Cornelius HELIX Installation Manual

HELIX

Installation Manual

Release Date: June 13, 2012

Publication Number: 621058497INS

Revision Date: April 7, 2014

Revision: A23

Visit the Cornelius web site at www.cornelius-usa.com

for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.

RECYCLE

These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.

This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this 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-usa.com

0-238-3600

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 Dr

Glendale Heights, IL

Tel: + 1 800-238-3600

Printed in U.S.A.

ive

Correct Disposal of this Product

This marking indicates that this product should not be disposed with other household wastes throughout the EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle it responsibly to promote the sustainable reuse of material resources. To return your used device, please use the return and collection systems or contact the retailer where the product was purchased. They can take this product for environmental safe recycling.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fire Hazard Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electrical Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fan Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Ventilation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Defrost Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Appliance Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Helix Machine Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Decommissioning and/or Transporting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Storage within the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Delivery, Inspection & Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Syrup Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CO2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CO2/Compressed Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Syrup Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Syrup Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Plumbing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drain Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Commissioning the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pressurizing the CO2/compressed air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pressurizing the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hopper Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

System Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sanitation Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Weekly Product Sanitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ice Maker Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Descaler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Preparing Replacement Product Bags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Syrup Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Ice Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Blender Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Helix Installation Manual

DANGER:

WARNING:

CAUTION:

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 and/or national and local codes 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.

Different Types of Alerts

SAFETY TIPS

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.

• 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

Helix Installation Manual

WARNING:

CAUTION:

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

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:

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

DANGER:

WARNING:

CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO small area, IMMEDIATELY ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO tremors which are followed rapidly by loss of consciousness and DEATH.

FIRE HAZARD WARNING

This unit contains a flammable refrigerant. Keep all flammable materials away from the compressor area. Always be sure to keep the area around the unit clean and free of clutter. Failure to keep this area clean may result in a fire hazard, injury or equipment damage.

Helix Installation Manual

2 system. If a CO2 gas leak is suspected, particularly in a

2 gas experience

ELECTRICAL WARNING

FAN WARNING

VENTILATION WARNING

This unit contains voltages that may represent a shock hazard. Always avoid touching metalic terminals and exposed wiring when the covers are off of the unit. Failure to comply could result in serious injury, death or equipment damage.

This unit contains fans. Caution must be taken to keep hands, etc. from contacting the rotating blades. Failure to avoid rotating blades could result in injury or equipment damage.

Keep ventilation openings, in the appliance enclosure or in the built-in structure, clear of obstruction.

Helix Installation Manual

WARNING:

CAUTION:

DEFROST WARNING

APPLIANCE WARNING

WATER USAGE

Do not use mechanical devices or other means to accelerate the defrosting process, other than those recommended by the manufacturer.

Do not use electrical appliances inside the food storage compartments of the appliance, unless they are of the type recommended by the manufacturer.

Connect only to the drinking water supply. This unit should NOT be connected to a chilled water line.

HELIX MACHINE USAGE

This appliance is intended to be used in staffed kitchen areas, by trained personnel only.

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.

DECOMMISSIONING AND/OR TRANSPORTING THE UNIT

Whenever the 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 trays, drizzle holders, lid holders and cup trays are removed from the unit and stored in a safe place for ship-

ment. The unit must be carefully tied down or stored in such a manner that the unit

CAUTION:

does not move during shipment.

STORAGE WITHIN THE MACHINE

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

Helix Installation Manual

SYSTEM OVERVIEW

Introduction

INTRODUCTION

The Helix unit is an automated smoothie machine. It allows blended drinks to be made easier and faster. All the products are stored in the Helix unit, removing the need for a back room package while retaining a small, compact footprint.

The Helix unit is not designed to be operated by employees or persons with reduced physical, sensory or mental capabilities, unless they have been given supervision or instruction concerning the use of the Helix unit in a safe way and they understand the hazards involved in operating the unit.

With automatically portioned drinks, quality is assured from drink to drink while requiring very little interaction from the user. Without the use of blending pitchers and sinks to rinse, product and water waste issues are reduced from traditional smoothie machines.

SPECIFICATIONS

50 Hz

Line Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 VAC, 50 Hz

Max. Current Draw:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Amps

Water Inlet Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. (.95 cm) I.D.

Water Supply Pressure. . . . . . . . . . . . . . . . . . . . . . . 0.24-0.83 MPa (35-120 psig)

Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 90° F (10 to 32.2° C)

Drain Outlet Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.665 in. (4.23 cm) I.D.

Clearance Requirements: . . . . . . . . . . . 12 in. (30.48 cm) top; 3 in. (7.62 cm) back

Equipment Weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 lbs (278 kg)

2/compressed air Tubing Size:. . . . . . . . . . . . . . . . . . . . . 1/4 in. (0.635 cm) I.D.

2/compressed air Supply Pressure:. . . . . . . . . . . 0.48-0.83 MPa (70-120 psig)

BIB Tray Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 gal. (7.6 liters)

Ice Storage Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 lbs (14.5 kg)

Ice Make Rate: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 lb/day (272 kg/day)

Unit Height: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in. (190.5 cm)

Unit Width: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 in. (66.04 cm)

Unit Depth: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 in. (86.36 cm)

Ambient Operating Temperature: . . . . . . . . . . . . . . . . . .55 to 95

A-Weighted Sound Pressure Level (during blender operation). . . . . . . . . . . <70dB

The Helix unit is capable of using syrups with particulate matter up to 1/8” in size.

F (12.8 to 35°C)

60 Hz

Helix Installation Manual

Line Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 VAC, 60 Hz

Max. Current Draw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Amps

Water Inlet Size:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. (.95 cm) I.D.

Water Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . 0.24-0.83 MPa (35-120 psig)

Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 90° F (10 to 32.2° C)

Drain Outlet Size:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.665 in. (4.23 cm) I.D.

Clearance Requirements: . . . . . . . . . . 12 in. (30.48 cm) top; 3 in. (5.08 cm) back

Equipment Weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 lbs (278 kg)

2/compressed air Tubing Size: . . . . . . . . . . . . . . . . . . . . 1/4 in. (0.635 cm) I.D.

2/compressed air Supply Pressure: . . . . . . . . . . . 0.48-0.83 MPa (70-120 psig)

BIB Tray Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 gal. (7.6 liters)

Ice Storage Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 lbs (14.5 kg)

Ice Make Rate:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 lb/day (272 kg/day)

Unit Height: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in. (190.5 cm)

Unit Width: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 in. (66.04 cm)

Unit Depth:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 in. (86.36 cm)

Ambient Operating Temperature:. . . . . . . . . . . . . . . . . . 55 to 95

F (12.8 to 35°C)

A-Weighted Sound Pressure Level (during blender operation) . . . . . . . . . . <70dB

The Helix unit is capable of using syrups with particulate matter up to 1/8” in size.

+ 23 hidden pages

Cornelius HELIX Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual