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Frutista Viper 3 Flavor Service Manual

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2. 2 faceplate from the unit 4 Slowly pull the blade assembly out of the barrel 5 Rinse and inspect the blade assembly for signs of wear 6 If there is significant wear on the blades Reverse or replace them depending on the wear pattern 7 Replace the blade assembly and bushings PN 2392 onto the motor shaft in the barrel Re install the faceplate and replace the four 4 mounting nuts Hand tighten 8 the nuts until the faceplate makes contact with the gasket then use a wrench to tighten the nuts an additional 1 4 turn Be careful not to over tighten the nuts or cracking of the faceplate may result 9 Refill the barrel with product See Filling a Barrel on page 27 When barrel fill is complete perform a motor calibration See Calibrating a 19 Motor on page 33 Cleaning the Syrup Connections Syrup connections should be cleaned at least every six months or when syrup types are changed Perform the procedure in Table 39 to clean the BIB connectors Table 39 Step Action 1 Open the merchandiser and select OFF for the barrel to be cleaned 2 Remove the quick disconnect from the BIB container 3 Fill a suitable pail or bucket with soap solution 4 Submerge the disconnect in the soap solution and then clean it using a nylon bristle brush Do not use a wire brush Rinse with clean water and dry O 2010 2015 Cornelius Inc 47 Publication Number
3. Table 25 Display Description POS LIGHTING This selection turns the Point Of Sale lighting on and off COMPRESSOR 1 This selection turns the compressor on and off HOT GAS SOL 1 This selection opens and closes the hot gas solenoid for barrel 1 PRODUCT SOL 1 This selection opens and closes the product solenoids and valves for barrel 1 CO2 VALVE 1 This selection opens and closes the CO2 solenoid and valve for barrel 1 LLS VALVE 1 This selection opens and closes the Liquid Line solenoid and valve for barrel 1 BRL MOTOR 1 This selection turns the barrel 1 motor on and off To move between one set of barrel parameters to the next press the Right or Left arrow keys This moves the high light to the first entry of the second barrel etc Totals Menu The Totals menu Figure 24 shows the cumulative run time of the system a component of the system or an error Some individual items may be reset where available by highlighting the item and pressing the RESET button The RESET button is only displayed for items that may be reset such as hours since the motor seal was changed or the number of compressor cycles Pressing the BACK button returns to the Choose menu and saves the changes The description of each item in the Totals list is shown in Table 26 Publication Number 621360041TBSER 28 O 2010 2015 Cornelius Inc CD To move between one set of barrel parameters and the next press the Right or Left arrow keys
4. Clock Setup Event Setup Barrel Data Option Setup Viscosity Setup CO2 Setup Software Ver Barrel Maint Figure 8 Software Structure 13 Maintenance Sub Menus Barrel Maint Manual Diag Totals Brix Setup Motor Setup System Setup Publication Number 621360041TBSER Viper Service Manual CCGinius gt CONTROL PANEL MENU DESCRIPTIONS The following section describes the information displayed on each control panel menu and the interactions and set tings that are controlled by that menu System Menus The system menu structure allows the user to control the unit through the control panel Operational settings optional parameters troubleshooting and error information are controlled through this menu system The Barrel Status menu shown in Figure 9 is the home screen for the unit During normal operation this screen is displayed on the control panel Refer to Table 2 for button functions BARREL 1 FREEZE 87 STATUS 2 FREEZE 68 45 EBENE GC Figure 9 Main Screen MENU ON OFF DFRST SPIN Table 2 Button Description MENU Displays the Main menu ON Turns on the highlighted barrel OFF Turns off the highlighted barrel Initiates a manual defrost on the highlighted barrel Manual defrost is DFRST limited to a two minute cycle If the barrel is off this selection initiates a full defrost cycle SPIN Turns off refrigeration if on and mixes the product in the
5. Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TiPS e Carefully read and follow all safety messages in this manual and safety signs on the unit e Keep safety signs in good condition and replace missing or damaged items e Learn how to operate the unit and how to use the controls properly e 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 e Keep your unit in proper working condition and do not allow unauthorized modifications to the unit NOTE The dispenser is not designed for a wash down environment and MUST NOT be placed in an area where water jet could be used O 2010 2015 Cornelius Inc 1 Publication Number 621360041TBSER Viper Service Manual Ginclius gt 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 DEATH OR EQUIPMENT DAMAGE 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
6. 621360041TBSER Viper Service Manual CCD Servicing Motorman Dispensing Valves NOTE Dispensing valves with caged o rings should be serviced lubricated every six months and o rings should be replaced once a year Refer to Figure 34 and perform the procedure in Table 40 to lubricate or change the caged o rings in each dispens ing valve on the unit m TORSION SPRING 8 SPRING FITTING RETAINING SPRING HOUSING SCREW Z DISPENSING VALVE BODY __ 33 CAGED O RING Figure 34 Self Closing Dispensing Valve Table 40 Step Action 1 Defrost freeze cylinders shut unit down disconnect electrical power from Unit 2 Perform the procedure in Table 41 to empty the barrels Remove the hex nuts and flat washers securing the faceplate to the freeze 2 barrel then remove the faceplate from the barrel 4 Carefully remove the large o ring from the faceplate 5 Unscrew the relief valve from the faceplate 6 Disassemble the dispensing valve see Figure 34 7 Remove the two screws and hold down plates securing the spring housing to the dispensing valve body then remove the housing 8 Remove the torsion spring from the dispensing valve 9 Remove the knob spring sleeve and lever from the dispensing valve 10 Remove spring fitting from dispensing valve 11 Press the valve with the caged O ring down and out of the dispensing valve body 12 Carefully r
7. Cornelius recommends that in conditions where the FCB machine is operational and the minimum throughput as described in Table 34 is not met on a per barrel basis product should be dispensed and discarded to increase throughput and help assure that product quality is maintained NOTE Data in Table 34 assumes equipment has been correctly installed commissioned and calibrated as per directions contained in all technical literature published by Cornelius and the recommenda tions contained in this document have been followed Cornelius recommends that in conditions where the FCB machine is operational and the minimum throughput is not met on a per barrel basis product should be dispensed and discarded to increase throughput and help assure that product quality is maintained Programmed Defrost Scheduling The control system in the Viper system includes a function to automatically defrost product in the barrel at programmed intervals based on the viscosity of the product Programmed defrosts are scheduled frequently to ensure that product quality within the barrel is maintained Failure to defrost regularly during periods of low throughput allow increased ice crystal size with a possible decrease in product quality Regular throughput of dispensed product replenishes the barrel frequently with liquid and reduces the requirements for programmed defrosts The unit automatically senses the lack of throughput and maintains the product quality by defrostin
8. EURO button to display the date in dd mm yy for mat Setting the Time Format Time format can be displayed in either 12 or 24 hour format To display the clock settings in 12 hour format 1 08 P press the 12 HR button To display settings in 24 hour format 23 05 press the 24 HR button Setting the POS Lighting POS Lighting is controlled by the POS LIGHTING field on the Option Setup menu Figure 20 To turn off the mer chandiser lighting press the OFF button while the POS LIGHTING field is highlighted To turn on the merchandiser lighting permanently press the ALWAYS button To turn the merchandiser lighting on and off with the Sleep set tings press the SLEEP button Setting the Type of Syrup Syrup type for each barrel may be selected by highlighting the desired barrel and pressing the appropriate button FCB FCB L FUB or FUB L FCB is for Frozen Carbonated Beverage FCB L is for Frozen Carbonated Beverages Light diet FUB is for Frozen Un carbonated Beverages and FUB L is for Frozen Un carbonated Beverages Light diet Each of these settings provides the proper viscosity and temperature settings for the type of syrup being used Barrel Maintenance Refer to the next section Barrel Maintenance Menu to perform barrel maintenance on the system MAINTENANCE MENU The Maintenance menu shown in Figure 21 is only available to service personnel or other authorized users if security is enabled The Maintenance menu i
9. The water pump is located near the rear center of the unit It is mounted on a bracket facing the rear of the unit To replace the pump perform the procedure in Table 50 Water Pump Figure 40 Rear View of Water Pump dam Table 50 Step Action Disconnect power from the unit Remove the rear cover and the side panels Disconnect the CO2 supply from the unit AJOIN Remove and drain the water supply from the unit Disconnect the quick disconnect input and output water lines from the bottom of the pump al Disconnect quick disconnect CO2 input from the bottom of the pump Remove the four 4 screws and locknuts holding the pump to the mounting bracket Replace the pump oo o Reverse the procedure to install the new pump CO2 PULSE VALVE REPLACEMENT The CO valves shown in Figure 41 are located near the center of the unit and are mounted on a bracket to the bottom of the chassis They control the injection of CO2 with the syrup water combination to provide the final mix ture for the product There are one of these solenoids for each barrel in the system When working in this area care should be taken not to damage or mis align the CO2 metering orifice To replace one of these valves perform the procedure in Table 51 O 2010 2015 Cornelius Inc 57 Publication Number 621360041 TBSER Viper Service Manual Gireliai D Mounting Tie Wrap Pulse Val
10. This highlights the first entry of the second barrel etc TOTALS POWER ON SLEEP Viper Service Manual 00079 34 00034 21 SYSTEM ERROR 00003 45 COMP RUN 1 00006 53 12 51P COMP CYCLES 1 0000012 MAR 04 BARREL REFG 1 00006 54 BACK MM GC Figure 24 Totals Screen Table 26 Display Value Description POWER ON HHHHH MM Shows how long the machine has been pow ered up SLEEP HHHHH MM Shows how long the machine has been in sleep mode SYSTEM ERROR HHHHH MM pis how long the machine has had a system COMP RUN 1 HHHHH MM Shows how long the compressor has been run ning since the last reset COMP CYCLES 1 HHHHHHHE Shows the number of compressor cycles since the last reset BARREL DEEG 1 HHHHH MM Shows how long the barrel has been in refriger ation mode MOTOR ON 1 HHHHH MM Shows how long the motor has been running on a specific barrel MOTOR SEAL 1 HHHHH MM Shows how long it has been since the motor seal was inserted on a specific barrel DEFROST 1 HHHHH MM Shows how long the barrel has been in defrost mode FILL CYCLES 1 HHHHHHHIE Shows the number of times the barrel has filled with product SYRUP RUN 1 HH MM SS pud how long the syrup solenoid has been SYRUP OUT 1 HHHHH MM Shows how long the syrup has been out ERROR 1 HHHHH MM Shows how long the barrel has had an error BRIX Setup Menu BRIX is important to the quality of the final product Th
11. as shown in Figure 4 and Figure 5 The CO2 system also supplies COe to the water boost pump the expansion tank regulator and the secondary CO tank regulators CO enters the expansion tank regulator and is reduced to approximately 30 psig to feed holding pressure on the expansion tank This provides a force to work against the barrel pressure when the product freezes and expands CO2 also enters the secondary regulators These regulators are used to adjust barrel overrun expansion for various products The pressure settings for various types of syrup are shown in Table 1 Overrun CO2 pressure is applied to the CO2 control solenoids through preset orifices and on to the in line check valves From the in line check valve the CO2 flows into the product line Secondary CO2 Regulator Assemblies 70 75 psig A O O 75 1psig LL oo CX To Viper Unit Bulk gt Cylinder Bag in Box 110 200 psig f Bag in Box Figure 4 Typical Bulk Cylinder CO2 Connection Publication Number 621360041TBSER 8 O 2010 2015 Cornelius Inc Cylinder 110 psig 70 75 psig Bag in Box Viper Service Manual 75 1psig Secondary CO2 Regulator To Viper Unit CS Bag in Box Figure 5 Typical Tank CO2 Connection Tab
12. con a nect a BIB containing syrup to the syrup line 7 Rotate the Product BRIX valve to the BRIX position and open the valve at the f end of the tube Hold a waste container under the BRIX tube to collect the sanitizing solution 8 from the syrup line and open the manual syrup flow valve to start filling the syrup line with syrup Continue to hold open the syrup flow valve until syrup starts coming out of the BRIX tube 9 Perform a BRIX setup See BRIX Setup Menu on page 29 10 Fill the barrel with product as described in Table 22 11 Perform motor calibration See Calibrating a Motor on page 33 Publication Number 621360041TBSER 52 2010 2015 Cornelius Inc CCGineliis Viper Service Manual COMPONENT REPLACEMENT The following are procedures for servicing the major components of the Viper system BARREL MOTOR SEAL REPLACEMENT The barrel motor seal is typically replaced during the semi annual preventative maintenance procedure The seal location is shown in Figure 35 Motor Shaft Motor Seal Figure 35 Front View Inside of Barrel w Faceplate Removed REMOVING THE EXISTING SEAL To remove the existing barrel seal perform the procedure in Table 45 Table 45 Step Action 1 Purge the barrel See Purging a Barrel on page 26 2 When purging is complete disconnect power from the unit Open the relief valve on the front of the barrel to ensure that pressure i
13. error occurs when the H20 sensor reports H20 OUT System no or low water pressure for more than one sec ond Error is cleared 10 sec after restoration CO pressure is below required operating pres sure This error occurs when the CO2 sensor CO2 OUT System reports no or low CO2 pressure for more than one second Error is cleared 10 sec after restoration Syrup pressure is below required operating pres sure This error occurs when the syrup sensor SYRUP OUT Barrel reports no or low syrup pressure for more than one second Error is cleared 10 sec after restora tion CLOCK System The real time system clock is not functioning Ge System Motor control EEPROM is bad or missing Table 7 Button Description BACK Returns the display to the Select menu Allows the user to reset the highlighted error This button only appears RESET on certain manually resettable errors Error Log Menu The Error Log screen displays information about any errors generated by the unit as shown in Figure 13 If no errors have been detected the right side of the display is blank To view more than one error press the Up or Down arrows on the right side of the display to scroll through the error log Button functions are described in Table 8 O 2010 2015 Cornelius Inc 17 Publication Number 621360041TBSER Viper Service Manual iq ERROR ERROR NUMBER 2 LOG 3 COMM FAIL OCCUR 2 44 PM 3 04 08
14. faceplate of the barrel to relieve pressure and completely fill the barrel 6 Run the barrel motor Use the procedure in Table 23 to rinse the barrel 2010 2015 Cornelius Inc 27 Publication Number 621360041TBSER Viper Service Manual CCGineliis Table 24 Step Action Procedure Repeat the Purge procedure in Table 21 to empty the 7 Complete the procedure batel Manual Diagnostic Menu The Manual Diagnostic menu shown in Figure 23 is used for troubleshooting and testing the system on a compo nent basis It allows the service technician to turn individual components of the system on and off for troubleshoot ing purposes Pressing the BACK button returns the display to the Main menu and turns off all the active loads This screen should only be used by qualified technicians to troubleshoot the system MANUAL POS LIGHTING COMPRESSOR 1 HOT GAS SOL 1 Y PRODUCT SOL 1 CO2 VALVE 1 MAR 04 LLS VALVE 1 AN MMS Cu Figure 23 Manual Diagnostic Screen The items shown in Table 25 are for the first barrel in the unit only The list includes additional components with their related barrel number i e Hot Gas Sol 2 etc A CAUTION The compressor can suffer damage if it is allowed to run without either a hot gas defrost or liquid line solenoid open The software is designed to turn on the hot gas solenoid for a barrel to prevent damage from occurring
15. strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The control board is located in the E Box It is mounted to the panel on four 4 plastic mounting studs shown in Figure 51 To replace the control board perform the procedure in Table 60 Table 60 Step Action 1 Disconnect power from the unit 2 Connect a static strap to your wrist and any convenient chassis ground on the unit 3 Unplug the eight 8 connectors from the control board Squeeze each of the mounting studs at the corners of the board while care fully lifting the board 5 Replace the board with a new board 6 Reverse the procedure to install the new board Mounting Studs Software Compatibility Frutista software is not compatible with standard Viper software versions When ordering replacement service parts for any unit check the software version of the UI and IO boards and be sure to order the correct board Publication Number 621360041TBSER 64 O 2010 2015 Cornelius Inc CCGineliis Viper Service Manual MOTOR BOARD REPLACEMENT When replacing or testing electronic components be sure to wear a static strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The motor board is located in the E Box to the right of the control board It is mounted to the p
16. the splash panel see Figure 27 L to the Off horizontal position From the Maintenance menu press the FILL button for the barrel This pres surizes the barrel with CO2 3 Observe the water and syrup fill solenoids If there are NO seal leaks these solenoids cycle off within a minute and remain off 5 If the solenoids cycle off and remain off the barrel seal is not leaking and the barrel is ready to be filled with product 6 If the solenoids do not cycle off or cycle off and on the seal is leaking and the seal installation process described in Table 45 and Table 46 must be repeated 7 If there are no leaks turn the 3 way Product Supply valve to the BRIX position BARREL MoToR REPLACEMENT The barrel motor does not require any special alignment when being replaced It mounts on four 4 bolts These bolts are screwed into threaded bosses in the foam pack barrel assembly as shown in Figure 38 To replace a bar rel motor perform the procedure in Table 48 O 2010 2015 Cornelius Inc 55 Publication Number 621360041TBSER Viper Service Manual Gireliai D Barrel Motor Mounting Bolts Foam Pack Figure 38 Side View of Motor Showing Two of the Four Mounting Bolts Table 48 Step Action 1 Perform the procedure in Steps 1 through 8 of Table 45 Disconnect the motor from the circuit by unplugging the connector Remove the motor by removing the four 4 bolts holdin
17. toTable 4 for button functions UNIT 1 FREEZE DATA OUTLET TEMP 33 F VISCOSITY 9 REFRIGERATION ON 12 51P AVOZ HRAHR 80 MAR 04 DEFROST TIMER 2 50 23 NAS BRL INS Figure 11 Unit Data Screen Table 4 Button Description BACK Returns the display to the Select menu Displays the data for a single barrel including Outlet Temperature Vis cosity if Refrigeration is On or Off Average Ounces of product dis pensed per hour for the last three hours and Defrost Lock Time until next defrost Displays the real time input voltage and frequency being supplied to the unit and the low high or both refrigeration pressures for the unit depending on the settings of the compressor sensors in the Unit Data screen as shown in Figure 32 Displays the version number of the UI I O Motor and Status boards installed in the unit BRL UNIT VER Error Status Menu The Error Status menu shown in Figure 12 displays any current errors contained in the Error Messages List There are three types of errors that can be generated by the system These error types and a description of their meaning are listed in Table 5 Table 5 Error Type Description System A System error displays the same information across all barrels in the unit O 2010 2015 Cornelius Inc 15 Publication Number 621360041TBSER Viper Service Manual CCGinelis Table 5 Error Type Description Barrel
18. 12 51P CLEAR 2 52 PM MAR 04 3 04 08 BACK ME c Figure 13 Error Log Screen Table 8 Button Description BACK Returns the display to the Select menu Setup Menu The Setup menu provides the means to change various settings to local preferences such as time date and tem perature formats It also allows the user to adjust the unit for the type of syrup being served in each barrel To access the Setup menu from the Barrel Status menu press the MENU button This displays the Select menu shown in Figure 10 Press the SETUP button to display the Setup menu shown in Figure 14 To set up the unit options use the Up and Down arrows on the right side of the control panel to highlight the choices on the display When the desired option is highlighted press the GO button to access that menu SELECT CLOCK SETUP EVENTS SETUP VISC SETUP CO2 SETUP 12 51P OPTION SETUP MARO4 BARREL MAINT BACK MAIN SETUP MAY LI EBEBNUU MEZI Figure 14 Setup Screen Table 9 Button Description BACK Returns the display to the Select menu MAIN Opens the Main menu SETUP Highlighted to indicate that the Setup menu is displayed MAINT Displays button and opens Maintenance menu if security is off or accessed GO Opens the highlighted selection on the current menu Clock Setup Menu Select the CLOCK SETUP menu from the Select menu shown in Figure 14 This displays the Clock Setu
19. 3105 p ull YOLVIN9IY YOLVIN93Y R a Houws 8 TUN JUNSSIYA eZ 91sq 9 38NSSIYA Y ty ty te 0000000 000000 0000000000000 C op ep ep sd sl 4 oisaoor oisdsz iv Adans 8 1V Alddns OILVWSAHOS TFJAVE 130d 43dlA KId NSZOD waeren O 2010 2015 Cornelius Inc Figure 6 3 Barrel System Schematic 10 Publication Number 621360041TBSER CCD Viper Service Manual 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 supply is split to each barrel and is fed to the water flow controls From the flow rate control the water passes through a single ball check valve and mixes with the syrup in a wye fitting for injection into the freeze barrel Syrup System Syrup enters the unit through a sold out switch It enters a similar flow control to the water system passes through a single ball check valve and into the wye fitting where it meets the water for injection into the freeze barrel CONTROL PANEL Introduction The Viper unit uses a microprocessor based control system that monitors and controls all of the major systems and components of the machine Temperatures and pressures are monitored along with pumps valves and the refrig eration system They are managed by the control system to provide a consistently high quality product with optimal efficiency
20. 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained per sons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation oper ating cleaning or maintenance instructions 12 use of non authorized parts 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 Cornelius product con tact www cornelius com 800 238 3600 Trademarks and Copyrights This document contains proprietary information and it may not be reproduced in any way without permission 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 TABLE OF CONTENTS Safety ET 1 Read and Follow ALL Safety Instructions elt kel n ken kk aa a n kaa n aaa nn an konn 1 Safety OVOIVIGW Za ray ia on Leek aha ere Ee K eae ear eas d ups re 1 See TEE EE 1 Different Types or Alerts ic n Zu os A ER Ee 1 Safety PS da A EA A 1 Qualified Service Personnel sucia Re Ree eee a gO eee an Boe SEG a cde 2 Sale ELTERE 2 S
21. A FRUTISTA VIPER 3 FLAVOR Service Manual Release Date September 09 2010 Publication Number 621360041TBSER Revision Date June 09 2015 Revision E 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 possi ble contingency in the installation operation or maintenance of this equipment This manual assumes that the per son 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 Warranty applicable to this Product and is sub ject 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 nat limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper voltage 3 inadequate wiring 4 abuse
22. A Barrel error is limited to a specific barrel A Limp error is an error that doesn t prevent the unit from operating but lim Limp its functionality The possible messages from the control system and a description of the errors are shown in Table 6 The button functions are described in Table 7 ERROR 1 MOTOR PWR STATUS COMP HIGH 12 51P MAR 04 BACK A cc Figure 12 Error Status Screen Table 6 Displayed Message Action Type Description Occurs when the barrel outlet temperature HOT GAS Off System exceeds 115 F for more than one minute and the compressor is on Occurs when the barrel outlet temperature HOT BARREL Off System exceeds 115 F for more than one minute and the compressor is off The motor controller reported a fault triacs are MTR CTL FAIL System shorted and there is a loss of motor on off func tionality TCO Temperature Cut Off has occurred on the TCO OPEN System refrigeration outlet of a barrel or the 24VAC power has failed A communications error occurred between the IO board and the UI board UI board cannot communicate with the motor board Compressor has been on for more than 45 min BARREL REFRG Barrel utes and the viscosity of the barrel is not satisfied with no draws Occurs if a calibration initiated from the Motor Setup menu fails This indicates that the power draw of the motor is outside the allowable calibra tion range This error is
