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Cornelius A.B.S. Unit, Operator'S Manual

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Cornelius A.B.S. Unit Operator'S Manual Download Page 50

Automated Beverage System

© 1999 The Coca-Cola Company, Cornelius and

McDonald’s Corporation. All Rights Reserved.

50

Troubleshooting

Important: Only qualified personnel should 
service internal components or electrical wir-
ing of the A.B.S. unit.

A.B.S. unit Service

The A.B.S. Unit is serviced by an authourized 
Coca-Cola Service Agent. 

Call 1-800-241-COKE.

Summary of Contents for A.B.S. Unit

Page 1: ...LACE ANOKA MINNESOTA 55303 1562 PHONE 763 421 6120 1 800 238 3600 FAX 763 422 3255 FOR SERVICE CALL COKE SMILE 1 800 241 COKE TABLE OF CONTENTS WARRANTY Page 2 INTRODUCTION Page 4 SAFETY Page 4 PARTS IDENTIFICATION FUNCTION Page 5 OPERATION MODES Page 11 FULLY AUTOMATIC OPERATION Page 11 SEMIAUTOMATIC OPERATION Page 17 MANUAL OPERATION Page 19 MAJOR SUBSYSTEMS Page 23 DAILY START UP Page 39 CLOSIN...

Page 2: ...e free from defects in materials and 3 For the lesser of one 1 year from the date of installation or ii fifteen 15 months from the date of shipment by Cornelius that such Product conforms with those industry govern ment or professional organizations standards to the extent expressly set forth in written product information disclosures in Cormelius product literature and documentation Provided that...

Page 3: ... parts and or Products must be shipped prepaid to Cornelius Return shipping costs of repaired or replacement parts or Products will be prepaid by Cornelius except that as to original purchasers in Alaska or Hawaii Cornelius will pay shipping cost only to Seattle or San Fransisco respectively Cornelius will not accept collect shipments Replaced products or parts become prperty of Cornelius any prod...

Page 4: ...ual mode Remove the conveyor Enter the man ual mode by pressing the Manual Auto button Don t pull cups from A B S Turret damage may occur to cup tubes Locate a sleeve of cups and remove a cup Hold the cup under the ice chute press EXTRA ICE and ice is dispensed Hold the cup under the nozzle press and hold the desired flavor button and the drink is dispensed Reinstall the conveyor and return the A ...

Page 5: ...ption PRINTED ON RECYCLED PAPER 10 Post Consumer Content 40 Pre Consumer Content 1 560000260 Ventilation Grill 2 560000245 Access Hole Cover 3 560000291 Air Filter 4 560000289 Front Panel Built before Serial No 56A0019AB102 560002774 Front Panel Serial No 56A0019AB102 and after Assembled Unit Diagram A B S Unit Access 1 2 3 4 TURRET FLAVOR DISPLAY CUP GRABBER CONTROL PANEL ON OFF SWITCH OPTIONAL P...

Page 6: ...mber Number Description 1 27921 560000320Conveyor Cover 2 27922 560000325 Conveyor Assembly 3 560000315 Cup Rest 4 560000306 Drip Tray Assembly Conveyor Cup Rest Assembly Diagram 1 27921 560000320 Conveyor Cover 2 27922 569000295 Conveyor Assembly 3 560000315 Cup Rest 4 560000306 Drip Tray Assembly Conveyor Assembly 1 2 3 4 POSITION A SENSOR CUP POSTIONING BRACKET CUP HOLDER THUMB SCREWS ...

Page 7: ...346 Ice Chute 4 560002728 Ice Chute Stiffener 5 560000398 Machine Screw Phillips Truss Head No 8 x 5 6 560001548 Ice Chute Shield 7 620014801 Lid Holder Assembly 8 28076 560001589 Ice Chute Cleaning Brush 1 560000392 Ice Chute Gasket 2 560000344 Ice Chute Mounting Plate 3 27926 560000346 Ice Chute 4 560002728 Ice Chute Stiffener 5 560000398 Machine Screw Phillips Truss Head No 8 x 5 6 560001548 Ic...

