IMI Cornelius, Inc. VIPER 3 FLAVOR User manual

VIPER 2 FLAVOR, VIPER 3 FLAVOR &

VIPER 4 FLAVOR

Service Manual

Release Date: October 28, 2008

Publication Number: 621260373SER

Revision Date: August 6, 2010

Revision: E

Visit the IMI 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 Warrant 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 not 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, (5) accident,

(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained

persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation,

operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%

compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the

product dispensed which are adversely impacted by changes in liquid scale or chemical composition.

Contact Information:

To inquire about current revisions of this and other documentation or for assistance with any 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.

Printed in U.S.A.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Different Types of Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cart Information and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dispensed Product Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overrun, as Applied to Carbonated Beverages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overrun Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overrun is a Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specific Product Ingredients Affect Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BRIX Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Low Dispensing Volume Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Carbonation Level in Liquid Product Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Freezing Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CO2 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Syrup System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Control Panel Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Unit Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Error Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Error Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Clock Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Events Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Setting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Setting the Sleep and Wakeup Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Viscosity Setup Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Options Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Barrel Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Manual Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Totals Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BRIX Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Motor Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pressure Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintaining Product Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Dispensed Product Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Programmed Defrost Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Sleep Mode Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Viscosity Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Monthly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cleaning Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Semi-Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Inspecting and Replacing Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cleaning the Syrup Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Servicing Motorman Dispensing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Sanitizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Emptying a Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Sanitizing the Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Flushing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Cleaning the Water Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Barrel Motor Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Removing the Existing Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Installing a New Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Motor Seal Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Barrel Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Motor Run Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Water Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

CO2 Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Syrup and Water Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

CO2 Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Condenser Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Hot Gas Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Liquid Line Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Syrup Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Water Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Control Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Backward/Forward Compatibility with Older Software Versions . . . . . . . . . . . . . . . . . . . . . . . . 71

Motor Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting Product Not Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Viper Service Manual

INTRODUCTION

MANUAL OVERVIEW

The organization of this manual allows the user to scan quickly to the subject of

interest along the left side of a page and to read the detail about the subject or

procedure 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 quickly 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 quickly 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

required to dispense the product.

Some of the system features and functions are listed below:

• Simple User Interface LCD Display

• Real Time Clock

• Incoming Line Voltage Sensing

• Pressure Sensing of Incoming Water, Syrup and CO

2

• System Error Handling

• Error Log

• Viscosity Control

Viper Service Manual

SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS

Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and

any warning/caution labels on the unit (decals, labels or laminated

cards).

• Read and understand ALL applicable OSHA (Occupational Safety

and Health Administration) safety regulations before operating this

unit.

Recognition

Different Types of Alerts

!

DANGER:

Indicates an immediate hazardous situation which if not avoided WILL result in

serious injury, death or equipment damage.

!

WARNING:

Indicates a potentially hazardous situation which, if not avoided, COULD result in

serious injury, death, or equipment damage.

CAUTION:

!

Indicates a potentially hazardous situation which, if not avoided, MAY result in

minor or moderate injury or equipment damage.

SAFETY TIPS

• Carefully read and follow all safety messages in this manual and

safety signs on the unit.

Recognize Safety Alerts

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.

!

Viper Service Manual

• Keep safety signs in good condition and replace missing or

damaged items.

• Learn how to operate the unit and how to use the controls properly.

• Do not let anyone operate the unit without proper training. This

appliance is not intended for use by very young children or infirm

persons without supervision. Young children should be supervised to

ensure that they do not play with the appliance.

• Keep your unit in proper working condition and do not allow

unauthorized modifications to the unit.

QUALIFIED SERVICE PERSONNEL

!

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:

!

WARNING:

Disconnect power to the unit before servicing following all lock out/tag out

procedures established by the user. Verify all of the power is off to the unit before

any work is performed.

Failure to disconnect the power could result in serious injury, death or equipment

damage.

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.

Viper Service Manual

SHIPPING AND STORAGE

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

!

DANGER:

CO

2 displaces oxygen. Strict attendtion MUST be observed in the prevention of

CO

2 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 CO

2 gas experience tremors which are followed rapidly by loss

of consciousness and DEATH.

MOUNTING IN OR ON A COUNTER

!

WARNING:

When installing the unit in or on a counter top, the counter must be able to support

a weight in excess of 450 lbs. to insure adequate support for the unit. FAILURE

TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT

DAMAGE.

Note:

Many units incorporate the use of additional equipment such as

icemakers. 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.

