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 VIPER (E) 3 FLAVOR

LOW OVERRUN

Service Manual

Release Date: May 10, 2016

Publication Number: 621360241LOEWSE

Revision: A

Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

Summary of Contents for VIPER E

Page 1: ...VIPER E 3 FLAVOR LOW OVERRUN Service Manual Release Date May 10 2016 Publication Number 621360241LOEWSE Revision A Visit the Cornelius web site at www cornelius com for all your Literature needs...

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: ...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 Li...

Page 4: ...ng the Type of Syrup 24 Barrel Maintenance 24 Maintenance Menu 24 Barrel Maintenance Menu 24 Purging a Barrel 25 Filling a Barrel 25 Run the Barrel Motor 26 Rinsing a Barrel 26 Manual Diagnostic Menu...

Page 5: ...ling a New Seal 44 Motor Seal Leak Test 46 Barrel Motor Replacement 46 Motor Run Capacitor Replacement 47 Water Pump Replacement 48 CO2 Pulse Valve Replacement 48 Syrup and Water Shutoff Solenoid Repl...

Page 6: ......

Page 7: ...uation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS Carefully read and follow all safety messages in this manual and safety signs on the unit Keep safety...

Page 8: ...e unit as this could result in personal injury CAUTION Before shipping storing or relocating the unit the unit must be sanitized and all sanitizing solution must be drained from the system A freezing...

Page 9: ...o 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 accurat...

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

Page 11: ...vable to facilitate installation service and maintenance Each barrel has a transparent faceplate with an integral relief valve and a removable self closing dispensing valve mounted on the front A remo...

Page 12: ...Viper Low overrun Service Manual Publication Number 621360241LOEWSE 6 2016 Cornelius Inc Figure 2 Low overrun Viper System 3 Barrel Refrigeration Schematic...

Page 13: ...Viper Low overrun Service Manual 2016 Cornelius Inc 7 Publication Number 621360241LOEWSE Figure 3 Low overrun Viper 3 Barrel Wiring Diagram...

Page 14: ...ary 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 t...

Page 15: ...ing syrup for mulation level of citric acids 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 th...

Page 16: ...lator that is preset to 30 psig It flows through the water booster pump to the regulator and through a sold out switch Once through the boost pump the water supply is split to each barrel and is fed t...

Page 17: ...cing Repairing the Machine Checking for Error Messages The control system is accessed using the control panel located behind the lighted merchandiser The control panel contains an LCD display and butt...

Page 18: ...xample 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 Selec...

Page 19: ...igure 8 Main Screen Main Menu To access the menus for the system from the Barrel Status menu press the MENU button This displays the Select menu shown in Figure 9 The Setup and Maintenance menus are a...

Page 20: ...5 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 secur...

Page 21: ...ionality TCO OPEN System TCO Temperature Cut Off has occurred on the refrigeration outlet of a barrel or the 24VAC power has failed COMM ERR IO System A communications error occurred between the IO bo...

Page 22: ...led 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 Barre...

Page 23: ...desired option is highlighted press the GO button to access that menu Figure 13 Setup Screen Clock Setup Menu Select the CLOCK SETUP menu from the Select menu shown in Figure 13 This displays the Cloc...

Page 24: ...ect 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 th...

Page 25: ...Increments the highlighted field by one increment Table 14 Step Action Procedure 1 Set daylight savings time Press DST button at the bottom of display to open day light savings time display shown in...

Page 26: ...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...

Page 27: ...t and right arrows to select the minute field and press the or buttons to change the minutes 15 min increments 7 Select AM PM field If the 12 hour clock option is selected use the left and right arrow...

Page 28: ...igure 13 CO2 Setup Menu The CO2 Setup menu shown in Figure 18 allows the user to adjust the percentage of time that the CO2 pulse valves are open This provides an adjustment of the overrun for the uni...

Page 29: ...he unit press the BACK button to store these settings and return to the Select menu shown in Figure 13 Setting the Temperature Format The temperature format displayed by the unit may be set to either...

Page 30: ...Frozen Un carbonated Beverages Light diet Each of these settings provides the proper viscosity and temperature settings for the type of syrup being used Barrel Maintenance Refer to the next section Ba...

Page 31: ...rel As the product level lowers in the barrel partially close the valve to avoid spurting 5 Complete the procedure When the barrel is completely empty close the dis pensing valve and press the STOP bu...

Page 32: ...re 21 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select Run function Press the SPIN button at the bottom of the display to start the motor in the highlighted barr...

Page 33: ...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 T...

