Cornelius 3 manual

FRUITISTA VIPER 3 FLAVOR Service Manual Release Date : September 9, 2010 Publication Number: 62136 0041TBSER Revision D ate: N/A Revision: A 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 all details or variations of the equip ment, nor to provide for eve ry possible contingency in the installation, operation or maintenan ce of this equipment. This manual a ssumes that th[...]

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

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

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . .[...]

[...]

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 lef t side of a page and to read the det ail about the subject or procedure on the rig ht side of the page. The manual p ro[...]

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

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

Viper Installation Manual Publication Number: 621360041TBSER - 4 - © 2010, IMI Cornelius Inc. ! DANGER: CO 2 displaces oxygen. Strict attention MUST be observe d in the preven tion of CO 2 gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particula rly in a small area, IMMEDIATELY ventilate the contam inated area[...]

Viper Installation Manual © 2010, IMI Cornelius Inc. - 5 - Publication Number: 621360041TBSER Each product formulation has its own pe culiarities regarding 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 greater the[...]

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 barre ls, each containing an internal scra per bar driven by an AC motor . A refrigeration system an d an intelligent, hot gas defrost system. The comp[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 7 - Publication Number: 6213600 41TBSER 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 refrigeration system. The wiring d iagram of the 3-Barrel V iper unit is shown in Figu re 2. This diagram shows the det ails of t[...]

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

Viper Service Manual © 2010, IMI Cornelius Inc. - 9 - Publication Number: 6213600 41TBSER 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 ter system is in the middle and the syrup system is at the bottom of the diagram. The CO 2 system interact s with both the wate[...]

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

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

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 thro ugh a sold-out switch. Once through the bo ost pump, the water supp ly is split to each barrel and is[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 13 - Publication Number: 621360041TBSER The control p anel has a structured organi zation of menus. The outline of this structure is shown in Figure 7. The Maintenance su b-menu is not visible when the security feature is on. The first menu that is displayed after the unit is powered up and st abil[...]

Viper Service Manual Publication Number: 621360041TBSER - 14 - © 2010, 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 Ver. [...]

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

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. 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 10, [...]

Viper Service Manual © 2010, 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 Er ror Messages List. There are thre e types of errors that can be generated by the system. The se error types and a description of th eir meaning a [...]

Viper Service Manual Publication Number: 621360041TBSER - 18 - © 2010, IMI Cornelius Inc. COMM ERR IO System A communications error occurred between the IO board and the UI board. COMM ERR MTR System UI board cannot communitcate wit h the motor board. BARREL REFRG Barrel Compressor has been o n for more than 45 minutes and the visco sity of the ba[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 19 - Publication Number: 621360041TBSER Error Log Menu The Error Log screen displays informa t ion about any errors gener ated by the unit, as shown in Figure 1 2. If no errors have been detected, the right side o f the display is blank. T o view more than one erro r , press the Up or Down arrows o[...]

Viper Service Manual Publication Number: 621360041TBSER - 20 - © 2010, IMI Cornelius Inc. Clock Setup Menu Select the CLOCK SETUP menu from t h e Select menu, shown in Figure 13. This displays the Clock Setup me nu, shown in Figure 14. Button functions are described in T able 10. Figure 14. Clock Setup S creen Setting the Clock Select the CLOCK SE[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 21 - Publication Number: 621360041TBSER T o set the date, perform the procedure in T able 12 and refer to Figure 14 . Setting Daylight Sav- ings Time Once the date and time are set properly , daylight savings time settings can be done. The Dayl ight Savings Time men u is shown in Figure 15. If dayl[...]

Viper Service Manual Publication Number: 621360041TBSER - 22 - © 2010, IMI Cornelius Inc. When the daylight savings settings are complete, pr ess the BACK button to save the settings and return to the Select menu, shown in Fig ure 13. Events Setup Menu The Event s Setup menu, shown in Figur e 16, allows the user to set sleep periods for the unit a[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 23 - Publication Number: 621360041TBSER When the slee p and wake up settings a nd the de frost lockout settings ar e complete, press the BACK butt on to save the settings and return to the Select menu, shown in Figure 13. Setting Events Events setup allows the user to set sleep periods for the unit[...]

Viper Service Manual Publication Number: 621360041TBSER - 24 - © 2010, IMI Cornelius Inc. When the sleep and wakeup settings are comple te, press the BACK button to save the settings and return to the Select menu, shown in Fig ure 13. Setting Defrost Lockout From the Barrel S tatus menu, shown in Figure 8, press the MENU button and then press the [...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 25 - Publication Number: 621360041TBSER 17, allows the user to adjust the viscos ity in each barrel to the optimum setting for each type of syrup. Figure 17. Viscos ity Setup Screen Refer to the Installation manual for the recomme nded settings based on syrup type. T o set all ba rrels in the syste[...]