Page 8: ...Tube Cover 12 21 oz 3 28377 569000199 42 Oz Cup Tube Kit N R 28373 569000172 12 Oz Cup Tube Assembly Kit Austrailian Small size N R 28374 569000173 16 Oz Cup Tube Assembly Kit Austrailian Medium size station 3 N R 28375 569000174 21 Oz Cup Tube Assembly Kit Austrailian Large size station 1 N R 569000175 32 Oz Cup Tube Assembly Kit N R 569000159 21 Oz Cup Tube Assembly Kit Austrailian Large size st...

Page 9: ...erved Illustrated Parts List 9 Automated Beverage System Ref CCUSA MFG Number Number Number Description Ice Bin Components Diagram 1 15346 Agitator Assembly 2 52887 Lid 3 53227 Disk 4 15087 Agitator Retainer 1 15346 Agitator Assembly 2 52887 Lid 3 53227 Disk 4 15087 Agitator Retainer Agitator Assembly 1 3 2 4 ...

Page 10: ... Parts List 10 Automated Beverage System Ref CCUSA MFG Number Number Number Description Nozzle Assembly Components Diagram 1 27940 560001545 Nozzle 2 27939 560001544 Diffuser 3 110677000 O Ring 4 180025000 O Ring 5 560110010 O Ring 6 325216000 Nozzle Brush Not Shown Nozzle Assembly 1 3 4 5 1 2 2A 2B DIFFUSER BODY DIFFUSER RING ...

Page 11: ...oca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 11 Fully Automatic Operation Operational Modes The A B S has three modes of operation Automatic Normal Operation Semiautomatic while in Auto Manual Location Diagram ...

Page 12: ...tic mode the customer places an order at the Drive Thru Special Ice Drinks Extra and no ice drinks are entered from the P O S as a grill order The A B S will auto matically produce the drink to the special order P O S Signal To Manager s Computer The order is transmitted from the P O S to the store computer and from there to the A B S unit Automatic Operation ...

Page 13: ...es Closes The cup grabber is lifted by a pneumatic cyl inder up to the cup The travel is sensed by the full travel sensor If full height is reached a pneumatic cylinder closes the grabber arms against the cup A sensor detects if cups are available Grabber Lowers Opens The cup grabber lowers pulling the cup from the cup tube and then the arms open dropping the cup into the conveyor If the grabber s...

Page 14: ...rink had been ordered the con veyor would have moved only one position and the second cup would have been extracted and dropped into the conveyor The two cups would then be moved clockwise until the first cup reaches the ice fill port Ice Portion Is Dispensed The ice gate is opened by a pneumatic cylin der for the time needed to dispense the selected ice portion Correct operation is insured by the...

Page 15: ...yor moves the cup to the beverage fill point The valve opens to dispense the desired syrup and water in the desired portions into the cup Beverage Dispensed The computer sends the drink portion of the order to the A B S where the information is interpreted and the drink is dispensed If the drink requires a top off the initial por tion will be dispensed After a delay the bal ance of the drink will ...

Page 16: ...s check for cup too high and a cup in position A If these sensors are clear the conveyor moves the cup to cup serve position D The display will indicate the flavor of the bev erage at cup serve position D Crew Member Serves Drink A crew member caps the drink while still on the conveyor and serves it with the remainder of the order Automatic Operation ...

Page 17: ...lius and McDonald s Corporation All Rights Reserved 17 Press Cup Size While in automatic mode to dispense a drink in the semi automatically press the desired cup size button Press Flavor Press the desired flavor button Semiautomatic Operation Unit in Automatic ...

Page 18: ...hen Correct Press Enter Sequence of pressing the cup size flavor and special ice buttons is not important At any time pressing any button will change the selection of the drink to be dispensed When the correct order is displayed press ENTER and the drink will be dispensed Any drink entered in this manner will display an illuminated asterisk in the SPECIAL sec tion of the Drink Position Display ide...

Page 19: ...al AUTO button Remove The Conveyor To dispense a drink in the manual mode remove the conveyor This is done by remov ing the thumb screws holding it in place and lifting the conveyor up Never Remove Cups From Cup Turret Assembly Manually pulling cups from the cup tubes can permanently damage the retainers Stock cup sleeves near the unit when in man ual mode Manual Operation ...

