Cornelius FRUITISTA 3 manuale d’uso

FRUITISTA VIPER 3 FLAVOR Service Manual Release Date: Sep t emb e r 9, 201 0 Publication Number: 6213600 41TBSER Revision Date: Dece mber 20, 2011 Revision: B Visit the IMI Cornelius web site at www.corne lius.com for all your Literature needs.[...]

The products, technical information, and instructions co ntained in this manua l are subject to change without notice. These instructions are not intended to cover a ll details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this eq uipment. This manual assumes th at the[...]

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Instructions. . . . . . . . . . . . . . . . . [...]

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Clock Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . .[...]

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Viper Installation Manual © 2010-2011, IMI Cornelius Inc. - 1 - Publication Number: 621360041TBSER INTRODUCTION M ANUAL O VERVIEW The organization of this manual allows th e user to scan quickly to the subject of interest along the lef t side of a pa ge and to read the det ail about the subject or procedure on the rig ht side of the page. The manu[...]

Viper Installation Manual Publication Number: 621360041TBSER - 2 - © 2010-2011, IMI Cornelius Inc. SAFETY INSTRUCTIONS R EAD AND F OLLOW ALL S AFETY I NSTRUCTIONS Safety Over view • Read and follow ALL SAFETY INSTRUCTIONS in this manual an d any warning/caution labels on the unit (dec als, labels or laminated cards) . • Read and underst and AL[...]

Viper Installation Manual © 2010-2011, IMI Cornelius Inc. - 3 - Publication Number: 621360041TBSER without supervision. Y oung children should be su pervised to ensure that they do not play with the appliance. • Keep your unit in proper wor king condition and do not allow unautho r- ized modifications to the unit. Q UALIFIED S ERVICE P ERSONNEL [...]

Viper Installation Manual Publication Number: 621360041TBSER - 4 - © 2010-2011, IMI Cornelius Inc. ! DANGER: CO 2 displaces oxygen. Strict attention MUST be observe d in th e pr ev en tio n of CO 2 gas leaks in the entire CO 2 and sof t drink system. If a CO 2 gas leak is suspected, particula rly in a small area, IMMEDIATELY ventilate the cont ami[...]

Viper Installation Manual © 2010-2011, IMI Cornelius Inc. - 5 - Publication Number: 621360041TBSER Each product formulation has its own pe culiarities regard ing the way the product absorbs carbonation and the wa y it releases carbonation. BRIX Affects Overrun Sugar in carbonated drinks is like anti-freeze in water . The higher the BRIX, the great[...]

Viper Service Manual Publication Number: 621360041TBSER - 6 - © 2010-2011, IMI Cornelius Inc. SYSTEM OVERVIEW I NTRODUCTION The Viper unit consists of the following systems and hardware: Multiple freeze barre ls, each containing an internal scraper bar d riven by an AC motor . A refrigeration syste m and an intelligent, hot gas d efrost system. Th[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 7 - Publication Number: 621360041TBSER T HEORY OF O PERATION The refrigeration system schematic is show n in Figure 1. It shows the basic con- figuration for the V iper refrigeratio n system. The wiring d iagram of the 3- Barrel V iper unit is sh own in Figure 2. This diagram shows the det ail[...]

Viper Service Manual Publication Number: 621360041TBSER - 8 - © 2010-2011, IMI Cornelius Inc. Figure 2. Fruitista Vipe r 3-Barrel Wiring Diagram[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 9 - Publication Number: 621360041TBSER An overall schematic of the three deliv ery systems cont ained in the unit are shown in Figure 5. The CO 2 system is on top, the wa te r system is in the middle and the syrup system is at the bottom of the diag ram. The CO 2 system interacts with both the[...]

Viper Service Manual Publication Number: 621360041TBSER - 10 - © 2010-2011, IMI Cornelius Inc. Figure 4. Typi cal Tank CO 2 Connectio n T able 1 provides guidelines for machi ne settings ba sed on general syrup type. Several factors, including sy rup formulation, level of citric acids, etc, will impact settings. These settings are to provide in it[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 11 - Publication Number: 621360041TBSER Figure 5. 3-Barrel System Schem atic[...]