23. Ginclius gt Publication Number 621360041TBSER 36 2010 2015 Cornelius Inc CG Viper Service Manual OPERATION MAINTAINING PRODUCT QUALITY It has been determined that the following factors can affect the rate at which product quality diminishes as indi cated by a change in product appearance 1 Dispensed Product Throughput 2 Programmed Defrost Scheduling 3 Viscosity Setting Cornelius recommends the following instructions be read and followed relative to operating and establishing set tings for the FCB equipment Cornelius equipment service manuals contain instructions on how to program set tings within the control system Operators who have not been trained on servicing Cornelius FCB equipment should not attempt to modify equipment settings but should contact an accredited service provider Cornelius makes the following recommendations to help assure maximum product quality Dispensed Product Throughput FCB equipment is designed to provide a high throughput of frozen carbonated product to meet peak draw demands Where low product throughput is experienced there is the potential for product quality to diminish The information shown in Table 34 outlines the minimum throughput per barrel that must be dispensed on a 24 hour basis Table 34 Viper Viscosity lt 4 Viscosity gt 4 Volume of dispensed product per barrel per 4 24 hours required to maintain product quality SS 60 07 NOTE
24. IX position Hold waste container under the BRIX tube to collect flush water from the syrup line and open the manual syrup flow valve to start filling the syrup line with sanitizing solution Continue to hold the syrup flow valve open until sanitizing solution starts coming out of the BRIX tube 5 Turn the Product BRIX valve in the Product position Publication Number 621360041TBSER 50 2010 2015 Cornelius Inc Gino D Viper Service Manual Table 43 Step Action 6 Manually override open the syrup flow valve to fill the barrel with sanitizing f solution 7 Fill the barrel with sanitizing solution by opening the faceplate relief valve until sanitizing solution comes out of the relief port 8 Hold a 16 oz cup under the dispense valve Hold the dispense valve fully open until the cup is full 9 Use the brush provided with the unit to clean the relief port and clean the out let of the dispense valve with sanitizing solution From the Barrel Status menu press the SPIN button while highlighting the 40 appropriate barrel This starts the scraper blade Allow blade to operate for j minimum of 10 but no more than 15 minutes Turn the scraper blade off by pressing the OFF button 11 Place a large container under the dispense valve and drain as much sanitizing solution as possible from the barrel When the pressure in the barrel drops from the Barrel Maintenance menu 12 pr
25. K CLOCK Bi EBENE REC Figure 16 Daylight Savings Setup Screen Table 13 Button Description BACK Returns the display to the Select menu CLOCK Opens the Clock menu DST Highlighted to indicate DST menu Decrements the highlighted field by one increment Increments the highlighted field by one increment Table 14 Step Action Procedure Press DST button at the bottom of display to open day l Setcayign ande me light savings time display shown in Figure 16 2 Select DST Use the up and down arrows to select DST 3 SetDST on Use the button to turn on daylight savings time 4 Select SPRING MONTH Use up and down arrows to select SPRING MONTH 5 Set SPRING MONTH Use the or buttons at the bottom of the display to set the correct month 6 Select SPRING WEEK Use up and down arrows to select SPRING WEEK Use the or buttons at the bottom of the display to f SNE set the correct week The choices are 1 2 3 or L 8 Select FALL MONTH Use the up and down arrows to select FALL MONTH 9 Set FALL MONTH Use the or buttons at the bottom of the display to set the correct month 10 Select FALL WEEK Use up and down arrows to select FALL WEEK Use the or buttons at the bottom of the display to Ke IRE set the correct week The choices are 1 2 3 or L When the daylight savings settings are complete press the BACK button to save the settings and return to th
26. OLLONS l OL anor 4 Li YASNIGNOO Med Wvod II I III TTT ITT IT I T IT II ITT TIT III III HOD HZ 12002 ANS stauuva SHOIVHOdVA3 mm e eem eem un m me mm e mm em mp de gp a lemon mmm moe ARA FRI i R l Ann napa nn aa anana ucro rinm rr L mS IER YOSNIAS PANSSAdd SH Sa az vinsNE xe ABV AWOd SSADOV HIA HSAs Se SLLVIAISHOS NOLLVHHODR IS at Figure 2 Frutista Viper System 3 Barrel Refrigeration Schematic 2010 2015 Cornelius Inc Publication Number 621360041TBSER Viper Service Manual
27. RIX Setup Screen Splash Panel Retaining Screws Figure 26 Splash Panel Mounting Screws Product Product Product Supply Supply Flow Flow Flow Supply Valve Valve Controls Controls Controls Valve Barrel 1 Barrel 2 Barrel 1 Barrel 2 Barrel 3 Barrel 3 Valves shown in BARREL position w Splash Panel amp Solenoid Covers Removed Figure 27 Product Control Valves O 2010 2015 Cornelius Inc 31 Publication Number 621360041TBSER Viper Service Manual iq Manual Water Control y Valve Manual Syrup Control Valve Syrup Flow Control Water Flow Control Do Not Adjust Figure 28 Flow Controls with Panel Removed Motor Setup Menu Motor setup is initially done at the factory and does not need to be changed unless a barrel motor or barrel compo nents are replaced adjusted or removed and reinstalled This menu allows you to select different motor types for each barrel in the unit and run the calibration procedure on that motor This procedure correlates the actual viscosity of the barrel and its contents with the electrical character istics of the motor These characteristics are stored by the control system and are accessed at the time of calibra tion for each particular motor Because of the differences between motor characteristics from different motor suppliers the Motor menu shown in Figure 29 is used to adjust the unit settings to match the motor type being installed It provides the correct table of
28. The control system is set up by the service provider to perform the tasks necessary to keep the Viper unit operating correctly In addition to controlling the unit the control system keeps track of the diagnostic information used when adjusting and or repairing the machine The control system needs to be accessed in the following situations e Installing the Viper e Modifying Operating Characteristics Checking Performance Servicing Repairing the Machine Checking for Error Messages The control system is accessed using the control panel located behind the lighted merchandiser The control panel contains an LCD display and buttons shown in Figure 7 There are 2 levels of access to the control panel The first level can be accessed by the operator for normal opera tion and the second level is used by qualified service technicians for installation and service functions The service functions can be secured locked out so that an operator does not have access to them The control panel has a structured organization of menus The outline of this structure is shown in Figure 8 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 stabilized is the BARREL STATUS or HOME menu shown in Figure 7 This menu is displayed when the unit is running in normal operation Control Panel Display The control panel display has two main areas The first area is the menu displ
29. aT i ET aa EE a ASE E EASE E i 27 Run the Barrel Motor xs RE Sade a a a a i A ES 27 RINSING ANB AN di iu etro daa hot hg duet a iia e tn D 27 Manual Diagnostic MODs as tas d Cie nee cited wees Aisha de oe Be a 498 8 eee ee 28 Totals MGM EE 28 BRIX Setup MENU 554 ke eee Saag A 29 Motor Setup ON UI EE EE 32 Calibrating a Motor d D e Due oe Bb cda ten UE ok on Ne oat e DE 33 En TEE 34 SOCU ko ate ia o Ma si Se A E ida Se kn og BA we eS 34 Pressure SEN SOUS atascada aid rra ai 35 Operation EIC EE 42 Maintaining Product Quality 22 koke a aw ska e 04a Ewe he eee kak Ee Ee ee ES RR Yes 42 Dispensed Product Throughput sv is o Ie e ee Seale eer a k Vai 42 Programmed Defrost Scheduling 42 Sleep Mode Recommendations 42 MISCOSIDV Setting i siut ad bey otis eU S Re PE Pes vd tie A ig Ra UPS eo 43 COZ Setting zet Os dis tete a d da Gere 5 ot at EEN 43 Staring ele eiae kaa ee E E Re a ERG ER Rd et 43 Preventative Maintenance re nn non won non non nou won n n n n n n n n n n non n non monn nh nnn 45 S MMA ssl de o KEE Seen er a Me ub teg eo ter EE EE 45 Monthly Maintenance uos ee RP eR a A Ke a A 46 Cleaning Air NON eki ota a aet Pe ed i A e aes dit 46 Semi Annual Maintenance ia E eet Poe ee EE 46 Inspecting and Replacing Scraper Blades eee o nen n enn nn non noon 46 Cleaning the Syrup Connections tel ll n kel n kaa eee 47 Servicing Motorman Dispensing Valves 48 Sanitizing the S
30. anel on three 3 plastic mounting studs and a threaded standoff shown in Figure 52 To replace the motor board perform the procedure in Table 61 Table 61 Step Action 1 Disconnect power from the unit Connect a static strap to your wrist and any convenient chassis ground on the unit Unplug the eight 8 connectors from the control board Squeeze each of the mounting studs at the corners of the board while care fully lifting the board Replace the board with a new board Reverse the procedure to install the new board Oc A ON Mounting Studs Rev 0134 Cornelius 620314868 100 Rev F IEC 01 15 W Ai ag Yo a m a m o N o IMI Cornelius PN FOQLIDA H9IH G31Ul0SI dN Figure 52 View of Motor Board in E Box O 2010 2015 Cornelius Inc 65 Publication Number 621360041TBSER Viper Service Manual C Gne TROUBLESHOOTING TROUBLESHOOTING THE SYSTEM Problem Probable Cause Remedy Unit will not run A Unit not plugged in A Plugin unit B Circuit breaker B Reset replace circuit breaker C No power at L1 or L2 on contactor C Check voltage at outlet Check wiring to contactor D Low voltage at T1 or T2 D Replace the contactor Sleep display on barrel A Sleep time set A Check sleep programming status menu B Clock incorrectly set B Check sleep programming C No wake time set C Check sleep programming Barrel s
31. are listed in Table 36 It is recom mended that a preventative maintenance procedure be performed every six 6 months This procedure should include all of the maintenance items described in Table 36 and the following sections Table 36 Preventative Maintenance Summary Maintenance Procedure Frequency of Maintenance Clean Air Filter Monthly or more often as necessary See Cleaning Air Filter on page 46 Check BRIX Every six months or when changing syrup types See BRIX Setup Menu on page 29 Seal Change Every six months Clean Condenser Coil Every six months or as necessary Sanitize Unit Every six months or when changing syrup types Change or Rotate Scraper Blades Every six months Check for Leaks Every six months Clean BIB Connectors amp check operation Every six months or when changing syrup of syrup sold out switches types Check Clock Setting Every six months or when changing to or from daylight savings time Change caged o ring on models w Every six months or when changing syrup Motorman Valves types A CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit All wiring and plumbing must conform to national and local codes O 2010 2015 Cornelius Inc 45 Publication Number 621360041TBSER Viper Service Manual C Gua D MoNTHLY MAINTENANCE A general inspection of the machine for leaks and c
32. ater Pressure Switch Replacement II rl cece a nna a wa nn aaa kon nn 62 Display Board Replacement 2 kwe be a A a a Aa 63 Control Board Replacement 2 civ dame tee Pas DA Re dias AE pr ed PE ach 64 Software Compatibility cuca ia dar dais ih Ard iod a P8 Dd dean Sen Dh 64 Motor Board Replacement EE 65 Tro bleshno otihg ix a REA WO AER ERRORES EGRE k CREE ROCA ER CR UR RR d 68 Troubleshooting the System L imis x co ero e ECHO CERE ces o ee Fro 68 Troubleshooting Product Not Cold 2 s W NENNEN A uere ha e eh Rr Ree NN 69 CG Viper Service Manual SAFETY INSTRUCTIONS READ AND FoLLow ALL SAFETY INSTRUCTIONS Safety Overview e Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning caution labels on the unit decals labels or laminated cards e Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety reg ulations before operating this unit Recognition Recognize Safety Alerts A This 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
33. ater from the system 5 Disconnect the wires from the switch 6 Remove the switch using two wrenches 7 Replace the switch with a new unit 8 Reverse the procedure to install the new switch 9 Restore the water supply and check for leaks 10 Check to ensure that the new switch is working properly DisPLAY BOARD REPLACEMENT When replacing or testing electronic components be sure to wear a static strap that is connected to a chassis ground This protects the electronic components from any static charge while working on the unit The display board is located on the back of the control panel display It is mounted to the panel with four 4 phillips head screws shown in Figure 50 To replace the board perform the procedure in Table 59 Mounting Mounting Screws Screws Figure 50 View of Display Board Table 59 Step Action 1 Disconnect power from the unit O 2010 2015 Cornelius Inc 63 Publication Number 621360041TBSER Viper Service Manual C Gini Table 59 Step Action Connect a static strap to your wrist and any convenient chassis ground on the unit Unplug the two 2 connectors from the display board Remove the four 4 screws from the corners of the board Replace the board with a new board oO oOo AJOIN Reverse the procedure to install the new board CONTROL BOARD REPLACEMENT When replacing or testing electronic components be sure to wear a static