Page 20: ...er the ice chute Dispense ice by pressing the EXTRA ICE button Ice Not Dispensed If there is an issue with CO2 ice may not dis pense In this case locate a supply of ice near the unit for manually filling the cups Dispense Beverage Hold the cup under the nozzle Press and hold the desired flavor button to dispense the bev erage Manual Operation ...

Page 21: ...s properly The conveyor drive pin must engage the drive socket on the gear box When installing the conveyor it may be necessary to move the conveyor manually to allow the drive pin to insert into the drive socket Tighten the thumb screws on the cover Clear The P O S Order Buffer If orders are on the screen the P O S buffer must be cleared To clear the P O S buffer the A B S unit must be in the MAN...

Page 22: ...lius and McDonald s Corporation All Rights Reserved 22 A confirmation question will appear Press ENTER to clear the entire order buffer or CLEAR to cancel action Return To Automatic Mode Press the Manual AUTO button to return to Automatic mode Manual Operation ...

Page 23: ...mpany Cornelius and McDonald s Corporation All Rights Reserved 23 Introduction to the A B S Unit Components of the A B S Turret Cup Lid Rack Ice Dispenser Control Panel Cup Extractor Conveyor Beverage Dispenser Pre Chiller Optional Major Subsystems ...

Page 24: ...t Major Subsystems ARROW CURSOR DOWN FLOAT OPTION Used to move the selection to the down when in manual mode used to add float to ordered drink in Automatic mode ARROW CURSOR DOWN FLOAT OPTION Used to move the selection to the down when in manual mode used to add float to ordered drink in Automatic mode Control Touch Panel ...

Page 25: ...re is an audible Beep If the button is incorrect and cannot function there will be a triple Beep indicating an error Display Touch Panel The display that is visible through the window in the Touch Panel is the message center for the A B S The display examples shown is only one of the many messages that may be displayed This display shows the status guides you through programming tells you what err...

Page 26: ...ation All Rights Reserved 26 A B S Unit Major Subsystems Control Panel Drink Position Drink Position Display The Drink Position Display corresponds to the four drink pickup positions on the con veyor As a drink moves to position D on the conveyor the details of the drink are dis played ...

Page 27: ...nd not from the P O S will be indicated as a SPECIAL This will be indicated by the being illuminated in the display If the drink has the special ice requirements EXTRA ICE the will be illuminated in the display Control Panel Drink Position If the drink has the special ice requirements EXTRA ICE the will be illuminated in the display If the drink is a FLOAT drink F will be illu minated in the displ...

Page 28: ...Donald s Corporation All Rights Reserved 28 A B S Unit Major Subsystems Cup Turret Components Location Diagram Cup Conveyor Components Location Diagram Turret Cup Extractor Conveyor Cup Turret Components Location Diagram Cup Conveyor Components Location Diagram Operation ...

Page 29: ...te until the correct turret face is forward allowing easy mounting of the cup tube In the standard con figuration the 5th cup size is not being used If there are two medium cup tubes when but ton 3 is pressed once the first medium turret cup face is forward the second time it is pressed the second medium turret face will rotate forward Other Cup Configuration The unit can be configured with four o...

Page 30: ...ion A signal is sent that the grabber is in position and then a pneumatic cylinder closes the grab ber arms If the arms close fully indicating No Cup the control system will attempt to pull a cup from a second tube of same size cup if present If no cup is available a SOLD OUT message will be displayed If a cup is available the cup grabber will be lowered and the cup pulled from the cup tube If the...

Page 31: ...bber detects the cup holders and thereby controls the movement of the conveyor and the position of the cup holders Note The conveyor will not operate if there is a cup or any obstruction in the cup holder at Cup Serve Point A Cup Rest The cup rest must be installed with the oval rails up and with the Cup Positioning Bracket must be at the rear of the drip tray Drive Seal Check to see drive seal is...

Page 32: ...for dispensing regardless of its size Cup In Position A Part of the conveyor assembly is the cup in position A sensor This senses if a cup is in the last conveyor position to prevent full cups from traveling into the grabber mechanism Reinstall Conveyor Align the drive pin on the left side of the con veyor assembly so that the conveyor seats properly The conveyor drive pin must engage the drive so...

