LEOPARD ERV™
Contents
1. c ccccccecesecceseceeeseeeeeeeeaeceesaeeeaeeeaeeaaesaeesaeeeaeseesaeseaeeeaeseeeseeeeaees lt 75 RH 40 C 105 F Voltage ReguiFeMeNntS nesrin iai iia 22 to 27 VAC 50 60 Hz Power COnsUMPIONiaii Linkai ov ca asa gas lc a a ia as lt 50mA in standby mode Valve Dimensions cccecceeseeeeeeeceeeeeneeeeaeeneenesseneeenenseneteenersens 5 wide X 4 75 long w o backblock X 5 5 high Water Soda StatiC Kusiai asta dase ean al Sienas aa ad a aa ia a a entice a a AET EREN 30 to 120 psi SyrUD Static ech scene aan as siai olas 30 to 90 psi Back BIOCK aa Medel Licensed Electric Valve Style Part number 60278110 Publication Number 620919579SER 6 2002 2014 Cornelius Inc CG Leopard ERV Installation Service Manual Water Quality Chloramines are a combination of chlorine and ammonia which are responsible for some degradation of rubber components Installing and maintaining a water filtration system can minimize the affects of Chloramines Syrup Quality e Use only Coke approved quality syrups Syrups must be free from pulp or other types of solids to work correctly e High sugar syrups are more viscous thicker than diet syrups Consequently they may cause more pressure drop within a system 2002 2014 Cornelius Inc 7 Publication Number 620919579SER Leopard ERV Installation Service Manual CCD LEOPARD ERV VALVE INSTALLATION A CAUTION Only trained and certified technicians should service t2. Publication Number 620919579SER 26 O 2002 2014 Cornelius Inc Guli WATER MoODULE REPLACEMENT Leopard ERV Installation Service Manual 5 Remove the old o ring from the mixing body and replace it with the new o ring from the kit 6 Insert the connectors from the new water module into the proper locations on the PCB 7 Place the water module onto the mixing body press down firmly while rotating the module clockwise by 90 degrees NOTE Make sure that the water module is fully engaged in the mixing body 8 Line up the bottom edge of the PCB with the slot in the base and push it down into place NOTE You should hear a click when the PCB is prop erly seated 2002 2014 Cornelius Inc 27 Publication Number 620919579SER Leopard ERV Installation Service Manual WATER MODULE REPLACEMENT 9 Snap the assembly into the base NOTE You should hear a click when the mixing body snaps into place 10 Make sure the connector is positioned below the motor shell 11 Reconnect the five syrup and water connectors to their proper locations on the PCB Syrup Connectors 12 Reconnect the keypad to its connector at the top of the PCB Publication Number 620919579SER 28 O 2002 2014 Cornelius Inc CD WATER MoODULE REPLACEMENT Leopard ERV Installation Service Manual 13 Replace the diffuser in the bottom of the base NOTE Installing
3. DEATH OR EQUIPMENT DAMAGE 2002 2014 Cornelius Inc 1 Publication Number 620919579SER Leopard ERV Installation Service Manual CCD SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury To ensure continued protection observe the following A WARNING Disconnect power to the unit before servicing following all lock out tag out procedures established by the user Verify all of the power is off to the unit before any work is performed Failure to disconnect the power could result in serious injury death or equipment damage A CAUTION Always be sure to keep area around the unit clean and free of clutter Failure to keep this area clean may result in injury or equipment damage SHIPPING AND STORAGE A 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 ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components Publication Number 620919579SER 2 2002 2014 Cornelius Inc Cie Leopard ERV Installation Service Manual INTRODUCTION KEY THINGS To Know Do For QUALITY DRINKS KEEP NOZZLES AND THE WATER SYRUP SYSTEM CLEAN AND HAVE THE CORRECT RATIO TEMPERATURE AND CARBONATION Make sure the correct syrup type has been connected Be sure filters are changed regul
4. Remove the lever by pulling it straight out from the rear of the valve 3 Angle the new lever so the end goes over the top of the spring when inserted Publication Number 620919579SER 20 O 2002 2014 Cornelius Inc CGinellus D Leopard ERV Installation Service Manual LEvER REPLACEMENT 4 Push lever into support base until lever pins are in base pivot points KEYPAD REPLACEMENT 1 Disconnect keypad from circuit board 2 Carefully peel keypad off of face of base Grab top corner and pull diagonally 2002 2014 Cornelius Inc 21 Publication Number 620919579SER Leopard ERV Installation Service Manual CG KEYPAD REPLACEMENT Remove protective paper from back of new keypad Position bottom of keypad flush with the top of the ledge on the front face while centering the keypad so it does not extend over the sides of the base Press firmly in place 5 Wrap keypad tail over top of circuit board and press con nector firmly into place SyrRuP MODULE REPLACEMENT 1 Remove the valve from the dispenser See REMOVING THE Leopard ERV FROM A DISPENSER and disas semble the valve See Leopard ERV VaLve DISASSEMBLY 2 Remove the syrup module from the mixing body by rotat ing the module clockwise viewed from the top of the assembly 90 degrees and then lifting it straight up NOTE The black v groove may stick to the mixing body and pull out of the syrup module
