Cornelius 3 - Manuals - manualsarea.com

Page 2 - Trademarks and Copyrights:

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of...

Page 7 - INTRODUCTION; ANUAL

Viper Installation Manual © 2010, IMI Cornelius Inc. - 1 - Publication Number: 621360041TBSER INTRODUCTION M ANUAL O VERVIEW 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 ...

Page 8 - SAFETY INSTRUCTIONS; ALL S; Different Types of Alerts; Recognize Safety Alerts

Viper Installation Manual Publication Number: 621360041TBSER - 2 - © 2010, IMI Cornelius Inc. SAFETY INSTRUCTIONS R EAD AND F OLLOW ALL S AFETY I NSTRUCTIONS Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminat...

Page 9 - ALL WIRING AND PLUMBING MUST CONFORM TO; CO

Viper Installation Manual © 2010, IMI Cornelius Inc. - 3 - Publication Number: 621360041TBSER 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 unauthor- ized modifications to the...

Page 10 - Overrun, as Applied to Carbonated Beverages

Viper Installation Manual Publication Number: 621360041TBSER - 4 - © 2010, IMI Cornelius Inc. ! DANGER: CO 2 displaces oxygen. Strict attention MUST be observed in the prevention of CO 2 gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area...

Page 11 - Viper Installation Manual; BRIX Affects Overrun; gas; Freezing Affects Overrun

Viper Installation Manual © 2010, IMI Cornelius Inc. - 5 - Publication Number: 621360041TBSER Each product formulation has its own peculiarities regarding the way the product absorbs carbonation and the way it releases carbonation. BRIX Affects Overrun Sugar in carbonated drinks is like anti-freeze ...

Page 12 - Viper Service Manual; SYSTEM OVERVIEW; NTRODUCTION; The Viper unit consists of the following systems and hardware:

Viper Service Manual Publication Number: 621360041TBSER - 6 - © 2010, IMI Cornelius Inc. SYSTEM OVERVIEW I NTRODUCTION 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 ...

Page 13 - HEORY

Viper Service Manual © 2010, IMI Cornelius Inc. - 7 - Publication Number: 621360041TBSER T HEORY OF O PERATION The refrigeration system schematic is shown in Figure 1. It shows the basic con-figuration for the Viper refrigeration system.The wiring diagram of the 3-Barrel Viper unit is shown in Figur...

Page 15 - Figure 3. Typical Bulk Cylinder CO

Viper Service Manual © 2010, IMI Cornelius Inc. - 9 - Publication Number: 621360041TBSER An overall schematic of the three delivery systems contained in the unit are shown in Figure 5. The CO 2 system is on top, the water system is in the middle and the syrup system is at the bottom of the diagram. ...

Page 18 - ONTROL; Introduction

Viper Service Manual Publication Number: 621360041TBSER - 12 - © 2010, IMI Cornelius Inc. Water System Incoming water flows to a water pressure regulator that is preset to 30 psig. It flows through the water booster pump, to the regulator and through a sold-out switch. Once through the boost pump, t...

Page 19 - Control Panel Display; Figure 6. Control System Display; Control Panel Buttons; Menu Buttons

Viper Service Manual © 2010, IMI Cornelius Inc. - 13 - Publication Number: 621360041TBSER The control panel has a structured organization of menus. The outline of this structure is shown in Figure 7. The Maintenance sub-menu is not visible when the security feature is on.The first menu that is displ...

Page 21 - System Menus; Figure 8. Main Screen; Main Menu; NOTE: If security is turned on, the MAINT button is not displayed.

Viper Service Manual © 2010, IMI Cornelius Inc. - 15 - Publication Number: 621360041TBSER C ONTROL P ANEL M ENU D ESCRIPTIONS 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 syst...

Page 22 - Unit Data Menu; Figure 10. Unit Data Screen

Viper Service Manual Publication Number: 621360041TBSER - 16 - © 2010, IMI Cornelius Inc. Figure 9. Select Screen When the Select menu is displayed, the Unit Data is highlighted. To access the Unit Data menu, press the GO button. Refer to Table 3, the Select menu, for button functions. Unit Data Men...

