Cornelius VIPER (E) 2 FLAVOR Service Manual Download Page 4

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Setting the Sleep and Wake up Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Setting Defrost Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Viscosity Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Options Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Setting the Temperature Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Setting the Date Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Setting the Time Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Setting the POS Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Setting the Type of Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Barrel Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Purging a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Filling a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Run the Barrel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rinsing a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Calibrating a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

System Menu   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Security  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39
Pressure Sensors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintaining Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dispensed Product Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Programmed Defrost Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Sleep Mode Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Viscosity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cleaning Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Semi-Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Inspecting and Replacing Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Cleaning the Syrup Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Servicing Motorman Dispensing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Sanitizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Emptying a Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Flushing the System of Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Sanitizing the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Summary of Contents for VIPER (E) 2 FLAVOR

Page 1: ...FLAVOR VIPER E 3 FLAVOR VIPER E 4 FLAVOR Service Manual Release Date November 06 2008 Publication Number 621260373SER Revision Date May 10 2016 Revision N Visit the Cornelius web site at www corneliu...

Page 2: ...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 alter...

Page 3: ...Variable 4 Specific Product Ingredients Affect Overrun 4 BRIX Affects Overrun 4 Low Dispensing Volume Affects Overrun 4 Carbonation Level in Liquid Product Affects Overrun 4 Freezing Affects Overrun...

Page 4: ...up Menu 34 Motor Setup Menu 37 Calibrating a Motor 38 System Menu 39 Security 39 Pressure Sensors 40 Operation 41 Maintaining Product Quality 41 Dispensed Product Throughput 41 Programmed Defrost Sche...

Page 5: ...ater Shutoff Solenoid Replacement 56 CO2 Regulator Replacement 57 Condenser Fan Motor Replacement 58 Compressor Replacement 59 Hot Gas Solenoid Replacement 59 Liquid Line Solenoid Replacement 60 Syrup...

Page 6: ......

Page 7: ...y hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS Carefullyreadandfollow allsafety messagesinthis manualandsafety signsontheunit Keepsaf...

Page 8: ...y result in injury or equipment damage SHIPPING AND STORAGE Before shipping storing or relocating the unit the unit must be sanitized and all sanitizing solution must be drained from the system A free...

Page 9: ...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 s...

Page 10: ...ike anti freeze in water The higher the BRIX the greater the resistance of the product to freezing Conversely in products with lower BRIX freezing takes place at higher temperatures than for high BRIX...

Page 11: ...ransparent 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 valve...

Page 12: ...Viper Service Manual Publication Number 621260373SER 6 2008 2016 Cornelius Inc Figure 1 Viper System 2 Barrel Refrigeration Schematic...

Page 13: ...Viper Service Manual 2008 2016 Cornelius Inc 7 Publication Number 621260373SER Figure 2 Viper System 3 Barrel Refrigeration Schematic...

Page 14: ...Viper Service Manual Publication Number 621260373SER 8 2008 2016 Cornelius Inc Figure 3 Viper System 4 Barrel Refrigeration Schematic...

Page 15: ...Viper Service Manual 2008 2016 Cornelius Inc 9 Publication Number 621260373SER Figure 4 Viper 2 Barrel Wiring Diagram W Transducer...

Page 16: ...Viper Service Manual Publication Number 621260373SER 10 2008 2016 Cornelius Inc Figure 5 Viper 3 Barrel Wiring Diagram...

Page 17: ...Viper Service Manual 2008 2016 Cornelius Inc 11 Publication Number 621260373SER Figure 6 Viper 4 Barrel Wiring Diagram...

Page 18: ...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 ap...

Page 19: ...s etc will impact settings These settings 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 a...

Page 20: ...Viper Service Manual Publication Number 621260373SER 14 2008 2016 Cornelius Inc Figure 8 2 Barrel System Schematic...

Page 21: ...Viper Service Manual 2008 2016 Cornelius Inc 15 Publication Number 621260373SER Figure 9 3 Barrel System Schematic...

Page 22: ...Viper Service Manual Publication Number 621260373SER 16 2008 2016 Cornelius Inc Figure 10 4 Barrel System Schematic...