34. ay area This area presents informa tion about the status and settings of the machine It also displays menus of actions that are taken to modify the functioning of the machine O 2010 2015 Cornelius Inc 11 Publication Number 621360041TBSER Viper Service Manual BARREL 1 FREEZE 87 Menu STATUS 2 FREEZE 68 Display Area 12 51P MAR 04 MENU OFF DFRST SPIN g DOMME CC Menu Buttons Figure 7 Control System Display Control Panel Buttons The second area are the buttons and arrows located across the bottom and on the right side of the control panel There are up to five buttons and four directional arrows that may be used on a screen to activate and control vari ous the functions of the system Each button that is active for a given menu has a label directly above it The label describes what that button controls For example from the Barrel Status menu pressing button 1 labeled MENU displays the Select menu with more options pressing button 3 labeled OFF turns off the highlighted barrel On each menu below the Select menu there is a button labeled BACK to save any settings and return to the pre vious menu There is another button GO to advance to the highlighted menu Publication Number 621360041TBSER 12 2010 2015 Cornelius Inc Viper Service Manual Initialization Screens Barrel Status Main Sub Menus Error Log O 2010 2015 Cornelius Inc Home Screen Setup Sub Menus
35. ay to stop the fill Press the BACK button to return to the Select menu NOTE When FILL button is pressed it changes to a STOP button Run the Barrel Motor Table 23 Step Action Procedure 1 Run a barrel From the Setup menu Figure 21 open the Barrel Maintenance menu shown in Figure 22 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select Run function Press the SPIN button at the bottom of the display to start the motor in the highlighted barrel 4 Stop the procedure Press the STOP button at the bottom of the display to stop the motor Press the BACK button to return to the Select menu NOTE When RUN button is pressed it changes to a STOP button Rinsing a Barrel When rinsing a barrel the Barrel Maintenance menu cannot be used The procedure must be done manually as described in Table 24 Table 24 Step Action Procedure 1 Empty a barrel If the barrel has liquid in it use the Purge procedure in Table 21 to empty the barrel 2 Rinse a barrel Go to the Barrel Status menu Figure 7 3 Select the barrel Use the Up and Down arrows to highlight the desired barrel 4 Turn off the barrel Press the OFF button at the bottom of the display to turn off the barrel 5 Override Water Solenoid Press the manual bypass on the water solenoid and fill the barrel with plain water Use the relief valve on the
36. barrel Main Menu To access the menus for the system from the Barrel Status menu press the MENU button This displays the Select menu shown in Figure 10 The Setup and Maintenance menus are accessed through the buttons shown at the bot tom of the display NOTE If security is turned on the MAINT button is not displayed SELECT UNIT DATA ERROR STATUS ERROR LOG 12 51P MAR 04 Figure 10 Select Screen Publication Number 621360041TBSER 14 O 2010 2015 Cornelius Inc C Ginclius gt Viper Service Manual When the Select menu is displayed the Unit Data is highlighted To access the Unit Data menu press the GO but ton Refer to Table 3 the Select menu for button functions Table 3 Button Description BACK Returns the display to the Barrel Status menu MAIN Highlighted to indicate current menu SETUP Opens the Setup menu MAINT Displays and opens Maintenance menu if security is off or accessed GO Opens the highlighted selection on the current menu Unit Data Menu The Unit Data screen shown in Figure 11 provides information about the individual barrels in the system When DATA is highlighted and the GO button is pressed on the Select menu the display shows the first barrel in the sys tem and some of its parameters To view the next barrel press the Down arrow on the right side of the display Con tinue pressing the down arrow to view the data on all barrels in the system Refer
37. d and press the or buttons to change the minutes 15 min increments Select AM PM field If the 12 hour clock option is selected use the left and right arrows to select the AM PM field Then press the or buttons to change between AM and PM Select DAY for Wakeup Repeat Steps 2 and 3 as needed Select WAKEUP Use the up and down arrows to highlight WAKEUP and repeat Steps 5 through 7 to set the WAKEUP times When the sleep and wakeup settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 14 Setting Defrost Lockout From the Barrel Status menu shown in Figure 9 press the MENU button and then press the SETUP button to dis play the Setup menu Use the up and down arrows on the right of the control to highlight the Events Setup menu then press GO to enter the menu Figure 17 The lockout can also be set day by day or for all days with up to three lockout periods of four hours each per day These lockout periods may be overlapped to provide from four to 12 hours of defrost lockout if desired When the periods are overlapped it is recommended that the defrost lockouts for sequential lockout periods be overlapped by 15 minutes The defrost lockout affects all barrels in the unit To set the defrost lockouts perform the procedure in Table 17 Table 17 Step Action Procedure 1 Set defros
38. dispensing valve spring housing to the left counterclockwise to put tension on the tension spring Apply just enough 20 tension so that the dispense valve shaft returns to the closed position after release Do not overtighten Overtightening results in a high activation force on the valve 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 sanitizer manufacturer s recommendations or when changing syrup types The sanitizing process consists of emptying the barrel washing the lines and barrel cleaning the BIB connectors rinsing and refilling the system Emptying a Barrel To empty the barrel perform the procedure in Table 41 Table 41 Step Action 1 From the Barrel Status menu press the DFRST button When the barrel is defrosted go to the Maintenance menu If the security fea 2 ture is active access the Maintenance menu by pressing and holding the far left and right buttons simultaneously for approximately five seconds 3 Remove the splash panel See BRIX Setup Menu on page 29 Turn the Product BRIX valve 90 degrees clockwise to shutoff product to the barrel Place a large waste container under the dispense valve and drain as much product as possible from the barrel When the pressure in the barrel drops
39. e Select menu shown in Figure 14 Publication Number 621360041TBSER 20 O 2010 2015 Cornelius Inc CCineliis Viper Service Manual Events Setup Menu The Events Setup menu shown in Figure 17 allows the user to set sleep periods for the unit and to lock out the defrost cycle during peak busy times Sleep periods and defrost lockouts may be programmed for any day of the week or for all days of the week depending on business requirements Button functions are described in Table 15 DAY SUN SLEEP 10 00 PM WAKEUP 08 00 AM DEFROST LOCK 2 09 30 A MAR 04 DEFROST LOCK 3 CLEAR Figure 17 Event Setup Screen Table 15 Button Description BACK Returns the display to the Select menu and saves current settings CLEAR Clears the highlighted field on the menu Decrements the highlighted field Increments the highlighted field When the sleep and wakeup settings and the defrost lockout settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 14 SETTING EVENTS Events setup allows the user to set sleep periods for the unit and to lock out the defrost cycle during peak busy times Sleep periods and defrost lockouts may be programmed for individual days of the week or for all days of the week depending on location requirements Setting the Sleep and Wakeup Times Sleep and wakeup times are set on the Event Setup menu shown in Fig
40. e perform the procedure in Table 12 and refer to Figure 15 Table 12 Step Action Procedure 4 Bet date Use up and down arrows on the right side of the con trol panel to highlight DATE display on screen 2 Select month field Use the left and right arrows to select month field Set correct month Use the or buttons at the bottom of the display to set the correct month Select day field Use the left and right arrows to select day field Set correct day Use the or buttons at the bottom of the display to set the correct day o Oc o Select year field Use the left and right arrows to select year field O 2010 2015 Cornelius Inc 19 Publication Number 621360041TBSER Viper Service Manual C Gne Table 12 Step Action Procedure Use the or buttons at the bottom of the display to 7 Set correct year set the correct year Setting Daylight Savings Time Once the date and time are set properly daylight savings time settings can be done The Daylight Savings Time menu is shown in Figure 16 If daylight savings time is off press the button to activate it The button functions are described in Table 13 To set daylight savings time perform the procedure in Table 14 NOTE Default daylight savings settings are for the U S CLOCK SETUP DST SPRING MONTH MAR ON SPRING WEEK 1 FALL MONTH FALL WEEK L 12 51P MAR 04 OCT BAC
41. e BRIX menu facilitates the extraction of a sample of product from the unit for BRIX measurement There is an automatic three second dispense of product that produces a con stant volume so that a BRIX comparison can be made between samples To perform a BRIX test perform the pro cedure in Table 27 Table 27 Step Action Procedure Make sure the status of all barrels is OFF on the 1 Set status of barrels E control display O 2010 2015 Cornelius Inc 29 Publication Number 621360041TBSER Viper Service Manual C inet Table 27 Step Action Procedure Remove drip tray access panel Remove the drip tray loosen the two screws hold ing the access panel and remove it Figure 26 Set product supply valve Turn product supply valve to the 180 degree BRIX position for the barrel you are testing See Figure 27 Access BRIX menu Press MENU Then press the SETUP button Set barrel for BRIX From the Setup screen Figure 14 open the BRIX Setup screen shown in Figure 25 Use the Up and Down arrows to highlight BRIX SETUP Press the GO button at the bottom of the display Select barrel Use the Up and Down arrows to highlight the desired barrel for BRIXing Perform BRIX procedure Locate the appropriate barrel sample tube and hold a cup under it Open the valve at the end of the sample tube Press the BRIX button and wait 3 5 seconds The product pump pump
42. e to reclaim refrigerant when replacing compressor Table 54 Step Action Disconnect power to the unit Remove the rear cover and side panels Label and disconnect all wires from the compressor Remove the four 4 mounting nuts from the base of the compressor Remove all insulation from around fittings oc E O Nj m Unsweat the suction line from the compressor Cut the discharge line on top of the compressor Make sure line can be spliced back together Remove the compressor and unsweat the discharge line Reverse the procedure to install the new compressor 10 Replace the dryer Evacuate the system and recharge it according to the Cornelius nameplate on A the unit 12 Replace the side panels and rear cover 13 Reconnect power to the unit and test the unit Publication Number 621360041TBSER 60 O 2010 2015 Cornelius Inc CCGineliis Viper Service Manual HoT GAS SOLENOID REPLACEMENT The hot gas valves and solenoids shown in Figure 46 are located near the center of the unit on the right and left sides Whenever a hot gas valve and solenoid is replaced the dryer should be replaced at the same time Perform the procedure in Table 55 to replace the solenoid Hot Gas Solenoid Figure 46 Hot Gas Solenoid 1 per barrel Table 55 Step Action 1 Disconnect power from the unit Remove the side panels Reclaim refrigerant from the sys
43. efrigerant A Repair leak and weigh in new not Cooling charge B Restricted condenser filter B Clean or repair C Condenser fan motor blade defec C Repair or replace tive D Hot gas valve leaking or open D Replace E Defective compressor E Repair or replace Restricted Air Flow A Dirty filter A Clean filter B Dirty condenser B Clean condenser C Damaged fins C Repair replace if necessary D Not enough clearance around D Ensure proper spacing around unit unit Fan Motor A Bad connection A Check connect B Bad motor B Replace motor C Cracked or bent fan blade C Replace fan blade Hot Gas Valve A Miswired A Correct wiring B Defective coil B Replace coil C Defective product delivery board C Replace No Low Refrigerant A Leak A Repair and weigh in new charge Sensors A Bad connection A Correct wiring B Bad sensor B Replace sensor C Sensor out of position C Reposition sensor and clip D Defective product delivery board D Replace O 2010 2015 Cornelius Inc 69 Publication Number 621360041TBSER Cornelius Inc www cornelius com