5. accident 6 alteration 7 misuse 8 neglect 9 unau thorized repair or the failure to utilize suitably qualified and trained persons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation operating cleaning or maintenance instructions 12 use of non authorized parts i e parts that are not 100 compatible with the Product which use voids the entire warranty 13 Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition Contact Information To inquire about current revisions of this and other documentation or for assistance with any Corne lius product contact www cornelius com 800 238 3600 Trademarks and Copyrights This document contains proprietary information and it may not be reproduced in any way without per mission from Cornelius This document contains the original instructions for the unit described CORNELIUS INC 101 Regency Drive Glendale Heights IL Tel 1 800 238 3600 Printed in U S A 2 TABLE OF CONTENTS Safety INSUUCHONS so nanus dans a ee sala a se 1 Read and Follow ALL Safety Instructions LL ks 1 Safety OVEIVIOW 222065 Med put Sele Souk oe a Ee Sea ot cooled SP it 1 PROCOGMINO NM reteset e oe cone dee OO 1 Different Types OASIS E LS S eee 1 Safety MS 1 Li i A AA bed wi Sued Im S Ta Ls 1 Qualified Service Personnel ici A is a a a ki O ee ee
6. ansas ir e tae eG ees 13 SYMPIOIS sanos as bl Cees Edo SS BARS ORGS Oe eee be ey Bate Be 13 No Syrup or Syrup Sold Out EMO ocr visi a at iia 13 Leopard ERV and Pocket PC Troubleshooting Guide 13 Repair Procedures si 2 55 a 1 45 5 0 sd ERA AAA eee eee ea ee 16 Mean Timet Repa siii a o aa sai alee a 16 Removing the Leopard ERV from a Dispenser LL as 16 Leopard ERV Disassembly 4454 k ns eg Li Sen AO kee ia lila a 18 Lever Keypad Replacement LLP ias 19 Lever Replacement asis a hee ew ee ering ate aa ROS Goatees See wade baw ens eae 20 Keypad Meplacementi mi in alee rd ee Ve eee eet Ye oe ate Yat 21 Syrup Module Replacement Lakis 22 Water Module Replacement ooooocococrr eee eee 26 PCB Replacement eis e Ete Bred hg eh A A Os 29 Water FItSKGleaninGs esteis AGW ee edades ias osea ao ses 30 Gleanings tee LA ee caen banal ale o Ur ca obs 30 Water Filter Replacement coja ad REA bee S 31 Filter and Retaining Ring Replacement oooooccooooooo ee 31 CCD Leopard ERV Installation Service Manual SAFETY INSTRUCTIONS READ AND FoLLow ALL SAFETY INSTRUCTIONS Safety Overview Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning caution labels on the unit decals labels or laminated cards Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety regu lations before operating this unit Recognition Recognize Safety Alerts A Thi
7. If this occurs remove the v groove carefully from the mixing body and replace it in the syrup module V Groove Publication Number 620919579SER 22 O 2002 2014 Cornelius Inc Guli SyrRuP MODULE REPLACEMENT Leopard ERV Installation Service Manual 3 Remove the syrup module connectors from the PCB using a small screwdriver Note their location on the board for replacement Do Not remove the connectors by pulling on the wires 4 Open the syrup module replacement kit P N 629097012 It contains a syrup module and a new o ring 5 Remove the old o ring and replace it with the new o ring from the kit 6 Insert the connectors from the new syrup module into the proper locations on the PCB 2002 2014 Cornelius Inc 23 Publication Number 620919579SER Leopard ERV Installation Service Manual C Ginclius gt SyrRuP MODULE REPLACEMENT 7 Place the syrup module onto the mixing body press down firmly while rotating the module counter clockwise by 90 degrees NOTE Make sure that the syrup module is fully engaged in the mixing body 8 Line up the bottom edge of the PCB with the slot in the base and push it down into place NOTE You should hear a click when the PCB is prop erly seated 9 Snap the assembly into the base NOTE You should hear a click when the mixing body snaps into place 10 Make sure the connector is positioned below the motor shell
8. Publication Number 620919579SER 24 2002 2014 Cornelius Inc Cre gt Leopard ERV Installation Service Manual SyrRuP MODULE REPLACEMENT 11 Reconnect the keypad to its connector at the top of the PCB 12 Replace the diffuser in the bottom of the base NOTE Installing the wrong diffuser on a Leopard valve results in flooding the base and possible dam age to the PCB Correct diffuser has only one red o ring at the top of the diffuser 13 Place the nozzle over the diffuser and rotate it 90 degrees to the right viewed from the bottom of the valve until it stops 2002 2014 Cornelius Inc 25 Publication Number 620919579SER Leopard ERV Installation Service Manual Cre gt WATER MODULE REPLACEMENT 1 Remove the valve from the dispenser See REMOVING THE Leopard ERV FROM A DISPENSER and disas semble the valve See Leopard ERV VaLve DISASSEMBLY 2 Remove the water module from the mixing body by rotat ing it counterclockwise away from the syrup module and then lifting it straight up NOTE The white v groove may stick to the mixing body and pull out of the water module If this occurs remove the v groove carefully from the mixing body and replace it in the water module 3 Disconnect the water module connectors from the PCB Make note of the locations 4 Open the water module replacement kit P N 629097013 It contains a new water module and a new o ring
9. Purge While in a Sold Out condition the valve can be put into a manual purge mode To activate purge mode continue to hold the button lever after the valve has automatically shut off After 5 seconds the valve purges both water and syrup sides for up to 1 minute or until the button lever is released Water Feature Unlike other valves a separate Water Only lever is no longer needed This feature is now accomplished electronically with a Water button located on the keypad The keypad option can be added to either a carbonated drink valve or a non carbonated drink valve Serial Numbers Each valve has a unique serial number This number indicates the date that the valve was built and the sequential number for that day 240506107 This is a valve that was built on 24 day of 5th month of 2006 Sequence number is 107 2002 2014 Cornelius Inc 3 Publication Number 620919579SER Leopard ERV Installation Service Manual CCD The Leopard ERV has the serial number recorded in three places The permanent number is stored in the PCB memory The number is also displayed on a bar coded sticker on the side of the base and on a small sticker on the front of the PCB When the valve is manufactured the serial number on the sticker is the same as in the PCB memory If the base is replaced the number must then be determined from the PCB memory or the sticker on the PCB Recharge After Power Loss The Leopard ERV requires