Viper Service Manual Publication Number: 621360041TBSER - 12 - © 2010-2011, 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 , the water supp ly is split to each barrel an[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 13 - Publication Number: 621360041TBSER The control p anel has a structured organi za tion 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 displayed after the unit is powered up and s[...]

Viper Service Manual Publication Number: 621360041TBSER - 14 - © 2010-2011, IMI Cornelius Inc. Figure 7. Software Structure Initialization Screens Barrel Statu s (Home Screen) Error Status Unit Data Error Log Clock Setup Event Setup Option Setup Viscosity Setup Brix Setup Motor Setup Barrel Maint. Manual Diag Totals Barrel Data Unit Data Software [...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 15 - Publication Number: 621360041TBSER C ONTROL P ANEL M ENU D ESCRIPTIONS The following section describes the info rm ation displaye d on ea ch contro l p anel menu and the interaction s and settings that are controll ed by that menu. System Menus The system menu structure allows the user to[...]

Viper Service Manual Publication Number: 621360041TBSER - 16 - © 2010-2011, IMI Cornelius Inc. Figure 9. Select Screen When the Select menu is displayed, the Unit Data is highlighted. T o access the Unit Data menu, press the GO button. Re fer to T able 3, the Select menu, for button functions. Unit Data Menu The Unit Data screen , shown in Figur e[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 17 - Publication Number: 621360041TBSER Error Status Menu The Error S tatus menu, shown in Figure 1 1, displays any current errors con- tained in the Error Messages List. There are three type s of errors that can be gene rated by the system. These error types and a description of th eir meanin[...]

Viper Service Manual Publication Number: 621360041TBSER - 18 - © 2010-2011, IMI Cornelius Inc. Error Log Menu The Error Log screen displays informa tion about any errors generated by the unit, as shown in Figure 12. If no err ors have been detected, the right side of the display is blank. T o view more than one error , press the Up or Down arrows [...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 19 - Publication Number: 621360041TBSER the right side of the display to scroll thr ough the error lo g. Button functions are described in T able 8. Figure 12. Error Log Screen Setup Menu The Setup menu provides the means to change various settings to local preferences, such as time, date an d[...]

Viper Service Manual Publication Number: 621360041TBSER - 20 - © 2010-2011, IMI Cornelius Inc. Clock Setup Menu Select the CLOCK SETUP menu from th e Select menu, shown in Figure 13. This displays the Clock Setu p menu, shown in Figure 14. Button functions ar e described in T able 10. Figure 14. Clock Setup Scre en Setting the Clock Select the CLO[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 21 - Publication Number: 621360041TBSER Setting Daylight Sav- ings Time Once the date and time are set prope rly , daylight savings time settings can be done. The Dayl ight Savings T ime menu is shown in Figure 15. If daylight savings time is off, pr ess the + button to activate it. The button[...]

Viper Service Manual Publication Number: 621360041TBSER - 22 - © 2010-2011, IMI Cornelius Inc. When the daylight savings settings are complete, press the BACK button to save the settings and return to the Select menu, sh own in Figure 13. Events Setup Menu The Events Setup menu, shown in Figure 16, allo ws th e user to set sleep periods for the un[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 23 - Publication Number: 621360041TBSER Setting the Sleep and Wakeup Times Sleep and wakeup times ar e set on the Event Setup menu shown in Figure 16. T o set the sleep and wakeup times, pe rform the procedure in T able 16. When the unit goes into a slee p peri od, the barr el automatically d [...]

Viper Service Manual Publication Number: 621360041TBSER - 24 - © 2010-2011, IMI Cornelius Inc. When the defrost lockout se tt ings are complete, pre ss the BACK button to save the settings and return to the Select me nu, shown in Figure 13. Viscosity Setup Menu The viscosity maint ained in the freeze barrels depends on the type of pr oduct being s[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 25 - Publication Number: 621360041TBSER T o set all barrels in the system to the same viscosity setting, perform St eps 1 through 4 in T able 18 and then pre ss th e AL L button at the botto m of the display while highlighting the viscosity setting you de sire for all the barrels. When the vis[...]