Page 23: ...controlling the unit the control system keeps track of the diagnostic information used when adjusting and or repairing the machine The control system needs to be accessed in the following situations...

Page 24: ...ur directional arrows that may be used on a screen to activate and control various the functions of the system Each button that is active for a given menu has a label directly above it The label descr...

Page 25: ...d the interactions and settings that are controlled by that menu System Menus The system menu structure allows the user to control the unit through the control panel Operational settings optional para...

Page 26: ...E If security is turned on the MAINT button is not displayed Figure 14 Select Screen When the Select menu is displayed the Unit Data is highlighted To access the Unit Data menu press the GO button Ref...

Page 27: ...that can be generated by the system These error types and a description of their meaning are listed in Table 5 MAINT Displays and opens Maintenance menu if security is off or accessed GO Opens the hi...

Page 28: ...t of a bar rel or the 24VAC power has failed COMM ERR IO System A communications error occurred between the IO board and the UI board COMM ERR MTR System UI board cannot communicate with the motor boa...

Page 29: ...rent draw when activated Motor is unplugged or thermal cutoff has tripped FILL ERROR Barrel Barrel has not filled properly within 2 min H2O OUT System Water pressure is too low for proper operation Th...

Page 30: ...GO button to access that menu BACK MAIN SETUP MAINT GO SELECT 12 51P MAR 04 CLOCK SETUP EVENTS SETUP VISC SETUP OPTION SETUP BACK MAIN SETUP MAINT GO Figure 18 Setup Screen Clock Setup Menu Select th...

Page 31: ...reen 2 Select hour field Use the left and right arrows to select hour field 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...

Page 32: ...at the bottom of display to open daylight savings time display shown in Figure 20 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...

Page 33: ...ation requirements Setting the Sleep and Wake up Times Sleep and wake up times are set on the Event Setup menu shown in Figure 21 To set the sleep and wake up times perform the procedure in Table 15 W...

Page 34: ...nd press the or but tons to change the hour 6 Set minute field Use the left and right arrows to select the minute field and press the or but tons to change the minutes 15 min increments 7 Select AM PM...

Page 35: ...are complete press the BACK button to save the settings and return to the Select menu shown in Figure 18 Options Setup Menu The Option Setup menu allows the user to set the various options available...

Page 36: ...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 t...

Page 37: ...ure for waking up a barrel is shown in Table 23 BARREL MAINT 12 51P MAR 04 1 PURGE 2 OFF BACK PURGE FILL SPIN Figure 25 Barrel Maintenance Screen Purging a Barrel NOTE When the PURGE button is pressed...

Page 38: ...p the fill Press the BACK button to return to the Select menu Table 21 Step Action Procedure 1 Run a barrel From the Setup menu Figure 24 open the Barrel Maintenance menu shown in Figure 25 2 Select t...

Page 39: ...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 solenoid for a barrel to prevent damage from occurring To move between o...

Page 40: ...atic 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 25 Table 24 Display Va...

Page 41: ...e 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 tim...

Page 42: ...Supply Valve Barrel 2 Valves shown in BARREL position w Splash Panel Removed Flow Controls Barrel 2 Flow Controls Barrel 1 Viper Service Manual Publication Number 621260373SER 36 2008 2016 Cornelius...

Page 43: ...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 differ...

Page 44: ...ght the desired barrel 3 Select the proper motor type Press the or buttons at the bottom of the display to select the proper motor type 4 Complete the procedure Press the BACK button at the bottom of...

Page 45: ...ure 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 secur...

Page 46: ...ible to install sensors in the field but it is not recommended because system refrigerant charge may be lost The low side pressure sensor is used to monitor compressor reversal If it is not installed...

Page 47: ...d help assure that product quality is maintained NOTE Data in Table 31 assumes equipment has been correctly installed commissioned and cali brated as per directions contained in all technical literatu...

Page 48: ...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 setting...

Page 49: ...er The air filter should be cleaned at least once a month more often in harsh environments Perform the procedure in Table 34 to clean the air cleaner Table 33 Preventative Maintenance Summary Maintena...