CART INFORMATION AND MOUNTING

These carts are also designed with movable wheels that act as outriggers to

provice stability to the unit when it is being moved.

Viper Service Manual

!

WARNING:

The above listed mounting bolts must be installed and the wheels extended and

locked in the outboard position prior to moving the unit.

Failure to comply could result in serious injury, death or equipment

damage.

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 CO2 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 hav 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 Ingredi-

ents 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. Conversly, in products with

lower BRIX, freezing takes place at higher termperatures 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.

Viper Service Manual

Low Dispensing Volume

Affects Overrun

When a unit sits idle fo 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, CO

2 gas has less tendancy to break out as the drink is dispensed. The

result is that these first drinks hav less overrun than drinks dispensed during

peak-use periods.

Carbonation Level in Liq-

uid Product Affects Over-

run

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 gass breakout in

frozen carbonated form and more overrun than drinks that contain 2.0 volumes

of CO

2 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”.

Viper Service Manual

SYSTEM OVERVIEW

INTRODUCTION

The Viper unit consists of the following systems and hardware:

Multiple freeze barrels, each containing an internal scraper bar driven by an AC

motor.

A refrigeration system and an intelligent, hot gas defrost system.

The components are enclosed in a powder-coated steel frame to prevent corro-

sion. It is covered with ventilated cladding panels and a lighted merchandiser.

The cladding is easily removable to facilitate installation, service and mainte-

nance.

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.

Viper Service Manual

THEORY OF OPERATION

The refrigeration system schematic is shown in Figure 1. It provides the basic

configuration for the Viper refrigeration system.

The wiring diagram of the 2-Barrel Viper unit is shown in Figure 4, the wiring dia-

gram of the 3-Barrel Viper unit is shown in Figure 5 and the wiring diagram of the

4-Barrel Viper unit is shown in Figure 6. These diagrams show the details of the

electrical connections in the unit.

Figure 1. Viper System 2-Barrel Refrigeration Schematic

Viper Service Manual

Figure 2. Viper System 3-Barrel Refrigeration Schematic

Viper Service Manual

Figure 3. Viper System 4-Barrel Refrigeration Schematic

Viper Service Manual

Figure 4. Viper 2-Barrel Wiring Diagram

620410577 REV B

J2J1

NOTE: #1 IS OPTIONAL PRESSURE SENSOR

LEGEND

Front Panel E-Box

Merchandiser Panel

M1

LCD BOARD

620314871

PUSH

BUTTONS

DISPLAY

J6

CAP1

CONDENSER

FAN

CAP2

H2O Sold-Out

CO2 Sold-Out

10

1

7

1

Syrup Soldout B1

Barrel Pressure B1

9

1

5

1

J5

RS232

1

J100

J200

J5

620314868

Motor

Controller

J2

J7

J8

Expansion

(Power)

Expansion

(Logic)

1

J6

24VAC

BLU

BRN

CONTACTOR

A1A2

T1 L1

T2 L2

T3 L3

1314

BRN

BLU

RED

YEL

BLK

GRN/YEL

COMPRESSOR

S

R

C

GRN/YEL

BRN

BLU

BLK

BACKLIGHT

Panel 1

620512776

L1CL1A L1B

1

L2CL2A L2B

1

J2

1

J3

J

4

1

MAIN

LED STATUS

620314874

EXTENDER

LED STATUS

620314875

DC-DC

Convertor

620607120

J

2

BACKLIGHT

Panel 2

620512776

J

2

DownLight

620512775

J3

J4

1

+

1

+

1

+

1

RED

YLW

RED/WHITE

RED

VIO

BLK

BLU/WH

YEL/WH

ORG/WH

YEL

ORG

BRN

BRN/WH

BLU

BLK

Barrel Pressure B2

Syrup Soldout B2

BLU

YEL

ORG/WH

BRN/WH

ORG

BRN

BLK

Outlet Temp B2

Outlet Temp B1

ORG/WH

BLK/WH

ORG

BLK

BLU

RED

I/O BOARD

620314869

J2J11 J4 J5 J6

1

18

1

EXPANSION PORT

J7

1

J8

J4

J3

RED

1

J10

J9

Indicates Splice that

happens in Connector

DownLight

620512775

Rear Panel E-Box

Terminal

block

(60Hz)

Or

EMI Filter

(50Hz)