Viper Service Manual Publication Number: 621360041TBSER - 26 - © 2010-2011, IMI Cornelius Inc. Option Setup Menu The Option Setup menu allows the user to set the various options available in the system. These options are listed in T able 20. The Option Setup m enu is shown in Figure 19. The functions of the display butto ns change, depending on th[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 27 - Publication Number: 621360041TBSER Setti ng the P OS Light ing POS Lighting is controlled by the POS LIGHTING field on the Op tion Setup menu (Figure 19). T o turn off the me rchandiser lighting, press the OF F button while the POS LIGHTING field is highlight ed. T o turn on the merchandi[...]

Viper Service Manual Publication Number: 621360041TBSER - 28 - © 2010-2011, IMI Cornelius Inc. technician, the “Do Not Drink” status indi cators are illuminated on the bar rels when entering the Barrel Maintenance menu. The procedure for purging a barrel is shown in T able 21. The procedure for filling a bar- rel is shown in T able 22. The pro[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 29 - Publication Number: 621360041TBSER Run the Barrel Motor NOTE: When RUN button is pressed, it changes to a STOP button. Rinsing a Barrel When rinsing a barrel, the Barr el Maintenance menu cannot be use d. The pro- cedure must be done manually , as descri bed in T able 24. Manual Diagnosti[...]

Viper Service Manual Publication Number: 621360041TBSER - 30 - © 2010-2011, IMI Cornelius Inc. Figure 22. Manual Diag nostic Screen The items shown in T able 25 are for the first barrel in the unit only . The list includ es additional components with their related barrel nu mber , i.e. Hot Gas Sol #2, etc. CAUTION: The compressor can suffer damage[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 31 - Publication Number: 621360041TBSER Figure 23. Tot als Screen BRIX Setup Menu BRIX is important to the quality of the final product. The BR IX menu facilitates the extraction of a sample of product from the unit for BRIX measuremen t. There is an automatic three se cond dispense of product[...]

Viper Service Manual Publication Number: 621360041TBSER - 32 - © 2010-2011, IMI Cornelius Inc. Figure 24. BRIX Setup Scre en Figure 25. Splash Panel Mounting Scr ews 4 Access BRIX menu Press MENU. Then press the SETUP button. 5 Set barrel for BRIX From the Setup screen (Fi gure 13), open the BRIX Setup screen, shown in Figure 24 6 Use the Up and D[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 33 - Publication Number: 621360041TBSER Figure 26. Product Contro l Valves Figure 27. Flo w Co ntrols with Panel Rem ove d Motor Setup Menu Motor setup is initially done at the facto ry and does not need to be changed unless a barrel moto r or bar rel com p on en ts are replac e d, adju st ed [...]

Viper Service Manual Publication Number: 621360041TBSER - 34 - © 2010-2011, IMI Cornelius Inc. to match the motor type being inst alled. It provides the co rrect tab l e of electrical characteristics from imbedded settings lo cated in non-volatile memo ry . Perform the procedure descri bed in T able 30 to change the motor type setting. Insure that[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 35 - Publication Number: 621360041TBSER ! CAUTION: Calibration must be performed whe n the product in the barrel is com - pletely liquid. There must not be an y ice on the scraper bla de. System Menu The System menu is use d dur ing pr oductio n to set up the unit. It also allo ws the technici[...]

Viper Service Manual Publication Number: 621360041TBSER - 36 - © 2010-2011, IMI Cornelius Inc. Security System security is located on the System menu. It allows a supervisor or service technician to keep unau thorized pers onnel fro m accessing the Maintenance menu. This feature is activated on the System menu. When security is turned on, users c [...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 37 - Publication Number: 621360041TBSER Figure 30. System Screen When the pre ssure sensors selection is high lighted, pr essing the NONE button removes the pressur e readings from the Unit Da ta screen, shown in Figur e 31. If LOW is selected, only the low pressure read ing is displayed. If H[...]

Viper Service Manual Publication Number: 621360041TBSER - 38 - © 2010-2011, IMI Cornelius Inc. OPERATION M AINTAINING P RODUCT Q UALITY It has been determined that the following fact ors can affect the rate at which pr oduct quality diminishes (as indica ted by a change in pr oduct appearance) . 1. Dispensed Product Throughput 2. Programmed Defros[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 39 - Publication Number: 621360041TBSER Programmed Defrost Scheduling The control system in the V iper system in cludes a function to automatically defrost product in the barr el at pro gr am m ed inte rv al s based on the viscosity of the product. Programmed defrost s are scheduled frequently[...]