Page 33: ...gas is controlled by solenoids Ice Dispensing Cycle The ice gate opens the agitator turns to refill the ice chute and to maintain ice on the cold plate the ice gate closes the agitator contin ues to fill the ice chute fr the set period of time Low Ice Refill Soon The LOW ICE REFILL SOON condition is sensed by the A B S through a temperature sensor located in the ice bin The LOW ICE REFILL SOON ala...

Page 34: ...iod pro grammed during setup the agitator will agi tate for a preset period to maintain ice on the coldplate The ice bin has a sensor that detects a low ice condition and displays a warning Ice Chute The ice chute directs the ice into the cup It can be removed for cleaning or replacement Access to the ice chute is obtained by remov ing the cup lid rack A B S unit Major Subsystems Operation Ice Dis...

Page 35: ...nd McDonald s Corporation All Rights Reserved 35 Ice Chute Removal Replacement 1 With the unit in manual mode remove the cup lid rack 2 WARNING Shut off the manual ice gate switch 3 Slide the gate out of the chute A B S Unit Major Subsystems Operation Ice Dispenser ...

Page 36: ...anism out and turn the chute clockwise 1 5 Holding the ice chute release mechanism rotate the ice chute clockwise and pull down Drop the ice chute down through the ice gate frame and replace it To reinstall ice chute follow procedures in reverse order 6 Return the A B S unit to normal operation A B S Unit Major Subsystems Operation Ice Dispenser ...

Page 37: ...n trols and two shutoffs The blocks are perma nently manifolded together to supply a single outlet nozzle The top view is depicted Beverage Dispensing The valve opens to dispense the desired syrup and water in the desired portions into the cup If foaming is an issue the service agent can program a top off The initial portion will be dispensed After a delay the balance of the drink will be dispense...

Page 38: ...any Cornelius and McDonald s Corporation All Rights Reserved 38 Optional Pre Chiller An optional pre chiller must be installed if carbon ated water and plain water are not chilled in a backroom package A B S Unit Major Subsystems Operation Pre Chiller ...

Page 39: ...elius and McDonald s Corporation All Rights Reserved 39 Fill Ice Bin Remove the ice bin lid and fill with ice cubes to the top of the bin Do not overfill The bin cover must be able to rest securely on the top of the bin Daliy Start Up Procedures Fill Ice Bin ...

Page 40: ...otate until the correct turret face is forward allowing easy filling of the cup tube Filling Cup Tubes Remove top cup tube cover and hold under the cup tube to catch cups and prevent them from falling through Return top cup tube cover Do not over fill the cup tubes Damage may result to the cup tubes or may result in cup jams When all tubes have been filled return to automatic mode by pressing the ...

Page 41: ...ay and exterior surfaces Pour warm NOT HOT water down the drip tray drain Reinstall cup rest and conveyor Remove and clean the valve nozzle and diffuser Wipe down and clean the A B S unit with sani tizing solution Remove Conveyor Cup Rest Remove the conveyor by removing the 3 thumb screws holding it in place Remove the cup rest by lifting it up and removing it Wash the conveyor conveyor cover and ...

Page 42: ...ip tray The cup positioning bracket located on the cup rest contains a spring that is positioned so it touches the cup in the cup holder as the cup moves past the spring This moves the cup to the rear based on the direction of movement of the cup holder This insures that all cups will be in the same position regardless of its size Reinstall Conveyor Align the drive pin on the left side of the con ...

Page 43: ...by twisting clockwise Then pull the diffuser straight down Separate the dif fuser Clean the beverage nozzle and diffuser using nozzle brush and rinse with carbonated water Reinstall diffuser nozzle Wipe Down A B S Unit At the end of closing shift the crew should wipe down the exterior of the unit with a sani tizing solution Closing Sanitation Procedures ...

Page 44: ...er and set aside 3 Remove all ice from the hopper and discard If necessary pour clean potable water slowly into the hopper to assist in melting the ice 4 After all the ice is removed inspect the cold plate areas and drains as follows A Remove the splash panel and the plastic cold plate access cover WARNING DO NOT USE SHARP OBJECTS METAL DEVICES OR ABRASIVES ON THE ICE HOPPER TOP COVER ICE CHUTE OR...