Page 23 - Error Status Menu; Figure 11. Error Status Screen

Viper Service Manual © 2010, IMI Cornelius Inc. - 17 - Publication Number: 621360041TBSER Error Status Menu The Error Status menu, shown in Figure 11, 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 ty...

Page 25 - Error Log Menu; Figure 12. Error Log Screen; Setup Menu; Figure 13. Setup Screen; Table 8

Viper Service Manual © 2010, IMI Cornelius Inc. - 19 - Publication Number: 621360041TBSER Error Log Menu The Error Log screen displays information about any errors generated by the unit, as shown in Figure 12. If no errors have been detected, the right side of the display is blank. To view more than...

Page 26 - Clock Setup Menu; Figure 14. Clock Setup Screen; Setting the Clock

Viper Service Manual Publication Number: 621360041TBSER - 20 - © 2010, IMI Cornelius Inc. Clock Setup Menu Select the CLOCK SETUP menu from the Select menu, shown in Figure 13. This displays the Clock Setup menu, shown in Figure 14. Button functions are described in Table 10. Figure 14. Clock Setup ...

Page 28 - Events Setup Menu; Figure 16. Event Setup Screen; Step

Viper Service Manual Publication Number: 621360041TBSER - 22 - © 2010, IMI Cornelius Inc. When the daylight savings settings are complete, press the BACK button to save the settings and return to the Select menu, shown in Figure 13. Events Setup Menu The Events Setup menu, shown in Figure 16, allows...

Page 29 - Setting Events; Button

Viper Service Manual © 2010, IMI Cornelius Inc. - 23 - Publication Number: 621360041TBSER 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 13. Setting Events Events setup allows...

Page 30 - Setting Defrost Lockout

Viper Service Manual Publication Number: 621360041TBSER - 24 - © 2010, IMI Cornelius Inc. 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 13. Setting Defrost Lockout From the Barrel Status menu, shown in Figur...

Page 31 - Figure 17. Viscosity Setup Screen; Pulse Valve Setup Screen

Viper Service Manual © 2010, IMI Cornelius Inc. - 25 - Publication Number: 621360041TBSER 17, allows the user to adjust the viscosity in each barrel to the optimum setting for each type of syrup. Figure 17. Viscosity Setup Screen Refer to the Installation manual for the recommended settings based on...

Page 32 - Option Setup Menu

Viper Service Manual Publication Number: 621360041TBSER - 26 - © 2010, IMI Cornelius Inc. To set all barrels in the system to the same duration setting, perform Steps 1 through 4 in Table 19 and then press the ALL button at the bottom of the display while highlighting the duration setting you desire...

Page 33 - Setting the Date Format; Maintenance Menu

Viper Service Manual © 2010, IMI Cornelius Inc. - 27 - Publication Number: 621360041TBSER Setting the Temperature Format 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 ...

Page 34 - Purging a Barrel

Viper Service Manual Publication Number: 621360041TBSER - 28 - © 2010, IMI Cornelius Inc. 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 some...

Page 35 - Filling a Barrel

Viper Service Manual © 2010, IMI Cornelius Inc. - 29 - Publication Number: 621360041TBSER NOTE: When the PURGE button is pressed, it changes to a STOP but-ton. Filling a Barrel NOTE: When FILL button is pressed, it changes to a STOP button. Run the Barrel Motor NOTE: When RUN button is pressed, it c...

Page 37 - Totals Menu; Figure 23. Totals Screen; Display

Viper Service Manual © 2010, IMI Cornelius Inc. - 31 - Publication Number: 621360041TBSER To move between one set of barrel 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 23) shows...

Page 38 - BRIX Setup Menu

Viper Service Manual Publication Number: 621360041TBSER - 32 - © 2010, IMI Cornelius Inc. 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 disp...

Page 40 - Motor Setup Menu; Model

Viper Service Manual Publication Number: 621360041TBSER - 34 - © 2010, IMI Cornelius Inc. Figure 27. Flow Controls with Panel Removed 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 rem...

Page 41 - Calibrating a Motor

Viper Service Manual © 2010, IMI Cornelius Inc. - 35 - Publication Number: 621360041TBSER Figure 28. Motor Setup Screen Calibrating a Motor Calibration of motors is typically required when a motor or any associated barrel components (i.e., scraper blades, seal, faceplate, etc.) is removed or replace...