Viper Service Manual Publication Number: 621360041TBSER - 26 - © 2010, IMI Cornelius Inc. T o set all ba rrels in the system to the same duration settin g, perform S teps 1 through 4 in T able 19 and then press the ALL button at the bottom of the display while highlighting th e duration setting yo u desir e for all the barrels. When the duration s[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 27 - Publication Number: 621360041TBSER Setting the Temperature Format The temperature for mat displayed by the un it may be set to either Centigrade or Farenheit. Press the ° F button to display readings in Farenh eit and press the °C button to disp lay reading s in Centigra de. Setting the Date[...]

Viper Service Manual Publication Number: 621360041TBSER - 28 - © 2010, IMI Cornelius Inc. The Maintenance menu is used for barrel mainte nance, diagnostics, BRIX setup and system information. It allows the te ch nician access to the unit during peri- odic mainte nance or tr oublesho oting prob lems. It so metimes ove rrides th e nor- mal inputs fr[...]

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 changes to a STOP button. Rinsing a Barrel When [...]

Viper Service Manual Publication Number: 621360041TBSER - 30 - © 2010, IMI Cornelius Inc. Manual Diagnostic Menu The Manual Diagno s tic menu, shown in F igure 22, is used for troubleshooting and testing the system on a component b a si s. It allows the se rvice technician to turn individual component s of the system on and off for trou bleshootin[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 31 - Publication Number: 621360041TBSER T o move between one set of barrel p arameters to the next, press the Right or Left arrow ke ys. This moves the highlight to the first entry of the second barrel, etc. Totals Menu The T otals men u (Figure 23) shows the cumulative run time of the system, a co[...]

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 se cond dispense of product that prod uces a constant volume[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 33 - Publication Number: 621360041TBSER Figure 24. BRIX Setup S creen Figure 25. Splash Pan el Mounting Screws Figure 26. Product Contro l Valves 15 Replace access panel Replace the hoses and the access panel. Secure the panel wit h the two screws removed in S tep 2. This completes the procedu re. [...]

Viper Service Manual Publication Number: 621360041TBSER - 34 - © 2010, IMI Cornelius Inc. Figure 27. Flo w Controls with Pane l Removed Motor Setup Menu Motor setup is initially done at the facto r y and does not need to be changed unless a barrel mo tor or barrel com ponents are replace d, adjusted or remo ved and reinstalle d. This menu allows y[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 35 - Publication Number: 621360041TBSER Figure 28. Motor Setup Screen Calibrating a Motor Calibration of motors is typically require d when a motor or any associated barrel components (i.e., scraper blades, seal, faceplate, etc.) is removed or replaced. Calibration estab lishes a new baseline fo r [...]

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 o f pressure sensors presen t in the sytem, as shown in Fig- ure 29. T[...]

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 unau thorized personnel from accessing the Mainte nance menu. This feature is activated on the System menu. When se curity is turned on, users can onl[...]

Viper Service Manual Publication Number: 621360041TBSER - 38 - © 2010, IMI Cornelius Inc. Figure 31. Unit Dat a Screen UNIT 12:51P MAR 04 LINE VOLTAGE: 2 29 LINE FREQUENCY: 60 LOW PSIG #1: 6 0 HIGH PSIG #1: 174 DATA BACK BRL UNIT VER[...]

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 fact ors can affect the rate at wh ich produc t quality diminishes (as indicated by a change in prod uct appearance). 1. Dispensed Product Thro ughput 2. Programmed Defrost Sch[...]

Viper Service Manual Publication Number: 621360041TBSER - 40 - © 2010, IMI Cornelius Inc. Programmed Defrost Scheduling The control system in the V iper system includes a function to automatically defrost product in the bar rel at programmed interval s b ased on the viscosity of the product. Programmed defrost s are scheduled frequently to ensure [...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 41 - Publication Number: 621360041TBSER S TARTING THE U NIT The following ta ble, T able 32, describes the basic procedure for st arting the Viper . Refer to the Operato r ’s M anual (P/N 621360041 TBOPR) for details on o p eration of the Viper unit. Table 32 Step Action Procedure 1. Op en the me[...]

Viper Service Manual Publication Number: 621360041TBSER - 42 - © 2010, IMI Cornelius Inc. PREVENTATIVE MAINTENANCE S UMMARY There are no daily maintenance procedures r equired on the Vipe r unit other than normal cleanup of spills or overspray an d emptying the drip tray . Normal equip- ment maintenance inter v als are listed in T able 33. It is r[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 43 - Publication Number: 621360041TBSER M ONTHLY M AINTENANCE A general inspection of the machin e for leaks and cleanliness should be done on a weekly basis. Any abnormal conditions sho uld be reported and corrected when noticed. Cleaning Air Filter The air filter should be cleaned at leas t once [...]

Viper Service Manual Publication Number: 621360041TBSER - 44 - © 2010, IMI Cornelius Inc. S EMI -A NNUAL M AINTENANCE There are several pro c edures that should be comple ted on a semi-annual ba sis. 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 maintenance[...]

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 pr ocedure in T able 37 to lubricate or change t[...]

