Cornelius FRUTISTA VIPER 3 FLAVOR, FRUTISTA VIPER E 3 FLAVOR Installation Manual

FRUTISTA VIPER (E) 3 FLAVOR

Installation Manual

Release Date: April 02, 2010

Publication Number: 621360041TBINS

Revision Date: April 26, 2016

Revision: F

Visit the Cornelius web site at www.cornelius.com

for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible
contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and
mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and con
struction 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 sub­ject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper 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 con­tact:

www.cornelius.com

800-238-3600

-

Trademarks and Copyrights:

This document contains proprietary information and it may not be reproduced in any way without 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 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CO

(Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Viper Machine Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Decommissioning and/or Transporting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Storage within the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dispensed Product Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overrun, as Applied to Carbonated Beverages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overrun Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overrun is a Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specific Product Ingredients Affect Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BRIX Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Low Dispensing Volume Affects Overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Carbonation Level in Liquid Product Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Freezing Affects Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Delivery, Inspection & Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Counter Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Backroom Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Water Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CO

Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2

CO

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2

Syrup Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Syrup Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Testing Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installing The Drip Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cart Information and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setting Up the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setting the System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Options Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Events Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setting Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CO

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2

Commissioning the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressurizing the CO

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2

Pressurizing the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressurizing the Syrup System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting BRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Testing BRIX Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Adjusting BRIX Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Filling the Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Calibrating a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Security Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SAFETY INSTRUCTIONS

!

DANGER:

!

WARNING:

!

CAUTION:

!

WARNING:

!

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

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 Installation Manual

Different Types of Alerts

Indicates an immediate hazardous situation which, if not avoided, WILL result in serious injury, death or
equipment damage.

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or
equipment damage.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or
equipment damage.

SAFETY TIPS

• Carefully read and follow all safety messages in this manual and safety signs on the unit.

• Keep safety signs in good condition and replace missing or damaged items.

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

• Do not let anyone operate the unit without proper training. This appliance is not intended for use by
very young children or infirm persons without supervision. Young children should be supervised to
ensure that they do not play with the appliance.

• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.

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.

QUALIFIED SERVICE PERSONNEL

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.

© 2010-2016, Cornelius Inc. - 1 - Publication Number: 621360041TBINS

Viper Installation Manual

!

WARNING:

!

CAUTION:

!

CAUTION:

!

DANGER:

!

WARNING:

IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER, ITS SERVICE
AGENT OR SIMILARLY QUALIFIED PERSONS IN ORDER TO AVOID A HAZARD.

SAFETY PRECAUTIONS

This unit has been specifically designed to provide protection against personal injury. To ensure continued
protection, observe the following:

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.

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

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

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 CO
contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO
experience tremors which are followed rapidly by loss of consciousness and DEATH.

2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the

2 gas

MOUNTING IN OR ON A COUNTER

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 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.

VIPER MACHINE USAGE

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction con­cerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance.

This appliance is not intended to be used in household and similar applications such as:

• Staff kitchen areas in shops, offices and other working environments

• Farm houses and by clients in hotels, motels and other residential type environments

Publication Number: 621360041TBINS - 2 - © 2010-2016, Cornelius Inc.

Viper Installation Manual

!

CAUTION:

• Bed and breakfast type environments

• Catering and similar non-retail applications

THE APPLIANCE HAS TO BE PLACED IN A HORIZONTAL POSITION

DECOMMISSIONING AND/OR TRANSPORTING THE UNIT

Whenever the viper unit is going to be removed from service and/or transported, the unit must be completely
drained of product and rinsed out to remove residual product.

When transporting the unit, make sure that the product bowl is removed from the top of the unit and stored in a
safe place for shipment. The unit must be carefully tied down or stored in such a manner that the unit will not
move during shipment.

STORAGE WITHIN THE MACHINE

Do not store explosive substances such as aerosol cans with a flammable propellant in this appliance.

© 2010-2016, Cornelius Inc. - 3 - Publication Number: 621360041TBINS

Viper Installation Manual

INTRODUCTION

SYSTEM OVERVIEW

Introduction

The Frutista Viper system is a state-of-the-art FCB/FUB machine. The Frutista Viper machine provides improved
drink availability, reliability and reduced complexity in a compact, reduced footprint machine.

