Cornelius ABS 2.0 Service Manual Download

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ABS 2.0

Service Manual

Release Date: December 16, 2019

Publication Number: 621058590SER

Revision Date: December 16, 2019

Revision: B

Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

Summary of Contents for ABS 2.0

Page 1: ...S 2 0 Service Manual Release Date December 16 2019 Publication Number 621058590SER Revision Date December 16 2019 Revision B Visit the Cornelius web site at www cornelius com for all your Literature needs ...

Page 2: ...failure to utilize suitably qualified and trained per sons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation oper ating cleaning or maintenance instructions 12 use of non authorized parts 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 whic...

Page 3: ...vice 11 Introduction to Abs 2 0 Programming 11 Default Settings Restoring Settings 11 Display Explanation 12 Entering the Technician Screen 13 Carousel Assembly Splash Panel Removal 14 Carousel Assembly Removal 14 Splash Panel Removal 15 Nozzle Diffuser Removal 16 Multi flavor Valve Configuration 19 Disassembly Of An MFV Valve Module 20 Reassembly of MFV Valve 21 Ice Chute cover Removal replace 23...

Page 4: ...ation 41 Sequence of Events 41 Empty Cup Tube Sensor 42 Replacement of Cup Grabber Pads 42 Replacement of Cup Picker 42 Cup Turret System 43 Description of Operation 43 Cup Holder Default Positions 43 Cup Holders Installation 44 Turret Drive Assembly 46 Turret Gear Box Motor 46 Encoder Disk 46 Turret Position Sensor 46 Shaft Coupler 46 Ice Chute Assembly 47 Ice Gate Description 47 Ice Chute Cover ...

Page 5: ... III Troubleshooting 51 Mechanical Issues 52 Beverage Ice related Issues 53 POS Related Issues 54 Schematics 55 Wiring Diagram 55 Plumbing Diagram Air CO2 57 ...

Page 6: ... IV ...

Page 7: ...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 Unit must be located in an area with nearest access to floor drain port preferably under the foot print of unit DO NOT Let anyone operate the unit without proper training This appliance is not intended for use by children Children should be supervised to ...

Page 8: ... 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 SHIPPING AN...

Page 9: ...dth 901 70 mm 35 5 inch Height 1905 mm 75 0 inch Unit weight Dry weight 267 62 kg 590 lbs Dry Operational weight With ice water etc 362 87 kg 800 lbs Cooling method Method of product cooling Cold plate on board chiller for condition C Ice storage capacity W o bin extender 61 24 kg 135 lbs Electrical Line voltage 621058590 115 10 VAC 60 Hz 1 Phase 621058773 220 240 VAC 50 60 Hz 1 Phase Current 3A C...

Page 10: ... Two 177 8 mm 7 inch touch screen dis play Number of Brands 8 Cup storage 6 cup dispenser Lid Storage 8 lid compartment Ice dispensing 1 portion controlled ice dispenser Product dispensing Cornelius Multi Flavor Valve Automatic cleaning Wand type cleaning nozzle Kit No of stage drinks 6 ACCESSORIES SUPPORTED ICE MAKER Table 4 List of ice maker compatible with ABS 2 0 SL NO BRAND MODEL 1 MANITOWOC ...

Page 11: ...ABS 2 0 Service Manual 2019 Cornelius Inc 5 Publication Number 621058590SER UNIT DRAWING Figure 1 Dimension Unit in mm ...

Page 12: ...C Power for all sensor 3 30V DC Power supply for Valve bank 4 A Turret motor capacitor B Agitator motor capacitor C Carousel motor capacitor 5 Circuit breakers as follows C 4A 12V DC D 4A 24V DC E 3A 30V DC 6 AC Power Inlet 5 3A 30V 5 4A 24V 5 4A 12V 2 24V DC 2 12V DC POWER SUPPLY POWER SUPPLY 6 AC Power Inlet 3 30V DC Power Supply for Valve Bank 1 MCB 4 Carousel motor capacitor 4 Turret motor cap...

Page 13: ...ing messages will be displayed as each test is being made When the tests are complete the final message will be displayed Figure 3 If the Initialing process ends with a No COM System Ports Found see message it means that the communication cable between the POS system and ABS system is not connected If it is not convenient to connect the cable at this time but you wish to proceed with the Set Up Ch...

Page 14: ...S 2 0 unit is in the MANUAL mode While in the MANUAL mode POS drink orders continue to be received and placed in the order buffer Figure 4 In the manual mode select the Brand then Press and hold button to dispense Beverage as required as same as Press ICE button to dispense ice There is no need of cup selection in manual mode NOTE When Manual mode please remove the carousel for dispense drinks See...

Page 15: ...f alarm conditions are present but previously acknowledged the ABS 2 0 status will indicate Warning While the Warning status is present the word AUTOMATIC will flash Figure 5 CLEAR THE POS ORDER BUFFER Table 5 Step Action Figure 1 Select Order Queue as shown Figure 6 Figure 6 2 A Delete Undesired Orders or Delete All B If several orders stack up and are no longer needed it may be easier to delete ...