Page 42 - System Menu; The description of these items is shown in Table 32.

Viper Service Manual Publication Number: 621360041TBSER - 36 - © 2010, IMI Cornelius Inc. System 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 pr...

Page 43 - Security; NOTE: If a pressure sensor is open, the pressure reading is 386 PSIG.

Viper Service Manual © 2010, IMI Cornelius Inc. - 37 - Publication Number: 621360041TBSER Security 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 m...

Page 45 - OPERATION; AINTAINING; Dispensed Product Throughput; Viper

Viper Service Manual © 2010, IMI Cornelius Inc. - 39 - Publication Number: 621360041TBSER OPERATION M AINTAINING P RODUCT Q UALITY 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 ...

Page 46 - Programmed Defrost Scheduling; Setting”. This setting is adjustable from 0 to 100%

Viper Service Manual Publication Number: 621360041TBSER - 40 - © 2010, IMI Cornelius Inc. Programmed Defrost Scheduling 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 ...

Page 47 - TARTING

Viper Service Manual © 2010, IMI Cornelius Inc. - 41 - Publication Number: 621360041TBSER S TARTING THE U NIT The following table, Table 32, describes the basic procedure for starting the Viper. Refer to the Operator’s Manual (P/N 621360041TBOPR) for details on operation of the Viper unit. Table 32 ...

Page 48 - PREVENTATIVE MAINTENANCE; UMMARY; Preventative Maintenance Summary

Viper Service Manual Publication Number: 621360041TBSER - 42 - © 2010, IMI Cornelius Inc. PREVENTATIVE MAINTENANCE S UMMARY 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 ...

Page 49 - ONTHLY; Cleaning Air Filter; Figure 32. Air Filter Location; Tab

Viper Service Manual © 2010, IMI Cornelius Inc. - 43 - Publication Number: 621360041TBSER M ONTHLY M AINTENANCE 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 T...

Page 50 - EMI; Inspecting and Replacing Scraper Blades

Viper Service Manual Publication Number: 621360041TBSER - 44 - © 2010, IMI Cornelius Inc. S EMI -A NNUAL M AINTENANCE There are several procedures that should be completed on a semi-annual basis. There procedures help to insure proper operation of the system on a long term basis. Refer to Table 33 f...

Page 51 - Servicing Motorman Dispensing Valves; cated) every six months and o-rings should be replaced once a year.

Viper Service Manual © 2010, IMI Cornelius Inc. - 45 - Publication Number: 621360041TBSER Servicing Motorman Dispensing Valves 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 34 and perform the ...

Page 52 - Sanitizing the System; Emptying a Barrel; To empty the barrel, perform the procedure in Table 38.

Viper Service Manual Publication Number: 621360041TBSER - 46 - © 2010, IMI Cornelius Inc. NOTE: Use Dow-Corning DC-111 (P/N 321471000) light grade silicone lubricant to lubricate the o-rings. Sanitizing the System The syrup systems should be sanitized every 180 days by a qualified service technician...

Page 53 - Sanitizing the Barrel

Viper Service Manual © 2010, IMI Cornelius Inc. - 47 - Publication Number: 621360041TBSER NOTE: The unit should be sanitized every 180 days by a qualified service technician following the sanitizer manufacturer’s recommendations. Flushing the System of Syrup After emptying the barrel, the barrel sho...

Page 54 - Flushing the System

Viper Service Manual Publication Number: 621360041TBSER - 48 - © 2010, IMI Cornelius Inc. Flushing the System Flush the wash water from the system by performing the procedure in Table 41. ! CAUTION: Flush the system thoroughly, residual sanitizing solution left in the system may create a health haza...

Page 55 - Cleaning the Water Filter; Figure 34. Water Filter Location; Disconnect power from the unit.

Viper Service Manual © 2010, IMI Cornelius Inc. - 49 - Publication Number: 621360041TBSER Cleaning the Water Filter 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, ...