Viper provides the highest quality in drink appearance and consistency while keeping operation and maintenance
simple and straightforward.

The unit consists of multiple freeze barrels that each contain an internal beater driven by an electric motor, a
refrigeration system, a timer-controlled, intelligent defrost system and interconnecting tubing and controls
required to dispense the product.

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

2 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 temperatures 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.

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, CO
is dispensed. The result is that these first drinks have less overrun than drinks dispensed during peak-use
periods.

Publication Number: 621360041TBINS - 4 - © 2010-2016, Cornelius Inc.

Figure 1.

2 gas has less tendency to break out as the drink

Viper Installation Manual

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 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”.

© 2010-2016, Cornelius Inc. - 5 - Publication Number: 621360041TBINS

Viper Installation Manual

INSTALLATION

DELIVERY, INSPECTION & UNPACKING

NOTE: Cornelius is not responsible for damaged freight. If damage is found, you must save all

packaging material and contact the freight carrier. Failure to contact the carrier within 48
hours of receipt may void your claim.

1. Inspect the carton and note any damage, regardless if it appears minor. If the carton is damaged,
note on the consignee copy of the freight invoice “exterior carton damage – concealed damage
possible” and contact the freight company immediately.

2. Remove any staples along the bottom edge of the carton and lift the carton off the pallet.

3. Remove the exterior carton sleeve, internal fillers and plastic bag around the unit. Carefully inspect
the unit for damage.

4. Remove the bolts holding the dispenser to the pallet.

5. Remove the packing fillers from the top of the unit.

6. Inspect the dispenser cabinet and make sure it has no scratches, dents or any other cosmetic
defects.

7. Make sure that the glass or plastic merchandiser panels are not scratched or cracked.

8. Open the packages of loose parts and inspect all of the parts for damage or missing parts. Check
the parts received against the packing list to insure receipt of all parts.

NOTE: If unit is installed more than three months from date of production, replace the seals

according to the instructions accompanying the spare seals supplied with the unit. Unite
date of manufacture is included in the unit serial no. as follows: The date code follows the
first letter of the serial number. The next four numbers reflect the date of manufacture.
The first two represent the year, the next two the week. For example, 62A0815xxxxxx
would be a unit produced during the 15th week of 2008.

COUNTER LOCATION

Select a location in a well ventilated area, close to a grounded electrical outlet and backroom connections. The
counter must be capable of supporting a minimum of 400 pounds. If possible do not place the unit close to hot
and/or steaming machines.

The minimum clearance is: 2 in. (5.08 cm) in back and 12 in. (30.48 cm) on top of the unit. If both sides have a
minimum clearance of 2” (5.08 cm), then the unit may be flush to the wall in the back.

NOTE: Condenser air is drawn in from the sides or back and discharged out the top. Failure to

maintain clearance space will reduce the capacity of the unit and cause premature
compressor failure.

BACKROOM REQUIREMENTS

Typically the supplies for the unit are located in a backroom adjoining the service area. Syrup, water and CO2
lines are then run from the backroom to the service area. The backroom supplies (syrup boxes, CO
and pumps) are typically installed on a rack system that sits on the floor, as shown in
is normally mounted against the wall.

Figure 2. The CO2 cylinder

2, water filters

Publication Number: 621360041TBINS - 6 - © 2010-2016, Cornelius Inc.

Viper Installation Manual

Power Cord

Syrup, Water and CO2

Input Lines

Figure 2.

SUPPLY CONNECTIONS

All of the electrical and supply connections to the unit are typically located near the bottom rear of the unit. There
are alternate locations for the electrical and supply connections on the bottom of the unit, below the rear
locations. The bottom connection locations may be used if the unit is located directly against a wall.

The electrical connection is located at the left side of the rear panel and the tubing supplies are located on the
right side, as shown in

Figure 3.

Electrical Requirements

Refer to the nameplate to determine the power requirements before connecting electrical power to the unit. All of
the power cords shall comply with safety requirements outlined in the EC Standards (EN60335-1 1 Clause 24.1)
in countries where CE compliance is required. All cords must be HD 21 or HD 22.

© 2010-2016, Cornelius Inc. - 7 - Publication Number: 621360041TBINS

Figure 3.