Cornelius VIPER 3 FLAVOR Installation Manual Download Page 5

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Viper Installation Manual

- 1 -

Publication Number: 621360041TBINS

SAFETY INSTRUCTIONS

EAD

AND

OLLOW

ALL S

AFETY

NSTRUCTIONS

Safety Overview

• Read and follow

ALL SAFETY INSTRUCTIONS

in this manual and any warning/caution labels on the

unit (decals, labels or laminated cards).

• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety

regulations before operating this unit.

Recognition

Different Types of Alerts

DANGER

Indicates an immediate hazardous situation which, if not avoided,

WILL

result in serious injury, death or

equipment damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or
equipment damage.

CAUTION

Indicates a potentially hazardous situation which, if not avoided,

MAY

result in minor or moderate injury or

equipment damage.

AFETY

IPS

• Carefully read and follow all safety messages in this manual and safety signs on the unit.

• Keep safety signs in good condition and replace missing or damaged items.

• Learn how to operate the unit and how to use the controls properly.

•

Do not

let anyone operate the unit without proper training. This appliance is

not

intended for use by

very young children or infirm persons without supervision. Young children should be supervised to
ensure that they do not play with the appliance.

• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.

NOTE: The dispenser is not designed for a wash-down environment and MUST NOT be placed in

an area where water jet could be used.

UALIFIED

ERVICE

ERSONNEL

WARNING

Only trained and certified electrical, plumbing and refrigeration technicians should service this unit.

ALL WIRING

AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD
RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the unit, be alert
to the potential of personal injury or damage to the unit.

Summary of Contents for VIPER 3 FLAVOR

Page 1: ...ER E 3 FLAVOR Installation Manual Release Date April 02 2010 Publication Number 621360041TBINS Revision Date April 26 2016 Revision F Visit the Cornelius web site at www cornelius com for all your Literature needs ...

Page 2: ...ng occurrences including but not limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper voltage 3 inadequate wiring 4 abuse 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and or repair of the Product 10 improper cleaning 11 failure to fol...

Page 3: ...4 Introduction 4 Dispensed Product Conditions 4 Overrun as Applied to Carbonated Beverages 4 Overrun Definition 4 Overrun is a Variable 4 Specific Product Ingredients Affect Overrun 4 BRIX Affects Overrun 4 Low Dispensing Volume Affects Overrun 4 Carbonation Level in Liquid Product Affects Overrun 5 Freezing Affects Overrun 5 Installation 6 Delivery Inspection Unpacking 6 Counter Location 6 Backro...

Page 4: ...ns Setup Menu 15 Events Setup Menu 17 Setting Viscosity 18 CO2 Setup Menu 19 Commissioning the Unit 21 Unit Location 21 Pressurizing the CO2 System 21 Pressurizing the Water System 21 Pressurizing the Syrup System 22 Setting BRIX 23 Testing BRIX Level 23 Adjusting BRIX Level 24 Filling the Barrels 26 Calibrating a Motor 26 Security Menu 27 Troubleshooting 29 Specifications 30 Noise Level 30 ...

Page 5: ...ages in this manual and safety signs on the unit Keep safety signs in good condition and replace missing or damaged items Learn how to operate the unit and how to use the controls properly Do not let anyone operate the unit without proper training This appliance is not intended for use by very young children or infirm persons without supervision Young children should be supervised to ensure that t...

Page 6: ...s in the entire CO2 and soft drink system If a CO2 gas leak is suspected particularly in a small area IMMEDIATELY ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentrations of CO2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH MOUNTING IN OR ON A COUNTER WARNING When installing the unit in or on a counter top ...

Page 7: ... removed from service and or transported the unit must be completely drained of product and rinsed out to remove residual product When transporting the unit make sure that the product bowl is removed from the top of the unit and stored in a safe place for shipment The unit must be carefully tied down or stored in such a manner that the unit will not move during shipment STORAGE WITHIN THE MACHINE ...

Page 8: ...ing of the product These items all affect overrun After these factors have been considered desired viscosity product consistency adjustment may be made on the unit The viscosity adjustment adjusts product texture from very wet to light Specific Product Ingredients Affect Overrun Each syrup has its own specific formulation of makeup Fruit flavors contain citric acids that colas do not Colas also di...

Page 9: ...carbonated form of that drink For example drinks with 3 0 volume of carbonation have more gas breakout in frozen carbonated form and more overrun than drinks that contain 2 0 volumes of CO2 gas Freezing Affects Overrun Freezing causes approximately a 5 7 percent expansion in dispensed frozen carbonated drinks The degree of freezing is limited because the finished drink is intended to be sipped thr...