Page 56 - COMPONENT REPLACEMENT; ARREL; Removing the Existing Seal

Viper Service Manual Publication Number: 621360041TBSER - 50 - © 2010, IMI Cornelius Inc. COMPONENT REPLACEMENT The following are procedures for servicing the major components of the Viper system. B ARREL M OTOR S EAL R EPLACEMENT The barrel motor seal is typically replaced during the semi-annual pr...

Page 57 - Installing a New Seal; NEVER; use oil or silicon; Motor Shaft

Viper Service Manual © 2010, IMI Cornelius Inc. - 51 - Publication Number: 621360041TBSER 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...

Page 58 - Motor Seal Leak Test; Seal

Viper Service Manual Publication Number: 621360041TBSER - 52 - © 2010, IMI Cornelius Inc. Figure 42. Side View of Seal and Spacer on Motor Shaft Motor Seal Leak Test After replacing the motor seal, it is advisable to test the seal under pressure before refilling the barrel with product. Perform the ...

Page 59 - OTOR; Figure 44. View of Motor Run Capacitors

Viper Service Manual © 2010, IMI Cornelius Inc. - 53 - Publication Number: 621360041TBSER Figure 43. Side View of Motor Showing Two of the Four Mounting Bolts M OTOR R UN C APACITOR R EPLACEMENT The motor run capacitors, shown in Figure 44, are mounted at the rear of the unit between the barrel moto...

Page 60 - ATER; Figure 45. Rear View of Water Pump

Viper Service Manual Publication Number: 621360041TBSER - 54 - © 2010, IMI Cornelius Inc. W ATER P UMP R EPLACEMENT 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 ...

Page 61 - ULSE; The CO

Viper Service Manual © 2010, IMI Cornelius Inc. - 55 - Publication Number: 621360041TBSER CO 2 P ULSE V ALVE R EPLACEMENT The CO 2 valves, 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 CO 2 with th...

Page 63 - NOTE: Be sure to reclaim refrigerant when replacing compressor.

Viper Service Manual © 2010, IMI Cornelius Inc. - 57 - Publication Number: 621360041TBSER C ONDENSER F AN M OTOR R EPLACEMENT 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 50 to remove and reinstall a motor. Fig...

Page 64 - OT

Viper Service Manual Publication Number: 621360041TBSER - 58 - © 2010, IMI Cornelius Inc. H OT G AS S OLENOID R EPLACEMENT The hot gas valves and solenoids, shown in Figure 50, are located near the cen-ter of the unit on the right and left sides. Whenever a hot gas valve and solenoid is replaced, th...

Page 66 - Figure 53. View of Water Pressure Switch

Viper Service Manual Publication Number: 621360041TBSER - 60 - © 2010, IMI Cornelius Inc. Figure 52. View of Syrup Pressure Switch and Valve W ATER P RESSURE S WITCH R EPLACEMENT The water pressure switch, shown in Figure 53, is located in back of the water filter, when viewed from the rear of the u...

Page 67 - ISPLAY; Figure 54. View of Display Board

Viper Service Manual © 2010, IMI Cornelius Inc. - 61 - Publication Number: 621360041TBSER D ISPLAY B OARD R EPLACEMENT 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...

Page 68 - Figure 55. View of Control Board in E-Box; Software Compatibility

Viper Service Manual Publication Number: 621360041TBSER - 62 - © 2010, IMI Cornelius Inc. C ONTROL B OARD R EPLACEMENT 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...

Page 70 - TROUBLESHOOTING; ROUBLESHOOTING; Problem; Check wiring to contactor.

Viper Service Manual Publication Number: 621360041TBSER - 64 - © 2010, IMI Cornelius Inc. TROUBLESHOOTING T ROUBLESHOOTING THE S YSTEM Problem Probable Cause Remedy Unit will not run. A. Unit not plugged in.B. Circuit breaker.C. No power at L1 or L2 on contac- tor. D. Low voltage at T1 or T2. A. Plu...

Page 71 - Troubleshooting Product Not Cold

Viper Service Manual © 2010, IMI Cornelius Inc. - 65 - Publication Number: 621360041TBSER Troubleshooting Product Not Cold Problem Probable Cause Remedy Compressor not Run- ning A. Barrel not in ON mode.B. No voltage to compressor. C. Bad start components.D. Compressor’s thermal overload protector “...