44. efrigeration system without having to connect external gauges to the system To view this information go to the Unit Data screen shown in Fig ure 11 and press the UNIT button The System screen shown in Figure 31 is displayed The number and type of sensors in the unit are typically set at the factory and should not be changed Data is only available on the sensors installed If a sensor that is not installed in the unit is activated incorrect data is displayed It is possible to install sensors in the field but it is not recommended because system refrigerant charge may be lost The low side pressure sensor is used to monitor compressor reversal If it is not installed on the unit the unit may not operate properly SYSTEM OF BARRELS 2 OF COMPRESSOR 1 SECURITY OFF CMP 1 SENSORS BOTH BACK NONE LOW HIGH BOTH Figure 31 System Screen When the pressure sensors selection is highlighted pressing the NONE button removes the pressure readings from the Unit Data screen shown in Figure 32 If LOW is selected only the low pressure reading is displayed If HIGH is selected only the high pressure reading is displayed NOTE If a pressure sensor is open the pressure reading is 386 PSIG LINE VOLTAGE 229 LINE FREQUENCY 60 LOW PSIG 1 60 HIGH PSIG 1 1741 BACK BRL UNIT MWA EBENEN Cu Figure 32 Unit Data Screen O 2010 2015 Cornelius Inc 35 Publication Number 621360041TBSER Viper Service Manual C
45. electrical characteristics from imbedded settings located in non volatile memory Perform the procedure described in Table 30 to change the motor type setting Insure that the motor type matches the settings listed in Table 28 based on model NOTE If the Motor Type shown is DEFAULT it indicates that the EEPROM is not installed or is faulty Table 28 Model Motor Type All 60 Hz 1 All 50 Hz 2 MOTOR 1 MOTOR TYPE 1 SETUP 2 MOTOR TYPE 2 12 51P MAR 04 BACK CAL Figure 29 Motor Setup Screen Publication Number 621360041TBSER 32 O 2010 2015 Cornelius Inc CCD Viper Service Manual Table 29 Button Description BACK Returns the display to the Select menu CAL Verifies the motor settings of a new motor S Decrements the highlighted field Increments the highlighted field Table 30 Step Action Procedure From the Maintenance menu Figure 21 open the Motor Setup menu shown in Figure 29 Use the Up and Down arrows to highlight the desired 1 Set barrel for Motor Type 2 Select the barrel barrel 3 Select the proper motor Press the or buttons at the bottom of the display to type select the proper motor type Press the BACK button at the bottom of the display to 4 Complete the procedure P P save the settings and return to the Setup menu Calibrating a Motor Calibration of motors is typically reguired whe
46. emove the caged O ring from the valve Wash all the parts in warm water Remove all traces of syrup and lubricant espe cially from the faceplate o rings and dispensing valve If parts are excessively 13 coated wipe clean with a paper towel to remove excess syrup and lubricant especially from caged o ring and dispensing valve Use a brush provided with the unit to clean the faceplate relief valve passages and the inside of the knob Publication Number 621360041TBSER 48 O 2010 2015 Cornelius Inc Gino D Viper Service Manual Table 40 Step Action Submerge all the parts in a 4 percent solution of approved sanitizing agent for 14 a the amount of time recommended by the sanitizer manufacturer Remove the parts from the sanitizing solution and place them on clean paper 15 towels 16 Assemble the dispensing valve Lubricate the caged o ring Carefully install the caged o ring onto the valve 17 from the straight end opposite tapered end Lubricate the grooves that the o ring rides to fill in all void areas around the o ring 18 Carefully install the valve with the caged o ring in the dispensing valve body Install the spring fitting knob and lever parts torsion spring and spring hous 19 ing assembly by reversing the removal procedure Do not tighten down the hold down plates securing the spring housing at this time After re installing the faceplate turn the
47. ess the PURGE button to re pressurize the barrel with CO2 As sanitizing solution level lowers in the barrel partially close the valve to avoid spurting O 2010 2015 Cornelius Inc 51 Publication Number 621360041TBSER Viper Service Manual Cines Flushing the System Flush the wash water from the system by performing the procedure in Table 44 A CAUTION Flush the system thoroughly residual sanitizing solution left in the system may create a health hazard Table 44 Step Action 1 Turn the Product BRIX valve to the Product position Manually open the manual water flow valve to start filling the barrel with wash 2 i water At the same time open the faceplate relief valve until water comes out From the Barrel Status menu press the SPIN button while highlighting the 3 appropriate barrel This starts the scraper blade Allow the blade to operate for fifteen seconds then turn barrel OFF by pressing the OFF button 4 To drain the water from the system turn the barrel OFF Place a container under the barrel dispensing valve Open the dispensing valve and dispense all rinse water from the barrel When the pressure in the 5 barrel drops from the Barrel Maintenance menu press the PURGE button to re pressurize the barrel with CO2 As the wash water level lowers in the barrel partially close the valve to avoid spurting Remove the sanitizing fitting p n cc 28688 from the BIB connector and
48. from the Barrel Maintenance menu 6 press the PURGE button to repressurize the barrel with CO2 As product level lowers in the barrel partially close the valve to avoid spurting T Disconnect the BIB from the unit NOTE The unit should be sanitized every 180 days by a qualified service technician following the sanitizer manufacturer s recommendations O 2010 2015 Cornelius Inc 49 Publication Number 621360041TBSER Viper Service Manual Quels D Flushing the System of Syrup After emptying the barrel the barrel should be flushed of product before proceeding with the sanitizing procedure Perform the procedure in Table 42 Table 42 Step Action 1 Fill a clean 5 gallon pail with plain water Connect a sanitizing fitting p n cc 28688 to the BIB connector Put the con nector in the bucket of water 3 Make sure the Product BRIX valve is in the BRIX position 2 Hold a waste container under the brix tube to collect syrup from the syrup line and open the manual syrup flow valve see Figure 28 to start filling the syrup i line with plain water Continue to hold the manual syrup flow valve open until clean water starts coming out of the BRIX tube 5 Release the manual syrup flow valve and turn the Product BRIX valve to the Product position 6 Open the manual water flow valve see Figure 28 to start filling the barrel with water At the same time open the faceplate relief valve unt
49. g the barrels more frequently when throughput is slow Sleep Mode Recommendations Cornelius recommends programming a sleep period for the machine during any amount of time over 3 hours that the unit is not used This increases the life of the machine and reduces energy consumption A wake up time must be programmed after the sleep period to return the unit to normal operation Cornelius recom mends programming the wake up time for approximately 20 minutes before the product is needed This is the time 2010 2015 Cornelius Inc 42 Publication Number 621360041TBSER Viper Service Manual CG recommended if the ambient temperature is at 75 F The times will vary depending on the ambient temperature a higher ambient temperature reguires more time for the product to cool Viscosity Setting The control system includes a function to select the desired product viscosity This function is referred to as Vis cosity Setting There are selectable viscosity ranges from 1 9 The higher the number selected the more viscous the frozen product in the barrel becomes This increased viscosity is achieved by freezing the product in the barrel to a lower temperature thereby increasing ice crystal size growth As the ice crystal size increases however there is potential for product guality to diminish Cornelius recommends that the viscosity settings be set at the lowest possible setting to achieve the desired drink qual ity In most typical instal
50. g the motor to the bar rel assembly Install the replacement motor and connect the connector Replace the motor seal scraper blade assembly onto the motor shaft in the barrel as described in Table 45 Reconnect power to the unit NIO al A C N Refill the barrel with product See Filling a Barrel on page 27 When barrel fill is complete perform a motor calibration See Calibrating a Motor on page 33 oo MOTOR RUN CAPACITOR REPLACEMENT The motor run capacitors shown in Figure 39 are mounted at the rear of the unit between the barrel motors To replace a run capacitor perform the procedure in Table 49 Motor Run Capacitors Figure 39 View of Motor Run Capacitors Table 49 Step Action 1 Disconnect power from the unit 2 Remove the rear cover 3 Disconnect the spade clips from the defective capacitor Publication Number 621360041TBSER 56 O 2010 2015 Cornelius Inc CGinclius gt Viper Service Manual Table 49 Step Action 4 Remove the mounting screw from the base of the capacitor Replace the capacitor Reverse the procedure to install the new capacitor Reconnect power to the unit Refill the barrel with product See Filling a Barrel on page 27 When barrel fill is complete perform a motor calibration See Calibrating a Motor on page 33 O o Oo o0 WATER PuMP REPLACEMENT
51. generated if the low side pressure is greater than 55 psi for greater than 30 sec Only checked when barrels are in freeze mode and compressor is running more than two minutes Indicates thermistor reading is at min or max value for 30 sec without changing COMM ERR IO System COMM ERR MTR System MTR CAL ERR Barrel CMP HI PRESS System BRL TEMP OUT Barrel Publication Number 621360041TBSER 16 O 2010 2015 Cornelius Inc CCD Viper Service Manual Table 6 Displayed 3 S Message Action Type Description Motor stalled A two minute defrost and two MOTOR STALL Barrel retries are allowed then the message is dis played METER FAIL Barrel Metering chip is nonresponsive Barrel viscosity is too high Motor cannot rotate BEL RECOVER SEI Automatic two minute defrost to thaw barrel COM ERR STAT Limp T error the system continues to The unit is experiencing voltage greater than HIGH VOLTAGE System 260VAC System is enabled when line voltage drops below 260VAC for two minutes The unit is experiencing voltage less than LOW VOLTAGE System 200VAC System is enabled when line voltage rises above 200VAC for two minutes The motor is reporting no current draw when acti NO MOTOR Barrel vated Motor is unplugged or thermal cutoff has tripped FILL ERROR Barrel Barrel has nat filled properly within 2 min Water pressure is too low for proper operation This
52. he seal over the motor shaft and press it firmly until is fully seated against the spacer and the seal cannot be pushed any further 7 Run your finger around the perimeter of the seal to insure it is flush against the back of the barrel 8 Reinstall the blade assembly Rotate the assembly while inserting it to insure that it is fully seated on the motor shaft Figure 36 9 Lubricate the faceplate o ring Re install the faceplate and replace the four 4 mounting nuts Hand tighten the nuts until the faceplate makes contact with the gasket then use a wrench to tighten the nuts an additional 1 4 turn Be careful not to overtighten the nuts or cracking of the faceplate may result 11 Clean the drip tray and tube using warm water 12 Perform the seal leak test in Table 47 Note Orientation Motor Shaft Publication Number 621360041TBSER 54 2010 2015 Cornelius Inc Spacer Figure 36 View of Motor Shaft with Spacer on Shaft Cinel D Viper Service Manual Spacer Figure 37 Side View of Seal and Spacer on Motor Shaft MOTOR SEAL LEAK TEST After replacing the motor seal it is advisable to test the seal under pressure before refilling the barrel with product Perform the procedure in Table 47 to verify that the seal is installed properly and not leaking When the seal passes the leak test perform the motor calibration routine on page 33 Table 47 Step Action Turn the 3 way Product Supply valve behind
53. hipping And Storage L eese bs dod kte ote Feo Clo he Ot A uL kk onn tud UE 2 CO2 Carbon Dioxide Warning EE ca para eke ede wae C4 eA SOS EERE k Sa RE 2 Mounting in or on Ren LEE EE 2 InfrodUctiol secsi d exa Edo oe a EE EE a d traced ek a 3 Manual Overview 4 e ERN ERR RETI A A ee a ER RE dE E 3 Dispensed Product Conditions 4 Overrun as Applied to Carbonated BEeVEragES esse eee ea n n kn na non n kn nn 4 RT We e auos kane Lauk a a a e Ge EE 4 Overtun 18 4 Maria bl scade corti G e ad Gated eed teed Ru egy Bae eda eee cee Ree 4 Specific Product Ingredients Affect Overrun Likas 4 BRIX Affects e EE 4 Low Dispensing Volume Affects Overrun lt 4 Carbonation Level in Liquid Product Affects Overrun n nasasa as 4 Freezing Affects Overrun west caw ac Ole i e co eH wide Rela hee ee 4 System e 5 aio ki wa n tea Ca tate S Ky eno ene ees ta ule EM eae ae ee Pd atte tud AS 5 THEO ODSPAloft utres EENEG 5 COLS Mt hat oy aire s acta AS bei dts 8 Water SYSTEM A RSE oe es Masa aes eae Dee yaad 11 SUD SySIBITE tie ace EE EEN 11 Control Panel po tie setlist o errada fhe hae te ed pan ANA OBOE Deu p Eg bek 11 Introductio en sus E an ki a aa A Cee SES Can AR 11 Control Panel Display onp 144455 o ras y ee een SES n 11 Control Pane BUNS iones asar obe er rb Sede oro EACH e e Wee 12 Control Panel Menu Descriptions tel lk kk kle n kaa n kk ne 14 System MENUS y A A r EE ere SERA A e E 14 ac MOD esr euet
