 IMI Cornelius Inc Viper Service Manual Run the Barrel Motor Table 22 Step Action Procedure 1 Run a barrel From the Setup menu Figure 25 open the Barrel Maintenance menu shown in Figure 26 2 Select the barrel Ge the Up and Down arrows to highlight the desired arrel 3 Select Run function Press the SPIN button at the bottom of the display to start the motor in the highlighted barrel 4 Stop the procedure Press the
88. w FCB 4 34 36 PSIG 30 Foaming Agent FCB Syrup w o FCB 4 32 36 PSIG 30 Foaming Agent FUB FUB 7 N A 30 NOTE For citric syrups adjust the CO2 pressures down by 2 4 PSIG from the above to compensate for the lower CO2 adsorption Publication Number 621260373SER 14 O 2008 2009 IMI Cornelius Inc Viper Service Manual eit IIYYVO 3233344 Wt 1FJAVE 323383 e LLA e y 4 0 8 9 AB SISd 0 Cit MNVL NOISNVdX3 Sl YILVM INV Z NI dNYAS tx 9ISd 8 440 LNO SISd SS NI LNI 0 z anuas 9 v TI A0 wem 9 O9ISd 82 440 LND 0 DISd Z NI LNI 0 Vit MNVL 0 0 NOISNVdX3 e 6 0 H 0 0 L NI dNYAS 0 H 8 SISd 87 440 102 a 8 r1 DISd SS NI 102 ES ke YALVMONV m 0 ANYAS DH 9ISd 8Z 440 1NI g Pouan gt ile 9ISd Z NI LNI SINTVA OH A a dni dNYAS ANY YILVM 0 EIA RENA 1OYLNO9 MOH IA MANO 3ATVA NOAH Z02 a E E 9 ewe eee ee amp e UI amp Me olsdss 440 no 8 A ae 9ISd P9 NI LNI A QION310S e LU m YOLVINDIY gs JUNSSIYA uo1v1n933 fa E Houms YINIVIS JUNSSIYA AN ai olsa 9 JUNSSIVA Y gt te te a e eee o dad oisdi i s2 Y 4 oisaoo oisasz 1v Alddns 8 LV Alddns e A ddns Z02 AlddNS YILVM OIL VIN3HOS TFAAVAE 130d H3dl Figure 9 2 Barrel System Schematic Publication Number 621260373SER 15 O 2008 2009 IMI Cornelius Inc Viper Service Manual LA KR ep c ep ep ep ep gp
89. with Older Software Versions With version 3 0 software release several of the boards used to control the equipment will not be backward compatible with boards containing version 2 x of the software Please refer to the table below for compatibility Table 59 ou Eco orb lon V2 x Part Number V3 x Part Number earn ality User Interface UI 620314871S 620314871 100S No Input Output IO 6203148695 620314869 100S No Motor Control 620314868S 620314868S Yes Status 6203148748 6203148748 Yes Language Chips 629096930XX 629096931XX No The user interface Ul board and the input output I O board must have same software version for correct operation If the UI board and the IO board do not have the same software versions an error will be displayed on the UI The error displayed will depend upon which board has 2 x software and has 3 x Either X BRL TEMP OUT will be displayed or H20 OUT will be displayed followed 30 seconds later with X BRL TEMP OUT If either of these messages is displayed after changing a control board check the software version The current software version for each board can be found through the menu screen Select MENU UNIT DATA then press the VER key The control boards will also have a label marked with the part number A 100 suffix has been added to the part numbers for each of these boards to indicate version 3 0 software release The foreign language chips are software version depe
90. y This function is referred to as Viscosity Setting There are selectable viscosity ranges from 1 9 The higher the number selected the more viscous the frozen product in the barrel becomes This increased viscosity is achieved by freezing the product in the barrel to a lower temperature thereby increasing ice crystal size growth As the ice crystal size increases however there is potential for product quality to diminish Cornelius recommends that the viscosity settings be set at the lowest possible set ting to achieve the desired drink quality In most typical installations using a sugar based syrup acceptable drink quality can be achieved by programmed viscosity set tings in the range of 3 5 for Viper Diet FCB syrups freeze much more readily than sugar based syrups so the viscosity setting should be selected at the minimum value available which is 1 or 2 for the Viper STARTING THE UNIT O 2008 2009 IMI Cornelius Inc The following table Table 32 describes the basic procedure for starting the Viper Refer to the Operator s Manual P N 6212603730PS for details on operation of the Viper unit 45 Publication Number 621260373SER Viper Service Manual C Get Table 32 Step Action Procedure 1 Open the merchandiser Open the merchandiser and expose the control panel 2 Turn on the barrels Turn all barrels on by pressing the buttons labeled ON to start the normal refrigeration process 3 Close th

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