10. the entire water module Filter and Retaining Ring Replacement 1 Remove the valve from the dispenser See REMOVING THE Leopard ERV FROM A DISPENSER and disas semble the valve See Leopard ERV VaLve DISASSEMBLY 2 Carefully remove the plastic retaining ring and filter from the water module 3 Place the new retaining ring on the machined end of the insertion tool 4 Place the new filter inside the water module Carefully slide the tool with the new filter ring in place into the water housing inlet NOTE Be careful not to scratch or damage the inside 1 of the water module inlet NOTE The orientation of the tool is not important at this time 2002 2014 Cornelius Inc 31 Publication Number 620919579SER Leopard ERV Installation Service Manual C Ginclius gt Filter and Retaining Ring Replacement 5 Once the ring is placed in the inlet reverse the tool and use the flat end to carefully push the retaining ring into position parallel with the filter 6 Make sure that the ring is pressed up against the filter and seated completely in the inlet 7 Reassemble the valve and reinstall it in the dispenser Publication Number 620919579SER 32 O 2002 2014 Cornelius Inc Cornelius Inc www cornelius com
11. xx xx gt Leopard_Downloader_v _PPC_setup exe Synchronize your Pocket PC with your computer Double click the NETCCF CORE PPC3 exe icon The framework automatically installs Double click the Leopard_Controller_vit _PPC_setup exe icon The controller automatically installs Double click the Leopard_Downloader_v _PPC_setup exe icon The downloader automatically installs 2002 2014 Cornelius Inc 9 Publication Number 620919579SER Leopard ERV Installation Service Manual CG 9 The Leopard Controller and the Leopard Downloader icons are now displayed and active on the PRO GRAMS screen on the Pocket PC Upgrade 1 oN OA E 0 Download the file s from the Cornelius web site www cornelius com to your PC Leopard ERV Pocket PC Controller vx xx xx gt Leopard_Controller_v _PPC_setup exe Leopard ERV Pocket PC Downloader vx xx xx gt Leopard_Downloader_v _PPC_setup exe You may upgrade either of these programs separately or at the same time It is presented here as updating both Synchronize your Pocket PC with your computer Double click the Leopard_Controller_vi _PPC_setup exe icon The controller automatically installs Double click the Leopard_Downloader_vi _PPC_setup exe icon The downloader automatically installs The Leopard Controller and the Leopard Downloader icons are now displayed and active on the PRO GRAMS screen on the Pocket PC Upgrading Leopard ERV s
12. 1 Sale PrecaullO Susi su asias asada irector sais eee ee 2 Shipping And Strada isssut ra cea e o dl aa ls cl a a o A e AU 2 Introduction isco eae A E A A a k a Re ek A a A AER 3 Key Things To Know Do For Quality Drinks keep nozzles and the water syrup system clean and have the correct ratio temperature and carbonati0N o 3 OVEVICW da ti beng Ca eee AA o AS 3 ProductiDescrplON sl de ada tans li ee ETA ee o de NS ne 3 Sn A hd gk eee ye a 4 Higa ge een L io E A ae oo Re 3 Manual Purges 28 or piee a ls a Crate rs i e OY a A 3 Water Feature 45464 nn deletes A Obed Mea A eae 3 Serial Numbers 203 wets Pe ee conta ER eee ot COS GEES oe eee 3 Recharge After Power OSS 5 asi meek eed ida ii 4 4 Second Dispense Lu uk LL S LL kar LS a S S 4 Valve Types ocacion bay eae 4 Push Button Valve tia e A a o A 5 Portion Control NAlV a is ais sume geet daras eee eg ee Sees 5 Portion Dispense Profile Pour Mode 20 e eee eee 5 Portion Dispense Top Off Mode o ooocococccr eee 6 Manual Keypad Portion Control Setup per programming device instructions o oococccoccccooo 6 Dimensions Capacities and Interface Requirements 000 0c eee ee eee 6 Water QUA nta aie eee deere Seed de eels beter oie EE eat 7 SV MUP OQUALIIY AA 7 Leopard ERV Valve Installation 0 02 c eee eee eee 8 In tallali ON no ea ssa gly is a kee eee eke tu Se a ey SSSA a A ha aR RE 8 Mounting Block Retrofit For No
13. A Dirty nozzle diffuser A Clean B Incorrect setup B Connect handheld and correct setup Off Taste one brand C Tubing and plastic components con C Replace all tubing and plastic components for that fla taminated for that flavor vor Portion controlled dis A Top off Feature is enabled A Disable if desired Top off option dispenses part of pense stops and then the total drink waits several seconds and then com dispenses a short pletes the rest of the drink to minimize the effects of amount again foaming No product dispensed A Leopard ERV has a time out feature A Release actuator and repress after a 60 second pour that shuts off flow after 60 seconds A LED constant Sold Out A Replace syrup BIB B LED blinking and will not dispense B Wait until valve is in operating mode ee a as valve is in charge mode C LED blinking on portion control keypad C Press Pour Cancel button to exit keypad program valve in keypad programming mode ming Publication Number 620919579SER 14 2002 2014 Cornelius Inc CG Leopard ERV Installation Service Manual Leopard ERV and Pocket PC Troubleshooting Guide Trouble Fault Cause Solution A Verify that the valve is not spot lighting an actual SOLD OUT condition and syrup supply 1 Check BIB and syrup pump ensure good supply of syrup to valve 2 Ensure BIB change did not result in air in syrup line Connect TomCat amp perform PURGE oper