Viper Service Manual Publication Number: 621360041TBSER - 40 - © 2010-2011, IMI Cornelius Inc. S TARTING THE U NIT The following t able, T able 32, describes the basic procedure for st arting the Viper . Refer to the Ope rator ’s Manu al (P/N 621360041TBOPR) for deta ils on operatio n of the Viper unit. Table 32 Step Action Procedure 1. Op en th[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 41 - Publication Number: 621360041TBSER PREVENTATIVE MAINTENANCE S UMMARY There are no daily maintenance pr ocedures required on the V iper unit oth er than normal cleanup of spills or overspray a nd emptying the drip tray . Normal equip- ment maintenance interval s are listed in T able 33. It[...]

Viper Service Manual Publication Number: 621360041TBSER - 42 - © 2010-2011, IMI Cornelius Inc. M ONTHLY M AINTENANCE A general inspection of the machine for leaks and cleanliness should be done on a weekly basis. Any abnormal conditions sho uld be reported and corr ected when noticed. Cleaning Air Filter The air filter should be cleaned at least o[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 43 - Publication Number: 621360041TBSER S EMI -A NNUAL M AINTENANCE There are several pro cedures that should be complete d on a semi-annual basis. There procedures h elp to insure proper operation of the system on a long term basis. Refer to T able 33 for a listing of the semi-annual mainte n[...]

Viper Service Manual Publication Number: 621360041TBSER - 44 - © 2010-2011, IMI Cornelius Inc. 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 33 and perform the procedure in T able 37 to lubricate or chan[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 45 - Publication Number: 621360041TBSER 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 sanitize d every 180 days by a qualified ser vice technician following the sa nitizer manufacturer’[...]

Viper Service Manual Publication Number: 621360041TBSER - 46 - © 2010-2011, IMI Cornelius Inc. Flushing the System of Syrup After emptying the barrel, the barrel s hould be flushed of product before pro- ceeding with the sanit i zin g proc edure. Perfor m th e pr oc ed ur e in T able 39. Sanitizing the Barrel Sanitize the syrup system and barrel b[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 47 - Publication Number: 621360041TBSER Flushing the System Flush the wash water from the system by perform ing the procedure in T able 41. ! CAUTION: Flush the system tho roughly, residual sa nitizing solution left in th e system may create a health haza rd. 7. Fill the barrel with sanitizing[...]

Viper Service Manual Publication Number: 621360041TBSER - 48 - © 2010-2011, IMI Cornelius Inc. COMPONENT REPLACEMENT The following are procedu res for servicing the major compon ents of the V iper system. B ARREL M OTOR S EAL R EPLACEMENT The barrel motor seal is typically repl aced during the sem i-annual preven tative maintenance procedure. The [...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 49 - Publication Number: 621360041TBSER Installing a New Seal Perform the proc edure in T able 43, Figure 41 and Figure 42 to replace the bar rel seal with a new seal. When installing a new seal, NEVER use oil or silicon based lubricant s. This can cause the new seal to rot ate and LEAK! Figur[...]

Viper Service Manual Publication Number: 621360041TBSER - 50 - © 2010-2011, IMI Cornelius Inc. Figure 42. Side View of Seal and Spac er on Motor Shaft Motor Seal Leak Test After replacin g th e mo to r se al, it is advi sable to test the seal under pressure before refilling the ba rrel with product. Perform the procedure in T able 44 to ver- ify t[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 51 - Publication Number: 621360041TBSER Figure 43. Side View of Motor Showi ng Two of the Fou r Mountin g Bolts M OTOR R UN C APACITOR R E PLACEMENT The motor run cap acitors, shown in Figure 44, are moun ted at the rear of the unit between the barrel motors. T o replace a run cap acitor , per[...]