Page 16: ...ress a Cup button to select the size of drink desired The display will indicate the selection made 2 Press a BRAND button to select the brand desired The display will indicate the selection made 3 Press the No Ice or Extra Ice or FLOAT button if either ice feature is desired or a float drink is requested Not pressing these buttons will cause the normal ice portion to dispense The display will indi...

Page 17: ...s factory set to satisfy the majority of all installations Do not make any adjustments until you are sure the factory settings will not satisfy the store requirements Touch Panel Layout Explanation Cup Size Water PW CW Used to Dispense ENTER Used to select or confirm a selection BRANDS Menu Automatic Mode Manual mode Order Queue SCREEN 1 SCREEN 2 See Figure 10 Ice Amount Figure 9 ...

Page 18: ...ples of the screen data Figure 10 1 Software Version 2 Page Menu 3 Order Queue 4 Cup Refill 5 Automatic Manual Dark is Selected Currently in Automatic Mode 6 Alarm cleaning due or past due 7 Order Current example L Large Regular Ice type Order ABS 2 0 Semi Auto or Order Number 8 Finished Drinks 1 6 left to right Coke is Position one 9 Flush CW has flushed the Nozzle ...

Page 19: ...N SCREEN Table 6 Step Action Figure 1 1 Select the Menu as shown in Figure 11 Figure 11 2 3 Select the Technician Icon as shown Figure 12 Figure 12 4 5 Enter 9876 then green arrow as shown Figure 13 Close the Keypad Clear the entry Figure 13 6 7 See the Technician Screen as shown Figure 14 Figure 14 ...

Page 20: ...ep Action Figure 1 Select manual button from start screen as shown Figure 15 Figure 15 2 Remove cover by loosening the 3 thumb screws and lifting it upwards Figure 16 3 Remove the carousel by lifting it upwards NOTE Avoid carrying carousel by cup holder Figure 17 4 Remove the grille by lifting it upwards NOTE Note cup locater spring position Figure 18 ...

Page 21: ...EW Figure 19 2 A From the Technician Screen select Diagnos tics menu In this menu select picker control and feedback button in this screen select the Top button to move picker to up This is to allow access to the screw behind the Lifter Grabber assembly B If no power air in the unit directly up down the Picker by hand MOUNTING SCREW Figure 20 3 Remove outer nozzle and diffuser before taking off pa...

Page 22: ...it is keyed only fits one way Figure 21 2 Pull diffuser down Clean with warm soapy water then sanitize and reinstall NOTE Do not soak for more than 2 minute Seal may warp Figure 22 3 Remove Seal from Diffuser by inserting thumb into center and pulling against the 2 surfaces to pull the seal away from the diffuser Figure 23 4 Line up the locating notches on inner 10circle of both the Seal and Diffu...

Page 23: ...h the Seal side up align the notches in the Diffuser with the ribs on Nozzle Base Push the Diffuser up into Nozzle Base Figure 26 7 The Diffuser will stay in place if correctly installed Figure 27 8 While pushing upwards rotate the Nozzle towards the back of the unit CCW Figure 28 9 The Nozzle should NOT sit on an angle It should sit even with the unit Figure 29 Table 9 Continued Step Action Figur...

Page 24: ...21058590SER 18 2019 Cornelius Inc 10 If the Nozzle is installed on an angle it is Incor rectly installed An incorrectly installed nozzle will have decreased performance dripping excess carryover etc Figure 30 Table 9 Continued Step Action Figure ...

Page 25: ...le 10 Step Action Figure 1 Each round shutoff Spindle needs to be pressed towards down as shown as in Figure 31 to allow fluid to flow past the back block into the valves Figure 31 2 Press the bottom snap Dovetail of back block towards down as indicated in Figure 32 Figure 32 3 MFV Valve Module placed on the back block Figure 33 4 Back block layout behind each valve bank Figure 34 ...

Page 26: ...dule is removed pull the locking clip upwards and remove Figure 35 2 Pull up and rotate valve upwards of bracket to remove from the module NOTE Check for all O rings on bottom of valves Figure 36 3 Rotate solenoid counterclockwise and remove to service the solenoid and plunger NOTE Solenoid should read 9 1ohms NOTE Solenoid wiring top left position Figure 37 ...

Page 27: ...II or equivalent on all O rings Figure 38 2 Start the solenoid at a 45 deg angle and ensure that rear flange of the valve fits behind the wall of the carrier bracket Figure 39 3 Ensure that bottom o rings seat and are not pinched in the outlet barbs Replacement of o rings black and lubrication with Dow 111 or equivalent is recommended Black quad rings shown on previous slide Figure 40 ...

Page 28: ...osition and ready to insert stainless steel locking clip Figure 41 5 Place valve on the backblock make sure wires are not pinched Push up on dovetail to lock valve Figure 42 6 Push spindles up to open shut offs Re connect wire harnesses Test for leaks and function Figure 43 Table 12 Step Action Figure ...

Page 29: ...CE CHUTE COVER REMOVAL REPLACE Table 13 Step Action Figure 1 Select manual button from start screen as shown in Figure 44 Figure 44 2 Lift chute upward to release the locking tabs as shown in Figure 45 Figure 45 3 Then lift chute upwards to remove as shown in Figure 46 Figure 46 ...