14. Goi LEOPARD ERV Installation Service Manual Release Date November 30 2004 Publication Number 620919579SER Revision Date April 02 2014 Revision H Visit the Cornelius web site at www cornelius com for all your Literature needs 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 this equipment This manual assumes that the person s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual This Product is warranted only as provided in Cornelius Commercial Warrant applicable to this Prod uct and is subject to all of the restrictions and limitations contained in the Commercial Warranty Cornelius will not be responsible for any repair replacement or other service required by or loss or damage resulting from any of the following occurrences including but not limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper volt age 3 inadequate wiring 4 abuse 5
15. Many valve errors can be cleared by repeating set up with a Tomcat unit Before replacing components attempt a new set up the time it takes to perform the set up procedure could save unnecessary and costly repair time If several valves or all valves on one unit are malfunctioning the cause is most likely a problem with the system recirc back room etc SYMPTOMS No Syrup or Syrup Sold Out Error i e valve does not dispense syrup or shuts down during dispense with lit LED To troubleshoot this condition perform the following procedure Leopard ERV and Pocket PC Troubleshooting Guide Trouble Fault Cause Solution A Faulty electrical wiring A Check electrical wiring No Power B Unit unplugged B Verify unit is getting power C Fuse or circuit breaker off C Check circuit breaker or fuse No Product dispensed A Other valves operating properly A Check back room supplies amp equipment from one dispensing B Back room equipment operating prop B Check syrup flow at backblock if flow is present valve erly replace syrup module A Wrong syrup running through valve A Replace with correct syrup B Valve not properly setup B Setup valve using iPaq or TomCat with correct ratio Water to Syrup ratio too and syrup no mechanical adjustments need to be low or too high made to the valve itself C Valve control system not working cor C Replace PCB rectly A Nozzle isn t seated correctly
16. R Leopard ERV Installation Service Manual Cre gt REPAIR PROCEDURES MEAN TIME TO REPAIR Description Time minutes Install Valve includes setup 10 Replace Syrup Module Replace Water Module Replace PCB Replace Keypad Replace Lever Replace Lever Keypad Replace Base BL oO Oo P PN GO O O Filter Cleaning amp Replacement REMOVING THE Leopard ERV FROM A DISPENSER 1 Remove valve cover by spreading finger tabs on bottom of cover and lifting it off Lift and pull cover to remove 2 Unplug the power wiring harness Publication Number 620919579SER 16 O 2002 2014 Cornelius Inc CGinellus D Leopard ERV Installation Service Manual REMOVING THE Leopard ERV FROM A DISPENSER 3 Turn off the backblock by turning the flow screws 4 Remove the retaining spring by pulling it upward 5 Pull the valve off the backblock 2002 2014 Cornelius Inc 17 Publication Number 620919579SER Leopard ERV Installation Service Manual CG Leopard ERV DISASSEMBLY 1 Perform the steps in the Removing the Leopard ERV from a Dispenser procedure above 2 When the valve has been removed remove the nozzle by rotating left 1 4 turn until it stops then remove the noz zle and pull out the diffuser assembly 3 Disconnect the keypad from the PCB 4 Remove the PCB by pulling straight up and away from the base Wa
17. a tion on syrup amp water air in line may trigger a sold out 3 Try the valve on a different flavor Does it operate normally If YES the problem is with the unit not the valve Trou bleshoot unit If NO go to Step 4 4 Hold the push button or lever for 3 sec to over ride the sold out Do both syrup amp water flow from the valve If YES flow sensors are malfunctioning go to Step 5 Keypad LED isonand A ED constant Sold Out If NO Motor may be stuck replace the appropriate not blinking module water or syrup If still not working replace the PCB 5 Replace syrup module amp quad ring most flow sensor failures occur on syrup side of valve Acti vate valve 5 10 times Does sold out clear If YES perform full setup with TomCat If NO go to Step 6 6 Replace water module amp quad ring Activate valve 5 10 times Does sold out clear If YES perform a full setup with TomCat If NO go to Step 7 7 Replace the PCB Activate valve 5 10 times Does sold out clear If YES perform a full setup with TomCat If NO try a different valve in this position If successful replace valve 8 If problem cannot be fixed call Cornelius Techni cal Service Portion size buttons do A Incorrect settings A Connect pocket pc and reprogram the sizes Keypad not dispense the cor programming is available if enabled rect amount O 2002 2014 Cornelius Inc 15 Publication Number 620919579SE
18. abled foaming by flowing at low flow rates at the beginning and end of the drink 2002 2014 Cornelius Inc Publication Number 620919579SER Leopard ERV Installation Service Manual lt 2 Leopard ERV and Pocket PC Troubleshooting Guide Trouble Fault Cause Solution A Pocket PC cable fault indicated by an A Remove cable from valve and hold Pocket PC in hand illuminated red light in the cable Upon red light going off reconnect Pocket PC should never be in contact with any other eguipment or metal No Communication B Comms Error appears on Leopard B Exit Leopard ERV Controller and reconnect between the valve and ERV controller screen Pocket PC C Multiple Controller programs open C Close all controller programs then re start controller by pressing icon ONCE D Leopard ERV valve not able to com D Exit Leopard ERV Controller disconnect Pocket municate with Pocket PC PC cycle valve power and retry communication A Product temperature A Check cooling system Excess Foaming B Dirty nozzle diffuser B Clean nozzle diffuser C Flow rate too high C Adjust flow to normal rate with Pocket PC or TomCat D No small diffuser O ring D Replace O ring A Retaining clip not properly seated A Turn back block shut off to off and adjust or replace Liquid leaking between back block and valve retaining clip B O rings worn or damaged B Replace O rings