Page 45: ...ertain to clean the entire surface area of the cold plate including all the corners Thoroughly rinse the hopper top cover agitator agitator cover and the cold plate with clean potable water Automated Beverage System 7 Using a long handle nylon bristle brush clean the interior of the ice chute with the warm soapy solution Access to the to the ice chute can be gained via the interior of the hopper a...

Page 46: ...a full tank or container of liquid dishwasher detergent by using 70o F 21o C to 100o F 38o C potable water and 5 oz 15 ml of liquid dishwasher detergent to one gallon of potable water Stir detergent solution to thoroughly mix the solution 4 Syrup Tank Systems A Observe and note CO2 pressure setting on the syrup tank s CO2 regulator then re adjust the CO2 regulator to 60 to 80 PSI Pressurize the sy...

Page 47: ...from the syrup system STEP 2 FLUSH THE SYRUP SYSTEMS 9 Syrup Tank Systems A Connect a syrup tank filled with potable water pressurized at 60 to 80 PSI into one of the syrup systems 10 Bag In Box Syrup System A Fill a five gallon container with potable water B Place syrup outlet tube with bag valve on end into container of potable water 11 Flush the detergent solution out of the syrup system and di...

Page 48: ...olution 17 Sanitize the syrup system and dispensing valve as follows A Place a waste container under the dispensing valve B Place the ABS unit in the TEST VALVE TEST mode and press each flavor button until all the water is expelled and sanitizer fills the tubing Activate the dispensing valve for one minute to purge all water out of and install sanitizing solution into the syrup system and dispensi...

Page 49: ... flush sanitizing solution out of the remaining syrup systems and dispensing valve 26 Remove the potable water source from the syrup system STEP 5 PURGE THE WATER OUT OF THE SYRUP SYSTEMS TO RESTORE UNIT OPERATION 27 Syrup Tank Systems A Noting syrup tanks CO2 regulator pressure setting observed in Step 4 preceding re adjust CO2 regulator to the observed pressure setting B Connect the tanks contai...

Page 50: ...ald s Corporation All Rights Reserved 50 Troubleshooting Important Only qualified personnel should service internal components or electrical wir ing of the A B S unit A B S unit Service The A B S Unit is serviced by an authourized Coca Cola Service Agent Call 1 800 241 COKE ...

Page 51: ... and McDonald s Corporation All Rights Reserved 51 Troubleshooting If the A B S unit fails to operate properly check to see that there is power to the unit Check the ice bin for ice If the A B S unit does not dispense check the Troubleshooting chart on pages 54 56 ...

Page 52: ...e level in the ice bin is too low Refill the ice bin with ice Press ENTER CLEAR CUP JAM Cup s jammed in the conveyor at the cup extraction position and the conveyor and turret are unable to operate Remove all cups from the con veyor cup holders at the Extract Position before pressing the ENTER button Another cup will be extracted and dispensing will continue NO CUP EXTRACTED The gripper did not or...

Page 53: ...weet A Carbonator not working B No CO2 pressure in carbonator C Valve ratio requires adjusting Call for service Call for service Call for service Beverages not sweet enough A Empty B I B container B Valve ratio requires adjusting Replace Call for service Beverages not cold A No ice in hopper B Drains plugged and water stand ing on coldplate Fill ice bin Clean ice bin and flush drain with warm wate...

Page 54: ...2 cylinder Call for refill bulk Call for service Call for service Ice will not dispense A Ice bin empty B Defective gate cylinder C CO2 supply disconnected or depleted D Agitator motor defective or wired incorrectly Fill ice bin Call for service Reconnect CO2 Replace CO2 cylinder Call for refill bulk Call for service Call for service Drinks too foamy A Carobonator pressure too high Normal operatin...

Page 55: ...Automated Beverage System 1999 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 55 Wiring Diagram WIRING DIAGRAM 115V WIRING DIAGRAM 230V ...

Page 56: ...Automated Beverage System 1999 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 56 Pneumatic Schematic ...

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