24VAC Solenoid

1

M2

1

Run

Capacitor

Run

Capacitor

BLU

BRN

BLU\ WH

BRN\ WH

BRN

BLU

#1

TCO

B2

TCO

B1

LLS B2

HGS B2

H20 B1

SYRUP B1

C02 B1

C02 B2

SYRUP B2

H20 B2

LLS B1

HGS B1

Pressure

Sensor

B1

Pressure

Sensor

B2

Indicates Connector

Cresent - Female

Pressure Switch Shown

with no pressures applied

Thermistor

Temperature

Cut-Off Switch

L2

L1

PE

11

1

Viper Service Manual

Figure 5. Viper 3-Barrel Wiring Diagram

Front Panel E-Box

Merchandiser Panel

620314871

LCD BOARD

PUSH

BUTTONS

DISPLAY

J6

1

J5

RS232

24VAC

BLU

BRN

CONTACTOR

A2A1

T1 L1

T2 L2

T3 L3

1314

BRN

BLU

620043050

AC-DC Converter

RED

RED/WHITE

620314869

I/O BOARD

1

18

1

EXPANSION PORT

J7

1

J9

J4

J3

1

J10

J8

Rear Panel E-Box

Terminal block

(60Hz)

Or

EMI Filter

(50Hz)

M2

1

Run

Capacitor

BRN

620314870

I/O Expander

620314873

Motor

Expander

LEGEND

Indicates Splice that

happens in Connector

24VAC Solenoid

RED

YEL

BLK

GRN/YEL

COMPRESSOR

S

R

C

GRN/YEL

BRN

BLU

BLK

24VAC

11

1

J2

VIO

BLK

BLU/WH

YEL/WH

ORG/WH

BRN/WH

BLU

YEL

BLK

ORG

BRN

BLK

7

1

SYRUP B1

BLK

SYRUP B3

9

1

Syrup Soldout B1

J4

J6

J5

J11

J100

J200

J5

620314868

Motor Controller

J2

J7

J8

Expansion

(Power)

Expansion

(Loic)

1

J6

J100

M1

1

Run

Capacitor

M3

1

Run

Capacitor

BLU

BLU\ WH

BRN

BRN\ WH

J200

620314874

LED Status

Main

L1CL1A L1B

1

Fill Switch B3

620512776

Backliht

Panel

J3

620512775

DownLiht

620512776

Backliht

Panel

J3

620512775

DownLiht

620512776

Backliht

Panel

J3

620512775

DownLiht

620314875

LED Status

Expander

L3CL3A L3B

1

J1

J2

620314875

LED Status

Expander

L2CL2A L2B

1

YEL

RED

BLK

RED

WH

BLU

BLK

BLU

ORG/WH

BRN/WH

BRN

ORG

YEL

BLU

BLU/BLK

BRN/BLK

BLU/BLK

YEL/BLK

ORG/BLK

BRN/BLK

BLK

GRY

BLK

GRY

BLK

BRN/BLK

ORG/BLK

BLU

BLK

ORG

BLK/WH

ORG/WH

BLK

ORG/BLK

BLK

BLU

YLW

BRN

YLW

TCO

B3

620042848 REV A

NOTE: ITEMS MARKED #1 ARE OPTIONAL

#1

TCO

B2

TCO

B1

Outlet Temp B3

Hi-Side Press.

Sensor CMP1

Lo-Side Press.

Sensor CMP1

Indicates Connector

Cresent - Female

Pressure Switch

Shown with no

pressures applied

Thermistor

Temperature Cut-Off

Switch

CAP1

CONDENSER

FAN

CAP2

Outlet Temp B2

Outlet Temp B1

LLS B2

HGS B2

H20 B1

C02 B1

C02 B2

SYRUP B2

H20 B2

LLS B1

HGS B1

H20 B3

C02 B3

LLS B3

HGS B3

Syrup Soldout B2

Fill Switch B1

Fill Switch B2

H2O Soldout

CO2 Soldout

Syrup Soldout B3

TCO

B3

Viper Service Manual

Figure 6. Viper 4-Barrel Wiring Diagram

Front Panel E-Box

Merchandiser Panel

620314871

LCD BOARD

PUSH

BUTTONS

DISPLAY

J6

1

J5

RS232

TCO

B2

TCO

B1

24VAC

BLU

BRN

CONTACTOR

A2A1

T1 L1

T2 L2

T3 L3

1314

BRN

BLU

620043050

AC-DC Converter

RED

RED/WHITE

620314869

I/O BOARD

1

18

1

EXPANSION PORT

J7

1

J9

J4

J3

1

J10

J8

Rear Panel E-Box

Terminal block

(60Hz)

Or

EMI Filter

(50Hz)

Outlet Temp B4

Outlet Temp B3

Hi-Side Press.