19. arly OVERVIEW Product Description The Leopard ERV is intended for use on post mix beverage dispensing machines The Leopard ERV is a purely volumetric valve which means it monitors and regulates the volumes of water and syrup being dispensed This allows the valve to compensate real time to pressure changes and maintain a constant ratio and flowrate Water Module As the Leopard ERV is dispensing a drink it s constantly reacting to changes in water and syrup pressures in order to maintain the selected finished drink ratio and flowrate The syrup flow is measured in real time utilizing pressure differential and then regulated by a linear stepper motor The water flow is measured in real time by a flow turbine and regulated by a second linear stepper motor These two flow measurements are input to a microprocessor which adjusts the stepper motors to maintain proper flowrate and ratio Figure 1 Sold Out Feature The Leopard ERV has a built in Sold Out feature on all valves A light is located on the front keypad face The Sold Out light informs the operator of insufficient flow from either the water or syrup During the sold out condition the valve dispenses a small amount of product water and syrup and shuts off regardless of how long the button or lever is activated Once the water syrup is replenished the Sold Out light turns off and the valve returns to normal operation automatically Manual
20. ate for 4 seconds The keypad LED flashes during the four second flow rate test mode Allow up to 0 1 second difference in switch actuation time e Once the four second dispense has finished the control returns to normal dispense mode Valve Type There are three different activation methods for the Leopard ERV Cup Activated Push Button and Portion Control Valve Activation Mode e Any valve may be set up with a keypad or a lever A keypad may be changed from one style to another by simply replacing the keypad and changing the setup as required with the Pocket PC programming device interface Cup Actuated Valve e Operate the cup actuated valve by pressing the cup against the lever until the cup is full then release the lever Publication Number 620919579SER 4 2002 2014 Cornelius Inc Leopard ERV Installation Service Manual Figure 2 Lever with Sold Out Figure 3 Lever with Water Button Push Button Valve e Operate the push button by pressing the PUSH switch and holding until the desired amount of product has been dispensed then release the PUSH switch Figure 4 Push Button Figure 5 Push with Water Figure 6 Water Only Button Portion Control Valve The portion control valve dispenses different size drinks by pressing the desired switch The valve also has a Can cel Pour dispense function The portion control valve can be programmed to dispense different drink sizes The portion c
21. change the Portion Control button volumes 1 Simultaneously press and hold the smallest and the largest portion buttons until the LED illuminates approximately 1 second 2 Place the appropriate size cup with desired amount of ice under the dispensing nozzle Press and hold the size button that you want to set until the desired volume of drink is dispensed into the cup Repeat step 2 to program each drink size NOTE Any drink size may be programmed as many times as desired before exiting the program mode It is not necessary to adjust all cup sizes while in the programming mode 3 To return a size to the default value press and hold the pour cancel and that button simultaneously for 2 sec onds 4 To exit press and release the Pour Cancel button This will save any changes The LED switches off to sig nal leaving the programming mode Figure 7 Portion Control Figure 8 Portion Control with Water Dimensions Capacities and Interface Requirements Finished Drink FOW Rate iento anette 1 5 to 4 5 0z sec Finished Drink Ratio RanQ oooncccincccnnccnncconoccnncncnnnccnonc crono cnn 3 5 1 to 8 5 1 Operational Temperature Range eccceccesecececeeeceeeeeeceeeeeeeeaeeeeeseeeseeesaeeaeseeesaeseaeseeesieeeaeeaas 0 C 32 F to 60 C 140 F Storage Temperature Range cccccesececeeeeeseeeeseceeeeeeeeaeceeeeeeesaeeeaeseeesaeesaeseaeseeesaeesaneeaeeaas 30 C 22 F to 70 C 158 F Operating Humidity Range
22. d be removed from the valve The indi cator will remain on for approximately 3 seconds Once the red light turns off reconnect the cable to the valve and restart the ERV interface software For its protection the Pocket PC should never be in contact with any other equipment Publication Number 620919579SER 10 2002 2014 Cornelius Inc CCD Leopard ERV Installation Service Manual VALVE SETUP IPAQ Leopard ERV setup is done electronically using a Pocket PC equipped with the Leopard ERV software and communication cable Once connected the Leopard ERV software allows the installer to not only setup flavor flowrate and portion control but also retrieve information such as diagnostics and valve history Setup using Pocket PC handheld device equipped with Leopard ERV software Setup requires the correct ratio cup a splitter the pocket PC and appropriate cable Information can be retrieved such as Serial Number Allows easy identification of valve Flavor Setup Allows easy identification of flavor setup Finished Drink Ratio Allows easy identification of ratio setup Flowrate Allows easy identification of flowrate setup Portion Sizes Volume of each button size Total Dispenses Total number of valve actuations Water Volume Dispensed Total volume of water valve has dispensed Syrup Volume Dispensed Total volume of syrup valve has dispensed Portion control can be set up 3 different ways in th