Page 10: ...ed more than three months from date of production replace the seals according to the instructions accompanying the spare seals supplied with the unit Unite date of manufacture is included in the unit serial no as follows The date code follows the first letter of the serial number The next four numbers reflect the date of manufacture The first two represent the year the next two the week For exampl...

Page 11: ...s may be used if the unit is located directly against a wall The electrical connection is located at the left side of the rear panel and the tubing supplies are located on the right side as shown in Figure 3 Figure 3 Electrical Requirements Refer to the nameplate to determine the power requirements before connecting electrical power to the unit All of the power cords shall comply with safety requi...

Page 12: ...p installation information in Table 2 and begin with the Water Supply Requirements section Strain Relief Terminal Block Figure 4 Table 1 3 Barrel 60Hz 3 Barrel 50Hz 30 A Circuit 30 A Circuit Table 2 Step Action 1 Insure that power to the unit is off DO NOT plug the power cord into the wall outlet at this time 2 Remove the right side and rear panel from the unit 3 Remove the cover from the electric...

Page 13: ...ly line Water Connections Use the appropriate fittings and clamps to connect the water line to the unit Run the tubing for the water 1 2 in ID Min from the water source in the backroom to the unit and make all appropriate connections Do not turn on the water supply to the unit CO2 Requirements WARNING CO2 displaces oxygen Persons exposed to high concentrations of CO2 will experience tremors follow...

Page 14: ... l p p u S 2 O C BIB Syrup BIB Syrup BIB Pump C E D A F I Water Filter Connections Tubing 1 2 Inch Beverage Tubing 3 8 Inch Beverage Tubing 1 4 Inch Beverage Tubing 3 8 Inch Tygon Tubing A B C D E F 1 2 Inch Hose Barb to 3 4 NPT 1 4 Inch Female Flare Nut and Barb 1 4 Direct Connection to Syrup Outlet on Syrup Pump Direct Connection to CO2 Inlet on Syrup Pump Direct Connection to Syrup Inlet on Syr...

Page 15: ...installed to secure the unit to the cart These carts are also designed with movable wheels that act as outriggers to provide stability to the unit when it is being moved WARNING The above listed mounting bolts must be installed and the wheels extended and locked in the outboard position prior to moving the unit FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY DEATH OR EQUIPMENT DAMAGE This complet...

Page 16: ...own in Figure 8 is displayed INITIALIZING PLEASE STAND BY FLASH EEPROM Figure 8 The software runs tests on the flash memory and the EEPROM If they pass PASS is displayed to the right of the appropriate line and the system displays the System Check State screen shown in Figure 9 SW REV UI 000 003 I O 000 002 MOTOR 000 001 STATUS 000 001 Figure 9 Once the System Check State verification is complete ...

Page 17: ...he Option Setup menu To access the Option Setup menu press the MENU button on the Barrel Status menu This displays the MAIN menu shown in Figure 11 Then press the SETUP button to display the Option Setup menu shown in Figure 12 SELECT 12 51P MAR 04 UNIT DATA ERROR STATUS ERROR LOG BACK MAIN SETUP MAINT GO Figure 11 Use the up and down arrows on the right side of the control panel to move between t...

Page 18: ...ttons 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 if using 12 hour format Table 5 Step Action Procedure 1 Set date Use the up and down arrows on the right side of the control panel to highligh...

Page 19: ...1 Set daylight savings time Press the DST button at the bottom of the display to open the daylight savings time display shown in Figure 14 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 the up and down arrows to select SPRING MONTH 5 Set SPRING MONTH Use the or buttons at the bottom of the display to set ...

Page 20: ...POS Lighting POS Lighting is controlled by the POS LIGHTING field on the Option Setup menu Figure 15 To turn off the merchandiser lighting press the OFF button 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 Setting the Type of Syrup Syrup...

Page 21: ...et the defrost lockouts perform the procedure in Table 8 Defrost lockouts should be overlapped by 15 minutes for sequential lockout Table 8 Step Action Procedure 1 Set defrost lockout Open the Events Setup menu shown in Fig ure 16 2 Select DAY Use the up and down arrows to highlight DAY 3 Set DAY Use the and buttons at the bottom of the display to set the desired day or all days 4 Select DEFROST L...

Page 22: ...being served Some products are served best at a higher viscosity while others require a lower viscosity for best quality The Viscosity menu allows the user to adjust the viscosity in each barrel to the optimum setting for each type of syrup Table 9 Step Action Procedure 1 Set sleep and wakeup times Open the Events Setup menu shown in Fig ure 16 by pressing the GO button 2 Select DAY Use the up and...