54. hown in Figure 18 allows the user to adjust the viscosity in each barrel to the optimum setting for each type of syrup VISC 1 VISCRANGE 6 48 110 SETUP 2 VISCRANGE 6 48 110 Y 12 51P MAR 04 BACK m MMS c Figure 18 Viscosity Setup Screen Refer to the Installation manual for the recommended settings based on syrup type Table 18 Step Action Procedure i From the Setup screen Figure 14 open the Vis 12 cosity Setup screen shown in Figure 18 2 Select barrel Use the Up and Down arrows to highlight the desired barrel 3 Select range field Use Left and Right arrows to select range field Use the or buttons at the bottom of the display to set the desired range 5 Select barrel Repeat Steps 2 through 4 for all barrels 4 Set range To set all barrels in the system to the same viscosity setting perform Steps 1 through 4 in Table 18 and then press the ALL button at the bottom of the display while highlighting the viscosity setting you desire for all the barrels When the viscosity settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 14 CO Setup Menu The CO2 Setup menu shown in Figure 19 allows the user to adjust the percentage of time that the CO2 pulse valves are open This provides an adjustment of the overrun for the unit when using different syrups The valves use a one second interval duration ti
55. il water comes out When the barrel is full press the SPIN button on the Barrel Status menu while 7 highlighting the appropriate barrel This starts the scraper blade Allow blade to operate for fifteen seconds 8 Turn barrel OFF by pressing the OFF button Place a waste container under the barrel dispensing valve Open the dispens ing valve and dispense all wash water from the barrel When the pressure in 9 the barrel drops from the Barrel Maintenance menu press the PURGE button to re pressurize the barrel with CO2 As the wash water level lowers in the bar rel partially close the valve to avoid spurting Perform rear barrel seal replacement See Barrel Motor Seal Replacement 10 on page 53 Perform inspection and replacement of scraper blades See Inspecting and 1i Replacing Scraper Blades on page 46 12 Perform a leak test on the barrel See Motor Seal Leak Test on page 55 Sanitizing the Barrel Sanitize the syrup system and barrel by performing the procedure shown in Table 43 Table 43 Step Action Use a clean 5 gallon pall filled with a sanitizing solution and water at a temper 1 ature of 90 F to 110 F 32 C to 43 C The sanitizing solution must have 200 ppm available chlorine Connect a sanitizing fitting p n cc 28688 to the BIB connector Put the con nector in the bucket of sanitizing solution 3 Make sure the Product BRIX valve in the BR
56. k Valves Wye Retaining Nuts Figure 44 6 Remove the two 2 locknuts from the base of the assembly and remove it from the unit 7 Remove the check valve from the valve being replaced 8 Install the check valve on the new valve and solenoid 9 Remove the valve and solenoid from the mounting bracket and replace it 10 Reverse the procedure to reinstall the bracket into the unit 11 Reconnect power to the unit and test the system CONDENSER FAN MOTOR REPLACEMENT The fan motor is located on the top of the unit as shown in Figure 45 If the motor needs replacement perform the procedure in Table 53 to remove and reinstall a motor O 2010 2015 Cornelius Inc 59 Publication Number 621360041 TBSER Viper Service Manual CGinelius gt Locking Nuts Locking Nuts Figure 45 Condenser Fan Mounting Nuts Table 53 Step Action Disconnect power from the unit Disconnect the fan by unplugging the connector Remove the four locking nuts securing the fan to the top of the condenser Lift the fan and shroud off the unit Remove the four screws and washers securing the fan to the shroud Replace the fan Reverse the procedure to install the new fan o Oo ol E 0 m Reconnect power to the unit COMPRESSOR REPLACEMENT Caution should be used when working with refrigerants To replace a compressor perform the procedure in Table 54 NOTE Be sur
57. lations using a sugar based syrup acceptable drink guality can be achieved by programmed vis cosity settings in the range of 3 5 for Viper Diet FCB syrups freeze much more readily than sugar based syrups so the viscosity setting should be selected at the minimum value available which is 1 or 2 for the Viper CO2 Setting The control system includes a function to adjust the desired product overrun This function is referred to as the CO2 Setting This setting is adjustable from O to 100 in 5 increments Typically 40 to 45 settings on the pulse valves creates 100 overrun STARTING THE UNIT Table 35 describes the basic procedure for starting the Viper Refer to the Operators Manual P N 621360041TBOPR for details on operation of the Viper unit Table 35 Step Action Procedure 1 Open the merchandiser Open the merchandiser and expose the control panel 2 Turn on the barrels Turn all barrels on by pressing the buttons labeled ON to start the normal refrigeration process 3 Close the merchandiser Close the merchandiser In approximately 20 minutes product is ready to serve Publication Number 621360041TBSER 43 2010 2015 Cornelius Inc CCD Viper Service Manual PREVENTATIVE MAINTENANCE SUMMARY There are no daily maintenance procedures required on the Viper unit other than normal cleanup of spills or over spray and emptying the drip tray Normal equipment maintenance intervals
58. le 1 provides guidelines for machine settings based on general syrup type Several factors including syrup for mulation level of citric acids etc will impact settings These settings are to provide initial adjustments to achieve product overruns in the 80 120 range Table 1 Settings Syrup Type Set Viscosity CO2 Setting Expansion Nominal Settings FCB 3 50 7 PSIG NOTE For citric syrups adjust the CO2 pressures down by 2 4 PSIG from the above to compensate for the lower CO2 adsorption O 2010 2015 Cornelius Inc Publication Number 621360041TBSER Viper Service Manual H amp NI dNYAS 4a NOISNVdX3 9ISd 94 440 119 py PISA SS NINO hil YILYM anv 1 da amas a L ey TRAVE IZINIL TT J0ONMN B i 0 9ISd 8Z 440 102 V GERS 9ISd EZ NI LAJ NOISNV XS f I i HE 0 Z NI dNMAS Pa me 0 AZ Olsd v 440 119 e 8 4 DISA 55 NINO Z4 TAVA 323393 ae i a i 0 ONIXIN osdsz4401n9 9 ASSEZNILNY 0 bit ANVL NOISNVdX3 0 0 0 0 HE NI dNIMAS de 0 0 5 olsd 8b 440 119 8 i oiassNi1no A S31VM QNV Ht Tau 323334 TT e nas L M DISA 82 430 1N9 y pe 0 iB OISd Z NI LND ARN V 0 9ISd E 14019 dWNd TOULNOD MOT 0 Osanna E FAN 3ATVA 93H2 709 Lageren geg 10 0 KM pee ee ees pann ke e Tann amp eme olsdss 440 1no 8 20140 9ISd PONILND GION
59. leanliness should be done on a weekly basis Any abnormal conditions should be reported and corrected when noticed Cleaning Air Filter The air filter should be cleaned at least once a month more often in harsh environments Perform the procedure in Table 37 to clean the air cleaner Table 37 Step Action 1 Open the merchandiser 2 Remove the filter shown in Figure 33 by grasping the two tabs and sliding it straight out the front of the unit 3 Wash the filter with clean water Shake out the excess water 4 Reinstall the air filter mesh side down 5 Close the merchandiser Tab Figure 33 Air Filter Location Semi Annual Maintenance There are several procedures that should be completed on a semi annual basis There procedures help to insure proper operation of the system on a long term basis Refer to Table 36 for a listing of the semi annual maintenance items Inspecting and Replacing Scraper Blades Scraper blades should be inspected for wear during the semi annual maintenance check To inspect the blades perform the procedure in Table 38 Table 38 Step Action 1 See Purging a Barrel on page 26 2 When purging is complete remove power from the unit Publication Number 621360041TBSER 46 O 2010 2015 Cornelius Inc CCD Viper Service Manual Table 38 Step Action Remove the four 4 3 4 in nuts from the faceplate and slowly remove the
60. me Setting a valve to 45 activates the valve for 450 msec out of each second The CO2 pulse valves may be set between 0 and 10095 in 596 increments To change the settings of the CO2 pulse valves perform the procedure in Table 19 O 2010 2015 Cornelius Inc 23 Publication Number 621360041TBSER Viper Service Manual 1 CO2 PULSE 45 2 CO2 PULSE 45 3 CO2 PULSE 45 Figure 19 CO2 Pulse Valve Setup Screen Table 19 Step Action Procedure Set CO2 Pulse valve duration From the Setup screen Figure 14 select the CO2 Setup screen shown in Figure 19 Use the Up and Down arrows to highlight the desired barrel Use Left and Right arrows to select duration field Use the or buttons at the bottom of the display to set the desired duration Repeat Steps 2 through 4 for all barrels Select barrel 2 3 Select duration field 4 Set duration 5 Select barrel To set all barrels in the system to the same duration setting perform Steps 1 through 4 in Table 19 and then press the ALL button at the bottom of the display while highlighting the duration setting you desire for all the barrels When the duration settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 14 Option Setup Menu The Option Setup menu allows the user to set the various options available in the system These options are listed in Table 20 The O
61. mperatures than for high BRIX products Thus BRIX affects overrun because the amount of sugar in a drink has a direct bearing on the product s freezing characteristics DRAWING 1 DRAWING 2 DRAWING 3 Figure 1 Low Dispensing Volume Affects Overrun When a unit sits idle for a period of time with no drinks being dispensed CO2 gas in the system takes a set When the first few drinks are drawn off after an idle period CO2 gas has less tendency to break out as the drink is dispensed The result is that these first drinks have less overrun than drinks dispensed during peak use periods Carbonation Level in Liquid Product Affects Overrun The higher the specific carbonation level in a given product the greater the potential for carbonation breakout in frozen carbonated form of that drink For example drinks with 3 0 volume of carbonation have more gas breakout in frozen carbonated form and more overrun than drinks that contain 2 0 volumes of CO2 gas Freezing Affects Overrun Freezing causes approximately a 5 7 percent expansion in dispensed frozen carbonated drinks The degree of freezing is limited because the finished drink is intended to be sipped through a straw This is not possible if the product is too solid Publication Number 621360041TBSER 4 2010 2015 Cornelius Inc CCD Viper Service Manual SYSTEM OVERVIEW INTRODUCTION The Viper unit consists of the following systems and hardware Multiple freeze bar
62. n a motor or any associated barrel components i e scraper blades seal faceplate etc is removed or replaced Calibration establishes a new baseline for the motor assembly This allows the system to determine proper viscosity settings for the new motor When a new Motor is installed in the unit or any of the barrel components are changed or adjusted the motor should be calibrated by performing the procedure described in Table 31 A CAUTION Calibration must be performed when the product in the barrel is completely liguid There must not be any ice on the scraper blade Table 31 Step Action Procedure It is VERY IMPROTANT that calibration be performed when the product in the barrel is in a 100 liquid state There can be no ice in the barrel or on the beater bar Select DFRST on the Barrel Status menu Figure 9 It is very important that calibration be performed on a fully defrosted barrel outlet temperature must be 41 F or barrel must be purged and refilled with new product Selecting DFRST while the barrel is off ini tiates a full defrost cycle Use the Up and Down arrows to highlight MOTOR SETUP on the Maintenance menu Use the Up and Down arrows to highlight the desired barrel Press the CAL button at the bottom of the Motor Setup menu to start the calibration process The calibration cycle continues for five 5 minutes to allow the gearbox to stabilize at temperature and ensure correct calibration At that time the mo
63. n di d 091 NO 104290002 ul suoddb sou4 221145 o40oipul ES B ajbway pUasaJo BE Od rcr 9325 2 s ENSCH eo Pees kn Sg a Bee f e E egen es dle dbo Tel 13811 d sl D ili ieee sbms 83 3 oor ooi lor kt VYE ARE INN errr rrr ry 88828 2073 oT Pr 9r or TIT E SZEREZ EZ SZ EZSZSZSZEE JAAA kt sa 0N3931 n a E es t I 5308 alll le eer Be FPUDYIJAN DE e mJ SelJl9S XXX 698VI 049 1epupdx3 0 1 m 2 noz G GN SH CIS 0L8v 18029 e sesvooz9 Br ES M YOSS 344402 i Co 804 lg r E i n 2vAvz em am z taval Aly MZ Aly isit Th CRI sees JOU XC ELE MINO 2H 05 SNO act Xo6g 3 oubg 1098 fete s SET e 34 Di tr G L A 17 me ala 21 a AW1dS 14 I m TEHOSI oer 44611 420g 4461 490g pe DORE H H KA 28190029 28190029 528190029 nag sd SE me ui Xog 3 pued iuo44 621360041TBSER Publication Number Figure 3 Frutista Viper 3 Barrel Wiring Diagram O 2010 2015 Cornelius Inc Viper Service Manual CCGineliis An overall schematic of the three delivery systems contained in the unit are shown in Figure 6 The CO2 system is on top the water system is in the middle and the syrup system is at the bottom of the diagram The CO2 system interacts with both the water and syrup systems lt provides pressure and carbonation for the syrup water product mix CO System A CO tank or bulk CO supply delivers carbon dioxide gas CO2 to an adjustable secondary CO2 regulator assembly that is attached to the tank