23. e Pocket PC Pour by Volume A numeric volume is entered for the corresponding cup size Pour by Teach The keypad button is pressed until the cup is full The valve then saves that finished drink volume into memory Copy Settings Portion control values can be copied from one to another using the pocket PC Default Portion Sizes Country specific default sizes Diagnostics Error Codes Alerts service personnel that a fault has occurred and may require attention Such as syrup sold out low water and valve malfunction Purge Mode Allows the system to be purged of water and syrup either simultaneously or separately System Flowrate Test Check maximum system flowrate Syrup Pressure Displays static or dynamic pressure psi on the Syrup Side Module Free Flow Dispenses an in ratio drink at the current flow rate 4 Second Dispense 2002 2014 Cornelius Inc 11 Publication Number 620919579SER Leopard ERV Installation Service Manual CCD POCKET PC TROUBLESHOOTING GUIDE When using the Pocket PC to install a Leopard valve the following information may be helpful to troubleshoot Pocket PC problems Pocket PC does not respond to input Perform a soft reset when You want to stop all running applications e After installing a new application If your Pocket PC stops responding to input To perform a soft reset e Locate the Reset button on the Pocket PC Use the stylus to lightly press the Reset bu
24. er by spreading finger tabs on bottom of cover and lifting Publication Number 620919579SER 8 O 2002 2014 Cornelius Inc Cine gt Leopard ERV M Installation Service Manual Oo NOT FF Q Lift retaining wire to the UP position Place Leopard ERV on mounting block and press retaining wire Down Connect wiring harness and turn dispenser power on Turn mounting block screws on Replace Cover Installation complete PockKET PC INSTALLATION NOTE THIS EQUIPMENT IS NO LONGER AVAILABLE FOR PURCHASE OR UPGRADE Installing the Pocket PC Software Installing Active Sync Required for Pocket PC to communicate with PC go to next step if previ ously installed 1 NO a fF WO DW Do not connect Pocket PC cable or cradle until Active Sync is installed Insert Active Sync CD into PC The program automatically starts Follow directions to install Active Sync Connect Pocket PC to the PC using either the cradle or cable Establish a new partnership to fully synchronize or use Guest to only copy files The Pocket PC and PC will automatically synchronize Installing Leopard ERV Pocket PC Software 1 ono a F OD Download three files from the Leopard ERV CD ROM or the Cornelius web site www cornelius com to your PC e Leopard ERV Pocket PC Compact Framework gt netcf core ppc3 arm cab Leopard ERV Pocket PC Controller vx xx xx gt Leopard_Controller_v _PPC_setup exe Leopard ERV Pocket PC Downloader vx
25. his unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES INSTALLATION The Leopard ERV can be installed on any dispenser with a Coca Cola LEV style mounting block FFV mounting block or identical screw pattern Mounting Block Retrofit Premium Leopard ERV Installation Mounting Block Retrofit For Non Coca Cola LEV style mounting blocks 1 Shut off syrup unplug carbonator pump shut off CO and water supply to the unit Release pressure in lines by activating valves and lifting relief valve on carbonator Turn power off to dispenser F ON Detach current valves Remove Cover Unplug wiring harness Lift retaining spring e Remove Valve Remove 4 screws from mounting block and save Remove old mounting block IMPORTANT Before installing new mounting block replace O Rings on each fitting Lubricate with Dow 111 or equivalent FDA approved lubricant Do not use petroleum jelly Install new Coca Cola LEV style mounting block and secure with 4 screws Turn syrup carbonator pump CO and water supply back on 9 Check for leaks Leopard ERV Installation 1 Remove Existing Valve e Remove Cover e Unplug wiring harness Turn mounting block screws off Lift retaining spring e Remove valve and set aside IMPORTANT Before installing new Leopard ERVM lubricate both O Rings with Dow 111 or equivalent FDA approved lubricant Do not use petroleum jelly 2 Remove Leopard ERV cov
26. inbase A Remove and re seat nozzle Liquid leaking from B Damaged nozzle B Replace nozzle around nozzle C Damaged valve C Inspect valve assembly Replace modules as required A System contaminated A Remove and check diffuser for contamination If there iui is contamination in the diffuser check system for con Sano S no Dea tamination and clean system and valve as reguired B Valve is not performing correctly B Inspect valve assembly Replace the appropriate module as required A Insufficient pressure or flow to reach A Perform diagnostic flow rate test with handheld to set flow rates determine system capabilities Check system pres sures flow rates cleanliness Clean and or repair as required Note that still water systems and high vis cosity syrups may not be able to develop adequate Flow rate lower than set system pressure to maintain the set flow rate The value or fluctuates valve will compensate and automatically reduce flow rate while maintaining correct ratio B Incorrect setup B Check setup of valve with respect to system correct syrup type Correct ratio Correct flow rate Re setup valve as required w TomCat A Initial dispense after applying power to A None Valve will act normally after initial dispense the valve or changing a setting Valve starts off at a low B Portion Control Valve Profile Pouris B Disable if desired Profile Pour option minimizes flow and then increases en