Viper Service Manual Publication Number: 621360041TBSER - 52 - © 2010-2011, IMI Cornelius Inc. W ATER P UMP R EPLACEMENT The water pump is located near the re ar , center of the unit. It is moun ted on a bracket facing the rea r of th e un it. T o replace the pump , perf orm the proc ed u re in T able 47. Figure 45. Rear View of W ater Pump 3 Disc[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 53 - Publication Number: 621360041TBSER CO 2 P ULSE V ALVE R EPLACEMENT The CO 2 valves, shown in Figure 46, are lo cated near the center of the unit and are mounted on a bracket to the bottom of the chassis. They control the inje ction of CO 2 with the syru p/water combination to provide the [...]

Viper Service Manual Publication Number: 621360041TBSER - 54 - © 2010-2011, IMI Cornelius Inc. S YRUP AND W ATER S HUTOFF S OLENOID R EPLACEMENT The syrup and water shutof f valves and solenoids are mounted on a single bracket, as shown in Figure 48. Perform th e procedure in T able 49 to re place the valves. Figure 48. View of Shutoff Solen oids [...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 55 - Publication Number: 621360041TBSER C ONDENSER F AN M OTOR R EPLACE MENT The fan mo tor is located on the top of the unit, as shown in Fi gure 49. If the motor needs re placement, perfor m the procedure in T able 50 to remove and reinstall a motor . Figure 49. Cond e nser Fan Mounting Nuts[...]

Viper Service Manual Publication Number: 621360041TBSER - 56 - © 2010-2011, IMI Cornelius Inc. H OT G AS S OLENOID R EPLACEMENT The hot gas valves and soleno ids, shown in Figur e 50, are located n ear the cen- ter of the unit on the right and left sides. Whenever a hot gas valve and solenoid is replaced, the dryer sho uld be repl aced at the s am[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 57 - Publication Number: 621360041TBSER L IQUID L INE S OLENOID R EPLACEMENT The liquid line valves and soleno ids, shown in Figure 51, are located near the center of the unit on the right and lef t sides. Whenever a liquid line valve and solenoid is replaced, the dryer shou ld be replaced at [...]

Viper Service Manual Publication Number: 621360041TBSER - 58 - © 2010-2011, 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, can be viewed from the rear of the unit. Acc ess to the sw itch is obtained by r emoving the le ft side panel of the u[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 59 - Publication Number: 621360041TBSER D ISPLAY B OARD R EPLACE MENT When replacing or testing electr onic comp onents, b e sure to wear a static strap that is connecte d to a ch as sis gr ou nd . Th is pr ot ec ts the electro nic com pon en ts from any static char ge while working on the uni[...]

Viper Service Manual Publication Number: 621360041TBSER - 60 - © 2010-2011, IMI Cornelius Inc. C ONTROL B OARD R EPLACEMENT When replacing or testing electr onic comp onents, b e sure to wear a static strap that is connecte d to a ch as sis gro u nd. Th is pr ot ec ts the electronic componen ts from any static charge while wo rking on the unit. Th[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 61 - Publication Number: 621360041TBSER M OTOR B OARD R EP LACEMENT When replacing or testing electr onic comp onents, b e sure to wear a static strap that is connecte d to a ch as sis gr ou nd . Th is pr ot ec ts the electro nic com pon en ts from any static char ge while working on the unit.[...]

Viper Service Manual Publication Number: 621360041TBSER - 62 - © 2010-2011, IMI Cornelius Inc. TROUBLESHOOTING T ROUBLESHOOTING THE S YSTEM Problem Probable Ca use Remedy Unit will not run. A. Unit not plugged in. B. Circuit breaker . C. No power at L1 or L2 on cont ac- tor . D. Low voltage at T1 or T2. A. Plug in unit. B. Reset/replace circuit br[...]

Viper Service Manual © 2010-2011, IMI Cornelius Inc. - 63 - Publication Number: 621360041TBSER Troubleshooting Product Not Cold Problem Probable Cause Remedy Compressor not Running A. Barrel not in ON mode. B. No voltage to compressor . C. Bad start components. D. Compressor ’s thermal overload protector “open”. E. Open or shorted compressor[...]

Viper Service Manual Publication Number: 621360041TBSER - 64 - © 2010-2011, IMI Cornelius Inc.[...]

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