Page 50: ...l maintenance check To inspect the blades perform the procedure in Table 35 Table 34 Step Action 1 Open the merchandiser 2 Remove the filter shown in Figure 37 by grasping the two tabs and sliding it...

Page 51: ...ding 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 unti...

Page 52: ...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 t...

Page 53: ...spensing valve body 19 Install the spring fitting knob and lever parts torsion spring and spring housing assembly by reversing the removal procedure Do not tighten down the hold down plates securing t...

Page 54: ...e 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 av...

Page 55: ...r At the same time open the faceplate relief valve until water comes out 3 From the Barrel Status menu press the SPIN button while highlighting the appropriate barrel This starts the scraper blade All...

Page 56: ...o Figure 39 for water filter location Water Filter Figure 39 Water Filter Location Table 42 Step Procedure 1 Disconnect power from the unit 2 Turn off and disconnect the water supply to the unit 3 Rem...

Page 57: ...eal with a new seal Table 43 Step Action 1 Purge the barrel See Purging a Barrel on page 31 2 When purging is complete disconnect power from the unit 3 Open the relief valve on the front of the barrel...

Page 58: ...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...

Page 59: ...the foam pack barrel assembly as shown in Figure 43 To replace a barrel motor perform the procedure in Table 46 Table 45 Step Action 1 Turn the 3 way Product Supply valve behind the splash panel see...

Page 60: ...ure in Steps 1 through 8 of Table 43 2 Disconnect the motor from the circuit by unplugging the connector 3 Remove the motor by removing the four 4 bolts holding the motor to the bar rel assembly 4 Ins...

Page 61: ...Reverse the procedure to install the new capacitor 7 Reconnect power to the unit 8 Refill the barrel with product See Filling a Barrel on page 32 9 When barrel fill is complete perform a motor calibra...

Page 62: ...rup and water shutoff valves and solenoids are mounted on a single bracket as shown in Figure 47 Per form the procedure in Table 50 to replace the valves Table 49 Step Action 1 Disconnect power from t...

Page 63: ...ove the rear cover and side panels 4 Remove the water and syrup lines from the input to the valves 5 Remove the Wye tube from the output top of the valves by loosening the nuts between the Wye and the...

Page 64: ...wo 2 screws and the right side panel 3 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 facepl...

Page 65: ...ndenser 4 Lift the fan and shroud off the unit 5 Remove the four screws and washers securing the fan to the shroud 6 Replace the fan 7 Reverse the procedure to install the new fan 8 Reconnect power to...

Page 66: ...dure in Table 56 Table 54 Step Action 1 Disconnect power from the unit 2 Remove the side panels 3 Reclaim refrigerant from the system 4 Carefully remove the insulation and remove the hot gas valve and...

Page 67: ...from the rear To replace the water pressure switch perform the procedure in Table 57 Water Pressure Switch Figure 53 View of Water Pressure Switch Table 56 Step Action 1 Disconnect power to the unit 2...

Page 68: ...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 57 Step Action 1 Disconnect power from the unit 2 Remove the side panel...

Page 69: ...r 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...

Page 70: ...e parts for any unit check the software version of the UI and IO boards and be sure to order the correct board as listed in Table 60 MOTOR BOARD REPLACEMENT When replacing or testing electronic compon...

Page 71: ...Mounting Studs Viper Service Manual 2008 2016 Cornelius Inc 65 Publication Number 621260373SER Figure 56 View of Motor Board in E Box...

Page 72: ...xit diagnostics turn to ON DFRST or SPIN D Replace Low High voltage ERROR A Line Voltage out of SPEC spec is 205 255 VAC for 60 Hz and 196 265 VAC for 50 Hz B Error range 180 260 A 1 Check line voltag...

Page 73: ...C Damaged fins D Not enough clearance around unit A Clean filter B Clean condenser C Repair replace if necessary D Ensure proper spacing around unit Fan Motor A Bad connection B Bad motor C Cracked or...

Page 74: ......

Page 75: ...Cornelius Inc www cornelius com...

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