27. n Coca Cola LEV style mounting blocks 8 Leopard SRV Installation siria a tae Fees 8 Pocket PC Installation Note This equipment is no longer available for purchase or upgrade 9 Installing the Pocket PC Software ooooooccocccoro ete 9 Installing Active Sync Required for Pocket PC to communicate with PC go to next step if previously installed as 9 Installing Leopard ERV Pocket PC Software 9 WP GRAIG iiie poto AE Me te bed et tae Gilead Soe Re BS Bk setts tea Bade nh eM es eA ee Mee 10 Upgrading Leopard ERV software using Leopard Downloader 10 Installing firmware into the Leopard ERV ccoo 10 Valve Setup IPAQ casa sa tae a da ara 11 Information can be retrieved such AS lt 11 Portion control can be set up 3 different ways in the Pocket PC 11 Draqnosteste ta Wot Ahi eRe Ara to pl athe ee 11 Pocket PC Troubleshooting Guide ooooooccoccnno e eee eens 12 Pocket PC does not respond to input ecu i i a bow ii ees Sh 4 ad wes 12 PocketPC how Baten asic Gu vou ccs oleate ete eee eee eee meee 12 Leopard ERV and Pocket PC software kaka 12 Software Revision Information 0 000 ee eee 12 Pocket PC Versi n a a ia eens Sarde alia o ais Ino i ain tines 12 Valve SoftWare VOS sites eters easier db tage need 12 Syt p File Versi senet 4056 Mer ande da ue oo e ers dd ll e al celo DA 12 Trouble Shooting and Repait
28. oftware using Leopard Downloader 1 Download Leopard firmware file from the Cornelius web site www cornelius com Leopard ERV Firmware for pcb Ipdxxxxx gt Ipdxxxxp lpd xxxx is the version number Open ActiveSync and connect the Pocket PC Copy the new file to the Pocket PC folder My Documents Installing firmware into the Leopard ERV 1 a fF oN 6 7 Connect the Pocket PC to the Leopard ERV via the Leopard ERV interface cable part 620316409 Start the program Leopard Downloader Tap the lt LPD File gt button Select the desired file in the menu Tap the lt Continue gt button and when prompted cycle power to the valve to start the downloading process This may be done by disconnecting the power at the valve or by shutting off power to the machine The screen indicates the program is downloading If not cycle power again to start the download Once the software has completely downloaded the program may be ended by pressing the lt Exit gt button NOTE Check the release notes to determine if there is additional setup required If none noted there is no need to re set any of the valve settings following a software upgrade NOTE Pocket PC Communication Cable The cable contains a ground fault protection indicator which detects when there is no commu nication between the Pocket PC and the valve When communications is lost within the cable a RED light will be illuminated At this time the cable shoul
29. ontrol keypad contains a hidden 5 button size By pressing the Medium and Extra Large por tion size the 5 size is dispensed When activated the LED on the keypad quickly blinks to notify the user of the 5 size dispense Portion Dispense Profile Pour Mode e The automatic dispensing function for each size switch is controlled by the replay of a stored volume mea surement cycle When activated the valve dispenses the full stored volume at the defined flow rates This function sets the first 20 of the total volume at a flowrate of 2 oz sec the next 60 of the total volume is set at the maximum available flowrate and the final 20 of the volume is set at a flowrate of 2 0z sec 2002 2014 Cornelius Inc 5 Publication Number 620919579SER Leopard ERV Installation Service Manual Cre gt Portion Dispense Top Off Mode e The automatic dispensing function for each size switch is controlled by the replay of a stored volume mea surement cycle When activated the valve dispenses 80 of the stored volume at the set flowrate There is a delay of 3 seconds then the valve dispenses the last 20 at the set flowrate During the 80 portion of the cycle the LED is off It blinks during the 3 second delay and the last 20 of the cycle The valve only tops off if the portion size is at least twice the top off volume 2 02 Manual Keypad Portion Control Setup per programming device instructions Perform the following steps to setup or
30. s is the safety alert symbol When you see it in this manual or on the unit be alert to the potential of personal injury or damage to the unit DIFFERENT TYPES OF ALERTS A DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or equipment damage A WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment damage A CAUTION Indicates a potentially hazardous situation 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 signs in good condition and replace missing or damaged items Learn how to operate the unit and how to use the controls properly Do not let anyone operate the unit without proper training This appliance is not intended for use by very young children or infirm persons 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 unauthorized modifications to the unit QUALIFIED SERVICE PERSONNEL A WARNING Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY
31. ter S RP Side Tab 5 Remove the assembly from the base by disengaging the Sea mixing body tabs and pushing upwards on the base 6 Pull the mixing body out of the base 7 If further disassembly is necessary refer to the various module replacement procedures later in this manual Publication Number 620919579SER 18 2002 2014 Cornelius Inc Cinek D Leopard ERV Installation Service Manual LEVER KEYPAD REPLACEMENT 1 Remove the valve from the dispenser See REMOVING THE Leopard ERV FROM A DISPENSER and disas semble the valve See Leopard ERV VaLve DISASSEMBLY Lever Keypad 2 Perform the Leopard ERV Disassembly procedure to access the lever keypad 3 Carefully remove the adhesive backed lever keypad from the base by pulling on the connector Membrane Keypad 4 Remove the paper backing and install the new lever key pad by aligning the pad with the base as shown 5 Ensure that the keypad is properly seated against the alignment tabs 2002 2014 Cornelius Inc 19 Publication Number 620919579SER Leopard ERV Installation Service Manual Cre D LEVER KEYPAD REPLACEMENT 6 Press the lever keypad firmly against the base using your index finger 7 Reassemble the Leopard ERV valve and mount the valve back on the dispenser LEVER REPLACEMENT 1 Remove the valve from the dispenser See REMOVING THE Leopard ERV FROM A DISPENSER 2