Page 34: ...ber of compressor cycles since the last reset BARREL REFG 1 HHHHH MM Shows how long the barrel has been in refriger ation mode MOTOR ON 1 HHHHH MM Shows how long the motor has been running on a specif...

Page 35: ...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 produ...

Page 36: ...with Panel Removed Splash Panel Retaining Screws Product Supply Valve Barrel 1 Product Supply Valve Barrel 2 Flow Controls Barrel 2 Flow Controls Barrel 1 Product Supply Valve Barrel 3 Flow Controls...

Page 37: ...teristics from embedded settings located in non volatile memory Perform the procedure described in Table 30 to change the motor type setting Insure that the motor type matches the settings listed in T...

Page 38: ...ates 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 33 for a listing of the button functions for t...

Page 39: ...shown in Fig ure 10 and press the UNIT button The System screen shown in Figure 30 is displayed The number and type of sensors in the unit are typically set at the factory and should not be changed D...

Page 40: ...wn in Figure 31 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...

Page 41: ...ly installed commissioned and calibrated as per directions contained in all technical literature published by Cornelius and the recommenda tions contained in this document have been followed Cornelius...

Page 42: ...qual ity In most typical installations using a sugar based syrup acceptable drink quality can be achieved by programmed vis cosity settings in the range of 3 5 for Viper Diet FCB syrups freeze much m...

Page 43: ...is 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 environments Perform the procedu...

Page 44: ...p Action 1 Open the merchandiser 2 Remove the filter shown in Figure 32 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 exce...

Page 45: ...sing Valve 8 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...

Page 46: ...Carefully remove the caged O ring from the valve 13 Wash all the parts in warm water Remove all traces of syrup and lubricant espe cially from the faceplate o rings and dispensing valve If parts are e...

Page 47: ...B from the unit Table 42 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 sur...

Page 48: ...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 Pr...

Page 49: ...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 pa...

Page 50: ...use oil or silicon based lubricants This can cause the new seal to rotate and LEAK Table 45 Step Action 1 Purge the barrel See Purging a Barrel on page 25 2 When purging is complete disconnect power...

Page 51: ...tor 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 ba...

Page 52: ...m pack barrel assembly as shown in Figure 37 To replace a bar rel motor perform the procedure in Table 48 Table 47 Step Action 1 Turn the 3 way Product Supply valve behind the splash panel see Figure...

Page 53: ...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 Install the replacement motor and connect the connector 5...

Page 54: ...etering orifice To replace one of these valves perform the procedure in Table 51 4 Remove the mounting screw from the base of the capacitor 5 Replace the capacitor 6 Reverse the procedure to install t...

Page 55: ...the procedure in Table 52 to replace the valves Table 51 Step Action 1 Disconnect power from the unit 2 Disconnect the CO2 supply from the unit 3 Remove the rear cover and side panels 4 Carefully rem...

Page 56: ...ystem 3 Remove 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...

Page 57: ...e the fan 7 Reverse the procedure to install the new fan 8 Reconnect power to the unit Table 54 Step Action 1 Disconnect power to the unit 2 Remove the rear cover and side panels 3 Label and disconnec...

Page 58: ...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 To replace the liquid line solenoid perform...

Page 59: ...e water pressure switch perform the procedure in Table 58 Table 56 Step Action 1 Disconnect power from the unit 2 Remove the side panels 3 Reclaim refrigerant from the system 4 Carefully unwrap the fo...

Page 60: ...replace the board perform the procedure in Table 59 Figure 49 View of Display Board Table 58 Step Action 1 Disconnect power from the unit 2 Remove the side panel from the unit 3 Turn off the water sup...

Page 61: ...re version of the UI and IO boards and be sure to order the correct board MOTOR BOARD REPLACEMENT When replacing or testing electronic components be sure to wear a static strap that is connected to a...

Page 62: ...e motor board perform the procedure in Table 61 Figure 51 View of Motor Board in E Box Table 61 Step Action 1 Disconnect power from the unit 2 Connect a static strap to your wrist and any convenient c...

Page 63: ...sleep programming C Check sleep programming Barrel status OFF A Not activated B Error has shut off motors C Unit in Diagnostics D Defective touch switch A Turn to ON DFRST or SPIN B Correct error tur...

Page 64: ...lter C Condenser fan motor blade defec tive D Hot gas valve leaking or open E Defective compressor A Repair leak and weigh in new charge B Clean or repair C Repair or replace D Replace E Repair or rep...

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Page 66: ...Cornelius Inc www cornelius com...

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