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 following the sa nitizer manufacturer’s recomm[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 47 - Publication Number: 621360041TBSER NOTE: The unit should be sanitized e ver y 180 days by a qualified ser vice technician following t he sanitize r manufacturer’s recomme ndations. Flushing the System of Syrup After emptying the barre l, the barrel shou ld be flushed of pr oduct before pro- [...]

Viper Service Manual Publication Number: 621360041TBSER - 48 - © 2010, IMI Cornelius Inc. Flushing the System Flush the wa sh water from the system by performing the pro cedure in T able 41. ! CAUTION: Flush the system tho roughly, residual sa nitizing solution left in t h e system may create a health hazard. Table 40 Step Actio n 1. Use a clean 5[...]

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 shou ld be removed and clean ed every six months, during the prevent ative maintenance procedures. T o inspect and clean the filter screen, pe rform the procedure in T able 42. Refer to[...]

Viper Service Manual Publication Number: 621360041TBSER - 50 - © 2010, IMI Cornelius Inc. COMPONENT REPLACEMENT The following are procedu res for servicing the major comp onents of the Viper system. B ARREL M OTOR S EAL R EPLACEMENT The barrel motor seal is typically repl aced during the semi-annual pr eventative maintenance procedure. The seal lo[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 51 - Publication Number: 621360041TBSER Installing a New Seal Perform the pro cedure in T able 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 lubricant s. This can cause the new seal to rotate and LEAK! Figure 41. V[...]

Viper Service Manual Publication Number: 621360041TBSER - 52 - © 2010, IMI Cornelius Inc. Figure 42. Side View of Seal and Spac er on Motor Shaft Motor Seal Leak Test After replacing the motor 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 that the s[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 53 - Publication Number: 621360041TBSER Figure 43. Side View of Motor Showi n g Two of the Four Mounting Bolts M OTOR R UN C APACITOR R E PLACEMENT The motor run cap acitors, shown in Figure 44, are mounted at the rear of the unit between the barrel motors. T o replace a run capacitor , perform the[...]

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 w a ter filter in the center of the unit. It is mounted o n a bracket f acing the rea r of the unit. T o replace the pump, pe rform the procedure in T able 47. Figure 45. Rear View of Water P[...]

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 lo cated 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 the syrup/water combination to provide the final m[...]

Viper Service Manual Publication Number: 621360041TBSER - 56 - © 2010, 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 replace the valves. Figure 48. View of Shutoff Solenoids w/ Acce[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 57 - Publication Number: 621360041TBSER C ONDENSER F AN M OTOR R EPLACE MENT The fan mo tor is locate d on the top of the unit, as shown in Figure 49 . If the motor needs re placement, perform the procedure in T able 50 to remove and reinstall a motor . Figure 49. Cond enser Fan Mounting Nuts C OMP[...]

Viper Service Manual Publication Number: 621360041TBSER - 58 - © 2010, IMI Cornelius Inc. H OT G AS S OLENOID R EPLACEMENT The hot gas valves and soleno ids, shown in Figure 50, are located near the cen- ter of the unit on the right and lef t sides. Whenever a hot gas valve and solenoid is replaced, the dryer should be replaced a t the sam e time.[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 59 - 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 the s[...]

Viper Service Manual Publication Number: 621360041TBSER - 60 - © 2010, IMI Cornelius Inc. Figure 52. View of Sy rup Pressure Switch and Valve W ATER P RESSURE S WITCH R EPLACEMENT The water pressure switch, shown in Figu re 53, is located in back of the water filter , when viewed from the rear of the unit. Access to the switc h is obtained by remo[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 61 - Publication Number: 621360041TBSER D ISPLAY B OARD R EPLACE MENT When replacing or testing electron ic comp onents, be sure to wea r a st atic strap that is connecte d to a chassis ground . This protec ts the electronic componen ts from any static char ge while working on the unit. The display[...]

Viper Service Manual Publication Number: 621360041TBSER - 62 - © 2010, IMI Cornelius Inc. C ONTROL B OARD R EPLACEMENT When replacing or testing electron ic comp onents, be sure to wea r a st atic strap that is connecte d to a chassis ground . This protects the electro nic components from any static charge while working on the unit. The control bo[...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 63 - Publication Number: 621360041TBSER M OTOR B OARD R EPLACEMENT When replacing or testing electron ic comp onents, be sure to wea r a st atic strap that is connecte d to a chassis ground . This protec ts the electronic componen ts from any static char ge while working on the unit. The motor boar[...]

Viper Service Manual Publication Number: 621360041TBSER - 64 - © 2010, 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 breake [...]

Viper Service Manual © 2010, IMI Cornelius Inc. - 65 - Publication Number: 621360041TBSER Troubleshooting Product Not Cold Problem Probable Cause Remedy Compressor not Run- ning A. Barr el not in ON mode. B. No volt age to compressor . C. Bad st art components . D. Compressor ’s thermal overload protector “open”. E. Open or shorted compress [...]

Viper Service Manual Publication Number: 621360041TBSER - 66 - © 2010, IMI Cornelius Inc.[...]

[...]

IMI Corneliu s Inc. www.cornel ius.com[...]