32. ter retainer set is place into the water side of the valve body Looking at the back of the unit inlet side the water side is on the right side of the valve with the motors facing up To clean the filter first remove the valve from the backblock Hold the valve back side upward under a faucet and run warm water on the filter allowing any dry dirt particles to loosen up see filter side in Figure 9 Use the nozzle brush or similar brush to remove the particles by brushing the filter gently and carefully Continue to rinse and brush the filter as necessary until all visible dirt particles are removed DO NOT attempt to remove re install the filter and retaining ring Damage to the sides of the water inlet may result and prevent sealing of the valve to the back block The retaining ring acts to keep the mesh filter screen in place while the valve is prepared to be placed and locked into the back block Locate and place the valve onto the back block assembly The entire valve assembly can now be secured to the back block with the wire locking clip Part No 620716402 Publication Number 620919579SER 30 O 2002 2014 Cornelius Inc Cinek D Leopard ERV Installation Service Manual Filter amp Retainer In Place Figure 9 WATER FILTER REPLACEMENT The following procedure is for replacing plastic retaining rings ONLY DO NOT attempt to remove or install metal rings If a filter with a metal retaining ring must be replaced replace
33. the electronics board to charge the power backup system before operation Drink operation is suspended until the valve is charged When power is connected to the Leopard ERV the LED on the electronics board and keypad begins to flash rapidly approximately 2 times a second When the valve is fully charged and ready for use the LED on the electronics board flashes slower approximately 1 time a second The LED on the keypad turns off An uncharged valve takes approximately 3 minutes to fully charge When connected to a Pocket PC or other programming device during this charge cycle a status indicator is displayed on the bottom of the first Leopard ERV software screen and does not allow connection until fully charged This charging only occurs when power is initially connected when the machine is turned off then back on or following machine turn on after power is lost to the valve Once the valve has fully charged following a power loss the first dispense is a setup dispense beginning at a low flowrate and gradually increasing to the set flowrate This dispense will be in ratio Once the valve has reached it s set flowrate it continues to dispense at that flowrate On an Leopard ERV equipped with Portion Control each of the sizes perform the same on the initial dispense 4 Second Dispense e Simultaneously press and hold the next to smallest and next to largest keypad buttons for 1 second The valve dispenses at the current flow r
34. the wrong diffuser on a Leopard valve results in flooding the base and possible dam age to the PCB Correct diffuser has only one red o ring at the top of the diffuser 14 Place the nozzle over the diffuser and rotate it 90 degrees to the right viewed from the bottom of the valve until it stops PCB REPLACEMENT 1 Disconnect the keypad connector 2 Remove the PCB from the base by lifting it straight up NOTE The PCB fits into a groove in the base and may be hard to remove Work the PCB carefully from side to side to loosen it from the base groove NOTE Too much pressure or flexing of the PCB may result in damage to the board 3 Replace the PCB with a new PCB 2002 2014 Cornelius Inc 29 Publication Number 620919579SER Leopard ERV Installation Service Manual Cie PCB REPLACEMENT 4 Line up the bottom edge of the PCB with the guides in the base and push it down into place NOTE You should hear a click when the PCB is prop erly seated PCB Guide PCB Guide 5 Reconnect the keypad connector to the PCB WATER FILTER CLEANING The following procedure illustrates the proper methods for cleaning of the filter in the Leopard Valve The filter is designed to block particles larger than 0 010 inches from entering the valve and possibly stopping the water flow sensor mechanism A nozzle brush P N 325216000 or equivalent is required for filter cleaning Cleaning The fil
35. tton The Pocket PC restarts and displays the Today screen NOTE A soft normal reset does not erase any programs or saved data Save any unsaved data before performing a soft reset Pocket PC Low Battery Recharge battery as soon as there is a low battery indication NOTE If the battery installed in your Pocket PC discharges completely you will lose all settings pro grams data and information LEOPARD ERV AND PocKET PC SOFTWARE Software Revision Information How can see if am using the latest software revision All Leopard ERV and Pocket PC software revision information is obtained by connecting the Pocket PC to the Leopard ERV via the Leopard ERV interface cable Software upgrades are done using the Pocket PC To view Pocket PC Version Start Leopard ERV Controller The current version is shown during this time Valve Software Version Start the Leopard ERV Controller and Connect Press the Valve Info button Current software version is dis played next to the Software Version text Syrup File Version Start the Leopard ERV Controller Press Setup and Change buttons The current Syrup File version is dis played directly above the pull down menu Publication Number 620919579SER 12 2002 2014 Cornelius Inc 2 Leopard ERV Installation Service Manual TROUBLE SHOOTING AND REPAIR Many operational problems are caused by problems with the system and or incorrect valve set up
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