Sensor CMP1

Lo-Side Press.

Sensor CMP1

M2

1

Run

Capacitor

BRN

620314870

I/O Expander

620314873

Motor

Expander

LEGEND

Indicates Connector

Cresent - Female

Indicates Splice that

happens in Connector

24VAC Solenoid

Pressure Switch

Shown with no

pressures applied

Thermistor

Temperature Cut-Off

Switch

CAP1

CONDENSER

FAN

CAP2

RED

YEL

BLK

GRN/YEL

COMPRESSOR

S

R

C

GRN/YEL

BRN

BLU

BLK

24VAC

11

1

J2

VIO

BLK

BLU/WH

YEL/WH

ORG/WH

BRN/WH

BLU

YEL

BLK

ORG

BRN

BLK

7

1

Outlet Temp B2

Outlet Temp B1

SYRUP B1

LLS B2

HGS B2

H20 B1

C02 B1

C02 B2

SYRUP B2

H20 B2

LLS B1

HGS B1

BLK

SYRUP B3

LLS B4

HGS B4

H20 B3

C02 B3

C02 B4

SYRUP B4

H20 B4

LLS B3

HGS B3

9

1

Syrup Soldout B1

Syrup Soldout B2

Fill Switch B1

Fill Switch B2

H2O Soldout

CO2 Soldout

J4

J6

J5

J11

J100

J200

J5

620314868

Motor Controller

J2

J7

J8

Expansion

(Power)

Expansion

(Loic)

1

J6

J100

M1

1

Run

Capacitor

M3

1

Run

Capacitor

M4

1

Run

Capacitor

BLU

BLU\ WH

BRN

BRN\ WH

J200

620314874

LED Status

Main

L1CL1A L1B

1

Fill Switch B3

Fill Switch B4

Syrup Soldout B4

Syrup Soldout B3

620512776

Backlight

Panel

J3

620512775

DownLight

620512776

Backlight

Panel

J3

620512775

DownLight

620512776

Backlight

Panel

J3

620512775

DownLight

620512776

Backlight

Panel

J3

620512775

DownLight

620314875

LED Status

Expander

L4CL4A L4B

1

J1

J2

620314875

LED Status

Expander

L3CL3A L3B

1

J1

J2

620314875

LED Status

Expander

L2CL2A L2B

1

YEL

RED

TCO

B3

TCO

B4

RED

BLK

RED

WH

BLU

BLK

BLU

ORG/WH

BRN/WH

BRN

ORG

YEL

BLU

BLU/BLK

BRN/BLK

BLU/GRY

BRN/GRY

BLU/GRY

YEL/GRY

ORG/GRY

BRN/GRY

BLU/BLK

YEL/BLK

ORG/BLK

BRN/BLK

BLK

GRY

BLK

GRY

BLK

BRN/BLK

ORG/BLK

BRN/GRY

ORG/GRY

BLU

BLK

ORG

BLK/WH

ORG/WH

BLK

ORG/BLK

BLK/GRY

ORG/GRY

BLK

BLU

YLW

BRN

YLW

#1

620046599 REV A

NOTE: ITEM MARKED #1 ARE OPTIONAL

Viper Service Manual

An overall schematic of the three delivery systems contained in the unit are

shown in Figure 9, Figure 10 and Figure 11. The CO

2 system is on top, the water

system is in the middle and the syrup system is at the bottom of the diagram.

The CO

2 system interacts with both the water and syrup systems. It provides

pressure and carbonation for the syrup/water product mix.

CO2 System

A CO2 tank or bulk CO2 supply delivers carbon dioxide gas (CO2) to an adjust-

able secondary CO

2 regulator assembly that is attached to the tank as shown in

Figure 7 and Figure 8. The CO

2 system also supplies CO2 to the water boost

pump, the expansion tank regulator and the secondary CO

2 tank regulators.

CO

2 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.

CO

2 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 CO

2 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 CO

2 flows into the product line.

Figure 7. Typical Bulk Cylinder CO2 Connection

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