64. o change the quantity OF COMPRESSORS This selection shows the number of compressors in the system Currently this number is fixed at one and cannot be changed SECURITY This selection allows the user to turn security on or off CMP X SENSORS This selection allows the user to choose which pressure sen sors are read for the compressor Table 33 Option Button 2 Button 3 Button 4 Button 5 of Barrels of Compressors Security OFF ON Compressor Sensors NONE LOW HIGH BOTH Security System security is located on the System menu It allows a supervisor or service technician to keep unauthorized personnel from accessing the Maintenance menu This feature is activated on the System menu When security is turned on users can only access the Main and Setup menus Pressing the extreme Left and Right buttons Buttons 1 and 5 on the bottom of the display simultaneously and holding them for approximately five 5 seconds unlocks the Security menu If security is left ON on the System menu when the system times out or when the user goes back to the Main menu security is re activated and the Publication Number 621360041TBSER 34 2010 2015 Cornelius Inc CCineliis Viper Service Manual Maintenance menu is not accessible To disable security access the System menu highlight Security and press the OFF button Pressure Sensors Pressure sensors allow the technician to view the high and low side pressures in the r
65. p menu shown in Figure 15 Button functions are described in Table 10 Publication Number 621360041TBSER 18 O 2010 2015 Cornelius Inc Viper Service Manual TIME 11 00 AM DATE 01 01 00 Figure 15 Clock Setup Screen Table 10 Button Description BACK Returns the display to the Select menu CLOCK Highlighted to indicate that the Clock menu is displayed DST Opens the Daylight Savings Time menu Decrements the highlighted field Increments the highlighted field Setting the Clock Select the CLOCK SETUP menu from the Select menu shown in Figure 14 This displays the Clock Setup menu shown in Figure 15 To set the time perform the procedure in Table 11 Table 11 Step Action Procedure 4 Set clock time Use up and down arrows on the right side of the con trol panel to highlight TIME display on screen 2 Select hour field Use the left and right arrows to select hour field 3 SE Use the or buttons at the bottom of the display to set the proper hour 4 Select minute field Use the left and right arrows to select minute field a Use the or buttons at the bottom of the display to 5 Get correct minute L set the proper minute If the 12 hour clock option is selected use the left and lect AM P 9 SE IPM field right arrows to select the AM PM field 7 Set AM PM Use the button at the bottom of the display to set the AM PM setting To set the dat
66. ption Setup menu is shown in Figure 20 The functions of the display buttons change depending on the highlighted selection on the Option Setup screen Refer to Table 20 for a listing of the button functions for the various field selections OPTION TEMP FORMAT OF DATE FORMAT USA TIME FORMAT 12 HR POS LIGHTING ALWAYS 12 51PM 1 SYRUP TYPE FCB 2 SYRUP TYPE FCB MMS Gc Figure 20 Option Setup Screen Table 20 Option Button 2 Button 3 Button 4 Button 5 Temp Format F C Date Format USA EURO Time Format 12 HR 24 HR POS Lighting OFF ALWAYS SLEEP Publication Number 621360041TBSER 24 2010 2015 Cornelius Inc CG Viper Service Manual Table 20 Option Button 2 Button 3 Button 4 Button 5 1 SYRUP TYPE FCB FCB L FUB FUB L X SYRUP TYPE FCB FCB L FUB FUB L When all the options are set to the desired settings for the unit press the BACK button to store these settings and return to the Select menu shown in Figure 14 Setting the Temperature Format The temperature format displayed by the unit may be set to either Centigrade or Fahrenheit Press the F button to display readings in Fahrenheit and press the C button to display readings in Centigrade Setting the Date Format The date format can be displayed in either United States or European format To display U S date format press the USA button This displays the date in mm dd yy format Press the
67. rels each containing an internal scraper bar driven by an AC motor A refrigeration system and an intelligent hot gas defrost system The components are enclosed in a powder coated steel frame to prevent corrosion It is covered with ventilated cladding panels and a lighted merchandiser The cladding is easily removable to facilitate installation service and maintenance Each barrel has a transparent faceplate with an integral relief valve and a removable self closing dispensing valve mounted on the front A removable drip tray with cup rest is located directly below the dispensing valves A programmable control system with a control panel that controls operational and diagnostic functions and settings is located behind the merchandiser THEORY OF OPERATION The refrigeration system schematic is shown in Figure 2 lt shows the basic configuration for the Viper refrigeration system The wiring diagram of the 3 Barrel Viper unit is shown in Figure 3 This diagram shows the details of the electrical connections in the unit O 2010 2015 Cornelius Inc 5 Publication Number 621360041TBSER Viper Service Manual XE HOLSIARIZHEL bd XE OOL GALWINSND SVO JTLT o aa1vinsND anona nn ev GEIOM dH LU ee ida vns ND WOLVIDWODOV SVO dH iH eese MOSSAD or EE EI III III III ti a ii ii San ss00ud QAL YINSNI Jani SSEADO YA HOSNAS FANSSIAYA 7 gi po lanoassonnanannnannann La C31 vInSNI XH H ann N
68. rrows to highlight the desired barrel Press the PURGE button at the bottom of the display to select purge for the highlighted barrel Place a container under the barrel dispensing valve open the dispensing valve and dispense all the prod uct from the barrel As the product level lowers in the barrel partially close the valve to avoid spurting When the barrel is completely empty close the dis pensing valve and press the STOP button at the bot tom of the display to turn off the purge Press the BACK button to return to the Select menu NOTE When the PURGE button is pressed it changes to a STOP button 1 Purge a barrel 2 Select the barrel 3 Select Purge function 4 Empty the barrel 5 Complete the procedure Publication Number 621360041TBSER 26 O 2010 2015 Cornelius Inc C inet D Filling a Barrel Viper Service Manual Table 22 Step Action Procedure 1 Fill a barrel From the Select menu Figure 21 open the Barrel Maintenance menu shown in Figure 22 2 Select the barrel Use the Up and Down arrows to highlight the desired barrel 3 Select Fill function Press the FILL button at the bottom of the display to fill the highlighted barrel 4 Finish filling the barrel When the fill completes intermittently open and close the relief valve to bleed CO2 from the barrel 5 Complete the procedure Press the STOP button at the bottom of the displ
69. s 3 released CAUTION Barrel pressure MUST be relieved before removing the faceplate Remove the four 4 3 4 in nuts from the faceplate and slowly remove the face plate from the unit Carefully pull the blade assembly out of the barrel Remove any remaining product from the barrel Rinse and inspect the blade assembly and barrel for signs of wear Replace if necessary Remove the seal and spacer from the rear of barrel When old seal and spacer are removed use a clean soft cloth to clean between the motor shaft and the barrel to remove any remaining product N oo E 00 INSTALLING A NEW SEAL Perform the procedure in Table 46 Figure 36 and Figure 37 to replace the barrel seal with a new seal When install ing a new seal NEVER use oil or silicon based lubricants This can cause the new seal to rotate and LEAK O 2010 2015 Cornelius Inc 53 Publication Number 621360041 TBSER Viper Service Manual Table 46 Step Action 1 Remove the old seal and the spacer see Table 45 2 Remove the new seal from its packaging 3 Clean the spacer 4 Slide the spacer with slots toward the motor housing over the motor shaft Lubricate the inside of the seal using Dow Corning 111 Lubricant and Sealant 5 NOTE Do not lubricate the static side outer portion of the seal This could cause the seal to rotate in the bore and leak 6 Carefully slide t
70. s product for approximately 3 seconds After the sample is dispensed Press BRIX twice more to dispense product two more times Discard all three of these samples 10 Press the BRIX button a fourth time Collect this sample in a cup and close the valve at end of the sample tube 11 Measure BRIX Place adequate amount of the product on a refrac tometer and read the BRIX value A target BRIX reading of 13 0 1 0 is normally desired for sugar based syrups Lower values for some diet syrups can be specified Check with the syrup manufacturer if you are not sure 12 Adjust BRIX If BRIX is not within the proper range adjust the syrup water mixture by opening or closing the syrup valve shown in Figure 28 and then retest 13 Clear hose When BRIX measurement is complete press the valve on the bottom of the appropriate water sole noid to flush out the hose before closing the valve at the end of the hose 14 Set product supply valve Turn product supply valve back to the BARREL position for the barrel you tested See Figure 27 15 Replace access panel Replace the hoses and the access panel Secure the panel with the two screws removed in Step 2 This completes the procedure Publication Number 621360041TBSER 30 O 2010 2015 Cornelius Inc C Ginclius gt Viper Service Manual BRIX 1 OFF SETUP 2 OFF 12 51P MAR 04 BACK BRIX STOP Figure 25 B
71. s used for barrel maintenance diagnostics BRIX setup and system information It allows the technician access to the unit during periodic maintenance or troubleshooting problems It sometimes overrides the normal inputs from the system in order to perform this task O 2010 2015 Cornelius Inc 25 Publication Number 621360041TBSER Viper Service Manual SELECT BARREL MAINT MANUAL DIAG TOTALS BRIX SETUP MOTOR SETUP SYSTEM BACK MAIN SETUP van GO Figure 21 Select Screen Barrel Maintenance Menu The Barrel Maintenance menu shown in Figure 22 allows the service technician to clean rinse and sanitize the system on a barrel by barrel basis The barrel must be OFF in order to perform the barrel maintenance functions As a warning to the technician the Do Not Drink status indicators are illuminated on the barrels when entering the Barrel Maintenance menu The procedure for purging a barrel is shown in Table 21 The procedure for filling a barrel is shown in Table 22 The procedure for running the scraper blade only on a barrel is shown in Table 23 and the procedure for waking up a barrel is shown in Table 25 BARREL 1 PURGE MAINT 2 OFF 12 51P MAR 04 BACK PURGE FILL SPIN EBENEN lt C gt Figure 22 Barrel Maintenance Screen Purging a Barrel Table 21 Step Action Procedure From the Select menu Figure 21 open the Barrel Maintenance menu shown in Figure 22 Use the Up and Down a
72. sure Sensing of Incoming Water Syrup and CO2 System Error Handling Error Log Viscosity Control 2010 2015 Cornelius Inc 3 Publication Number 621360041TBSER Viper Service Manual qm DISPENSED PRODUCT CONDITIONS OVERRUN AS APPLIED TO CARBONATED BEVERAGES OVERRUN DEFINITION Overrun is defined as product expansion that takes place in the frozen carbonated drink It is caused primarily by CO gas breakout and secondarily by freezing OVERRUN IS A VARIABLE The percentage or degree of overrun depends on a number of factors The specific syrup BRIX low dispensing volume carbonation level in the liquid product and freezing of the product These items all affect overrun After these factors have been considered desired viscosity product consistency adjustment may be made on the unit The viscosity adjustment adjusts product texture from very wet to light SPECIFIC PRODUCT INGREDIENTS AFFECT OVERRUN Each syrup has its own specific formulation of makeup Fruit flavors contain citric acids that colas do not Colas also differ in ingredients from one brand to another Each product formulation has its own peculiarities regarding the way the product absorbs carbonation and the way it releases carbonation BRIX Affects Overrun Sugar in carbonated drinks is like anti freeze in water The higher the BRIX the greater the resistance of the product to freezing Conversely in products with lower BRIX freezing takes place at higher te
73. t lockout Open Events Setup menu shown in Figure 17 2 Select DAY The DAY field is highlighted 3 Set DAY Use the and buttons at the bottom of the display to set the desired day or all days Use the up and down arrows to highlight 4 Select DEFROST LOCK 1 DEFROST LOCK 1 5 Set hour field Use left and right arrows to select hour field 6 Use the and buttons at the bottom of the display to set the desired hour 7 Set minute field Use left and right arrows to select minute field 8 Use the and buttons at the bottom of the display to set the desired minute in 15 min increments If the 12 hour clock option is selected use the left 9 SC and right arrows to select the AM PM field 10 Use the button at the bottom of the display to set the AM PM field Repeat Steps 2 through 10 for the DEFROST 11 Select DEFROST LOCK 2 LOCK 2 time if desired Repeat Steps 2 through 10 for the DEFROST 12 Select DEFROST LOCK 3 LOCK 3 time if desired Publication Number 621360041TBSER 22 2010 2015 Cornelius Inc C Ginclius gt Viper Service Manual When the defrost lockout settings are complete press the BACK button to save the settings and return to the Select menu shown in Figure 14 Viscosity Setup Menu The viscosity maintained in the freeze barrels depends on the type of product being served Some products are served best at a higher viscosity while others require a lower viscosity for best quality The Viscosity menu s