Page 23: ...of time that the CO2 pulse valves are open This provides an adjustment of the overrun for the unit when using different syrups The valves use a one second interval duration time Setting a valve to 45 activates the valve for 450 msec out of each second The CO2 pulse valves may be set between 0 and 100 in 5 increments To change the settings of the CO2 pulse valves perform the procedure in Table 11 B...

Page 24: ...to save the settings and return to the Select menu shown in Figure 12 Refer to the service manual for other controller functions and features Table 11 Step Action Procedure 1 Set CO2 Pulse valve duration From the Setup screen Figure 12 select the CO2 Setup screen shown in Figure 18 2 Select barrel Use the Up and Down arrows to highlight the desired barrel 3 Select duration field Use Left and Right...

Page 25: ... are to provide initial adjustments to achieve product overruns in the 80 120 range NOTE For citric syrups adjust the CO2 pressures down by 2 4 PSIG from the above to compensate for the lower CO2 adsorption Pressurizing the Water System Perform the procedure in Table 14 to verify the water connection to the unit Table 12 Step Action 1 Open the CO2 cylinder valve slightly to allow lines to slowly f...

Page 26: ...ied 4 Turn the product supply valve to the down BRIX position and open the valve at the end of the sample tube 5 Place the end of the tube in a bucket 6 Manually lift the water valve at the front of the unit Figure 19 to fill the water system 7 When water flows from the sample tube the system is full and you may pro ceed to Table 12 and pressurize the CO2 system 8 Repeat Steps 4 through 7 for each...

Page 27: ...the syrup valve at the front of the unit Figure 19 to fill the syrup system 5 When syrup flows from the sample tube the system is full 6 Check the system for syrup leaks 7 Repeat Steps 2 through 5 for each barrel in the unit 8 Verify that the Do Not Drink and Out of Product lights go off on all barrels and the Syrup Out message clears Table 16 Step Action 1 Remove the drip tray by sliding it forwa...

Page 28: ... a refractometer and read the BRIX value A target BRIX reading of 12 2 0 2 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 11 If BRIX level needs to be adjusted perform the Adjusting BRIX Level proce dure in Table 17 12 Repeat this procedure for each barrel in the system 13 Replace splash panel on u...

Page 29: ... for 30 seconds each to remove air from the barrels 8 Go to the Barrel Maintenance menu and press FILL to fill the barrel 9 Fill the barrel by opening up the barrel faceplate relief valve for the barrel See Figure 23 Fill the barrel to the level shown in Figure 23 approx half way between the relief valve and the top of the barrel for 20 25 overrun 10 After finishing BRIX testing and adjustment for...

Page 30: ...d transit can cause a shift in calibration Calibration establishes a new baseline for the motor assembly This allows the system to determine proper viscosity settings for the motor As a part of installation each barrel should be calibrated using the procedure in Table 18 and Table 19 CAUTION Calibration must be performed when the product in the barrel is completely liquid There must not be any ice...

Page 31: ...to save the settings and return to the Setup menu Table 19 Step Action Procedure 1 Select Motor Setup Use the Up and Down arrows to highlight MOTOR SETUP on the Maintenance menu 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Start calibration Press the CAL button at the bottom of the Motor Setup menu to start the calibration process 4 The calibration cycle continu...

Page 32: ...s 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 extreme 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 syste...

Page 33: ... on Bar rel Status menu A Sleep time set B Clock incorrectly set C No or incorrect wakeup time set A Check programming B Check programming C Check programming Barrel Status OFF A Not activated B Error has shut down barrels C Unit in diagnostics A Turn barrels to ON or SPIN B Correct error turn barrels to ON C Exit diagnostics turn barrels ON No water pressure A Water source not turned on B Filter ...

Page 34: ... 0 17 MPa 90 psig 0 62 MPa max Ventilation Clearance Standard Condenser 2 on both sides or back 12 on top of the unit Equipment Weight 2 Barrel Unit 410 lb 3 Barrel Unit 465 lb 4 Barrel Unit 500 lb CO2 Tubing Size 3 8 in I D 75 ft max CO2 supply pressure to Viper should never exceed 75 psig 0 52 MPa CO2 Pressures To Unit 70 75 psig To BIB Pumps 75 psig To Barrels 36 40 psig typically for FCB To Ex...

Page 35: ......

Page 36: ...Cornelius Inc www cornelius com ...

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