74. tatus OFF A Not activated A Turn to ON DFRST or SPIN B Error has shut off motors B Correct error 8 turn to ON DFRST or SPIN C Unit in Diagnostics C Exit diagnostics amp turn to ON DFRST or SPIN D Defective touch switch D Replace Low High voltage A Line Voltage out of SPEC specis A 1 Check line voltage ERROR 205 255 VAC for 60 Hz and 196 2 Check T1 T2 with Compressor 265 VAC for 50 Hz running B Error range 180 260 B Correct line voltage Frozen Barrel A Low Brix A Correct cause and reset Brix B Broken beater bar B Replace beater bar C Broken drive coupler C Replace the drive coupler D No defrost D Program defrosts in unit E Are defrosts programmed all days E Reprogram to all days Publication Number 621360041TBSER 68 O 2010 2015 Cornelius Inc C Gne D TRouBLESHOOTING PRODUCT Nor COLD Viper Service Manual Problem Probable Cause Remedy Compressor not Running A Barrel not in ON mode A Turn barrel to ON B No voltage to compressor B Check power at contactor L1 L2 T1 T2 C Bad start components C Check components and wiring D Compressors thermal overload D Check resistance of compressor protector open windings and check incoming line voltage E Open or shorted compressor wind E Check resistance of compressor ings windings F Bad control board F Troubleshoot replace if necessary Compressor Running but A Low r
75. tel ria E te D e DO ene qot Eta afe e T xu 14 Unit Data E EE na taye Me Ok W ALSS ne Liao sul e de 15 Error Status Menu Aide ane e Pa AP do kode A adds 15 Error Log Menu eee E EN A aa y aoe 17 EES Et e bee ee cap a a sp ewe eg ae fe e eza Ee 18 Clock Setup Menus sekimo ea Denise ahi Wide AR Ee ER E ot dex aes 18 Settingthe CI GKz szei a at tus as Me a cele ot Moe 28 Me ees te 19 Setting Daylight Savings TIME L et ken kk kn a w kon n kok won koman konn nn 20 Events Setup Menus cuca akor ke ok a e a REG sk OEE a a 21 SEELEN s rt IA EE ai eri ed EE de E 21 Setting the Sleep and Wakeup Times 21 Setting Defrost LKOSKOUL EE LW aa a o LS 22 Viscosity Setup Menu 20 i405 eas ook via a a a aa 23 COZ Setup Men zseni das ei iaa deis iaa ias gil aa 23 Option Setup MEN E EE 24 Setting the Temperature Format 25 Setting the Date Format oes NEE A a A ger e A 25 Setting the Time Format xu ec tente is tab PR a 25 Setting the POSLighting stes does ederet as de db DE e sod db ete bm Oi ES 25 setting the Type of Syrup e oak pee xt Pru ba Etpe et ed a Joe ed E es 25 Barrel Maintenance educi seb te ow o tata d and s e we eR aes Itn d con ei omes 25 Maintenance Mentes eoo iren tet rs S Mentel e n Sa core dard SES Dens LSS 25 Barrel Maintenance Menu 26 6224 RR e ba e E RR REG DRE REESE ERE Yu 26 Purging a Barrel cit bio bu d e tede x erue eae ideas d ead scies utr reta ds 26 Filling a Barrel creirie aa a E Aa aaa
76. tem Carefully remove the insulation and remove the hot gas valve and solenoid Replace the hot gas valve and solenoid Replace the insulation around the valve and solenoid Replace the filter dryer Evacuate the system Restore the proper refrigerant charge to the system and verify proper system operation O 0 JO O0 EF 0 N Liquip LINE SOLENOID REPLACEMENT The liquid line valves and solenoids shown in Figure 47 are located near the center of the unit on the right and left sides Whenever a liquid line valve and solenoid is replaced the dryer should be replaced at the same time To replace the liquid line solenoid perform the procedure in Table 56 Liquid Line Solenoid Figure 47 Liquid Line Solenoid 1 per barrel 2010 2015 Cornelius Inc 61 Publication Number 621360041TBSER Viper Service Manual G ss gt Table 56 Step Action a Disconnect power from the unit Remove the side panels Reclaim refrigerant from the system Carefully unwrap the foam insulation from around the valve and solenoid Remove the liquid line valve and solenoid Replace the liquid line valve and solenoid and insulation Replace the filter dryer Evacuate the system Restore the proper refrigerant charge to the system and verify proper system operation O o JO 0 AI 0 N SYRUP PRESSURE SWITCH REPLACEMENT The syrup pressure switches Sold O
77. the equipment NOTE Many units incorporate the use of additional equipment such as ice makers When any addition equipment is used you must check with the equipment manufacturer to determine the additional weight the counter will need to support to ensure a safe installation Publication Number 621360041TBSER 2 2010 2015 Cornelius Inc CG Viper Service Manual INTRODUCTION MANUAL OVERVIEW The organization of this manual allows the user to scan guickly to the subject of interest along the left side of a page and to read the detail about the subject or procedure on the right side of the page The manual provides the detail needed for newcomers to the industry while allowing experienced technicians to skip over the details and move guickly through the material This manual is designed as a guide to the technician in maintaining and servicing the Viper system The Viper system is simple in design and has built in features and diagnostic controls to help the service technician guickly and accurately service the machine The unit consists of multiple freeze barrels that each contain an internal beater driven by a rear mounted electric motor a refrigeration system timer controlled automatic hot gas defrost system and interconnecting tubing and controls reguired to dispense the product Some of the system features and functions are listed below e Simple User Interface LCD Display e Real Time Clock Incoming Line Voltage Sensing Pres
78. tor stops and it is calibrated 1 Re assemble barrel 2 Defrost the barrel 3 Select Motor Setup 4 Select the barrel 5 Start calibration O 2010 2015 Cornelius Inc 33 Publication Number 621360041TBSER C inet D Viper Service Manual Table 31 Procedure Press the BACK button at the bottom of the display to return to the Maintenance menu Step Action 7 Complete the procedure 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 compressors and the number of pressure sensors present in the system as shown in Figure 30 The description of these items is shown in Table 32 NOTE Changing these values to a number that doesn t match the physical number of items in the system generates errors or turns off some of the equipment present in the system When the individual fields are highlighted the display buttons change Refer to Table 33 for a listing of the button functions for the various field selections OF BARRELS 2 OF COMPRESSOR 1 SYSTEM 12 51P MAR 04 SECURITY OFF CMP 1 SENSORS BOTH CMP X SENSORS LOW zi BACK SEEGER REC Figure 30 System Screen Table 32 Display Description OF BARRELS This selection shows the number of barrels in the system and allows the user t
79. 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 CO2 CARBON DIOXIDE WARNING A DANGER CO2 displaces oxygen Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and soft drink system If a CO2 gas leak is suspected particularly in a small area IMMEDIATELY ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentrations of CO2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH MOUNTING IN OR ON A COUNTER A WARNING When installing the unit in or on a counter top the counter must be able to support a weight in excess of 450 Ibs to insure adequate support for the unit Failure to comply could result in serious injury death or damage to
80. ure 17 To set the sleep and wakeup times perform the procedure in Table 16 When the unit goes into a sleep period the barrel automatically defrosts for four minutes Also if a barrel is off when the sleep cycle starts the barrel continues to be in the off state when the sleep cycle ends If a barrel is run ning when the sleep cycle starts the barrel starts back up when the sleep cycle ends Wakeup should be scheduled for approximately one hour before product is required NOTE Setting the sleep time after midnight requires you to set it during the next day i e Saturday night at lam must be set as 1am on Sunday etc If this type of setting is required you cannot set another sleep cycle during that following day i e Sunday Table 16 Step Action Procedure 4 Set sleep and wakeup Open the Events Setup menu shown in Figure 17 times by pressing the GO button 2 Select DAY The DAY field is highlighted Use the or buttons at the bottom of the display 3 penne to set the desired day or all days 4 Select SLEEP Use the up and down arrows to highlight SLEEP O 2010 2015 Cornelius Inc 21 Publication Number 621360041TBSER Viper Service Manual Table 16 C inet Step Action Procedure Set hour field Use the left and right arrows to select the hour field and press the or buttons to change the hour Set minute field Use the left and right arrows to select the minute fiel
81. ut Indicators are located along the left and right sides of the unit near the front There is one switch for each barrel in the system Figure 48 shows the syrup pressure switch on the left side of the unit To replace the syrup pressure switch perform the procedure in Table 57 Syrup Pressure Switch Table 57 Step Action Disconnect power to the unit Remove the appropriate side panel Turn off the syrup supply to the unit Drain the syrup from the system Disconnect the wires on the pressure switch Remove the switch using two wrenches Replace the switch with a new unit Reverse the procedure to install the new switch o o oc E wo NN m Restore the syrup supply and check for leaks _ o Check switch operation WATER PRESSURE SWITCH REPLACEMENT The water pressure switch shown in Figure 49 can be viewed from the rear of the unit Access to the switch is obtained by removing the left side panel of the unit when viewed from the rear To replace the water pressure switch perform the procedure in Table 58 Publication Number 621360041 TBSER 62 O 2010 2015 Cornelius Inc Viper Service Manual Water Pressure Switch Figure 49 View of Water Pressure Switch Table 58 Step Action 1 Disconnect power from the unit 2 Remove the side panel from the unit 3 Turn off the water supply to the unit 4 Drain the w
82. ve 1 or 3 UR Yan Auc 2 B gt p a Pulse Valves Figure 42 Front View of CO2 Pulse Valves Table 51 Step Action Disconnect power from the unit Disconnect the CO2 supply from the unit Remove the rear cover and side panels Carefully remove the tubing from the rear of the valve Remove the mounting tie wrap from the rear of the valve Replace the valve Reverse the procedure to reinstall the valve into the unit Test the unit for CO2 leaks Replace the rear and side panels G 0 HH oic BA OINI a o Recomnect power to the unit SYRUP AND WATER SHUTOFF SOLENOID REPLACEMENT The syrup and water shutoff valves and solenoids are mounted on a single bracket as shown in Figure 43 Perform the procedure in Table 52 to replace the valves Publication Number 621360041TBSER 58 O 2010 2015 Cornelius Inc CCGineliis Viper Service Manual Syrup Shutoff Valves 8 Solenoids Figure 43 View of Shutoff Solenoids w Access Panel Removed Table 52 Step Procedure 1 Disconnect power from the unit Disconnect and bleed the water and syrup lines to remove pressure from the system 3 Remove the rear cover and side panels 4 Remove the water and syrup lines from the input to the valves Remove the Wye tube from the output top of the valves by loosening the nuts between the Wye and the check valves 5 Chec
83. ystem EUR 49 Emptying a Barrel i ovs o pend bue back ken da wet Sheed UC Dag xS ERES LS 49 Flushing the System Of SYTUD eua sidad obere at a eS hee E dud De 50 Sanitizing the Ba era Eon Rr Sce ERR Vet S S a S x eo 50 Flushing tlie System sve tx Pa eels Sea Pe EVEN ek ee ERES eee e eee a E 52 Component Replacement enhn nn aa hh nna n nn 53 Barrel Motor Seal Replacement 53 Removing the Existing Seal Lis kis Lk da pie Ge votan E Reno Li E ERA et LS 53 Iistalliriq a New Seal pk hber LED ut pee ubere oS Reb ess BOE niet EE 53 Motor Seal Leak LEE 53 erg Eod that HA ou Sees E ol eee triada 55 Barrel Motor Replacement ewe ti ires ey OPES Er ERU S ed RW des iae 55 Motor Run Capacitor Replacement eee seen kk an rne 56 Water Pump Replacement e DEENEN e 9 e fa kot ui ER ROS 57 CO2 Pulse Valve Replacement lel len n kan n ken n kan n n ka n kk aa knn na 57 Syrup and Water Shutoff Solenoid Replacement e rese ee ee a ae eee eens 58 Condenser Fan Motor Replacement Il ler l ken nn ka a kann kann n kaa kman 59 Compressor Replacement aus as seo se Pot agua Lee ree E ase taye 60 Hot Gas Solenoid Replacement elle ek ken kk ea kwa n n ka an m ka ak mn nn 61 Liquid Line Solenoid Replacement eee l sen kk sa n knn n ka an m kn ak mn nn 61 Syrup Pressure Switch Replacement zzz ken n n kn n a knn anan n na a n mn nn 62 W

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