Page 30: ...ABS 2 0 Service Manual Publication Number 621058590SER 24 2019 Cornelius Inc 4 Press downward to replace the Ice chute cover and ensure the sensor working fine Figure 47 Table 13 Step Action Figure ...

Page 31: ...nected to each in let on the cold plate Refer to the cold plate diagram below Figure 48 NOTE All inlet connections are clearly marked with a label adjacent to the inlet connections Always check for leaks on all connections Product Line Connections To connect the syrup and water from the back room package to the unit NOTE If lines are to be cut mark the line numbers above the cut with a marker If s...

Page 32: ...ould be cold Remove the carousel assembly to allow easy access to the area under the valve for the ratio cup Refer Table 8 for accessing the MFV valves in the unit Table 14 Step Action Figure 1 Select the Unit setup Menu from technician screen as shown Figure 49 Figure 49 2 Select the Beverage Dispense Calibration Figure 50 Figure 51 Front View Valve ...

Page 33: ... sec 88 7ml sec this procedure will update the default value Figure 52 1 From the Beverage Dispense Calibration screen select the button for Carbonated Water 1 Hold the water compartment of the ratio cup under the nozzle and press the 4 SECOND DISPENSE button Target volume for CW1 is approximately 9 ounces 226 16 ml Turn the CW1 adjustment screw on the MFV valve clockwise to increase the flowrate ...

Page 34: ...valves Table 15 Step Action Figure 1 After both CW valves are adjusted do another 4 second dispense and measure the volume dispensed in the ratio cup Select Update Actual Water Volume in oz and using the key pad enter the volume measured in the ratio cup and press the green arrow Figure 53 Figure 54 2 Press Save and then press Update Beverage Dispense Times The dispense times for all drink sizes a...

Page 35: ...are set the syrup ratio must be adjusted The water flow rates were set to a target flow rate of 3 0 oz sec 88 72 ml sec and now the syrup flow rates must set to achieve the correct ratio required for each brand To check the ratio required select the brand on the right screen and set the valve according to the ratio displayed NOTE Always adjust the ratio for the syrup with the highest viscosity fir...

Page 36: ...sing the table below determine the volume of syrup that should dispense in the 4 second pour Example The ratio for the brand is 5 25 and it is a carbonated CW drink the unit should dispense 75 7 ml of syrup in the 4 second dispense If the ratio for the brand is 5 25 and it is plain water PW drink the unit should dispense 66 3 ml of syrup in the 4 second dispense Table 16 Ratio CW PW ml Syrup 5 25 ...

Page 37: ... all the brand names that are resident in the ABS 2 0 system The listed brands are the default brands position in units Table 17 DEFAULT SETTINGS POS PROGRAMMING DATA VALVE DISPLAY ID POS ID ACTUAL brand 1 COCA COLA 1 2 DIET COKE 2 3 Dr PEPPER 3 4 SPRITE REMIX 4 5 SPRITE 5 6 FANTA ORANGE 6 7 BARQ S ROOT BEER 7 8 HAWAIIAN PUNCH 8 ...

Page 38: ... installed at valve 2 We must now tell the ABS 2 0 system that Diet Coke is installed on valve 2 The SYRUP MAP EDIT must be set at 2 Then the LABEL must be set to display DIET COKE Figure 58 When this has been done the ABS 2 0 system will then display Diet Coke as the flavor dispensed on valve 2 Figure 58 Syrup Map Explanation 1 Drink List Create a drink list showing the exact position of each dri...

Page 39: ...0SER Mapping Second Step Table 19 Step Action Figure 1 From unit setup Menu select the Map Brands to Valves as shown in Figure 59 Figure 59 2 Brand mapping menu as shown in Figure 60 Figure 60 3 Select the Valve s as shown in Figure 61 Order 1 4 5 8 Left to right Figure 61 ...

Page 40: ... in the ABS system and present this to the POS programmer The chart at the back of the installation manual can be used for this purpose Refer Table 17 4 Select the brand to assign the valve by scroll the brand s using of up down arrow as shown in Figure 62 Figure 62 5 Save the Mapping and back to home or pre vious menu Figure 63 Table 19 Continued ...

Page 41: ...etup menu as shown in Figure 64 Figure 64 2 From the Ice Dispense Calibration Menu Select the Cup Size Amount of Ice and Press DISPENSE button as shown in Figure 65 and measure the weight of the Ice Figure 65 3 If weight is not correct adjust the Ice dis pense time by pressing the up down arrow as shown in Figure 66 if correct weight is obtained Save the setting by pressing the save button Figure ...

Page 42: ...igure 67 ALARM and WARNING MESSAGES Follow the steps to alarm logging Table 21 Step Action Figure 1 From the staring page select the Menu page Icon as shown in Figure 68 Figure 68 2 From the menu page select Alarm Log ging button to entering the menu as shown in Figure 69 Figure 69 3 In the alarm logging menu all alarms and cleanings messages are listed Use scroll button to view all the messages F...

Page 43: ...ABS 2 0 Service Manual 2019 Cornelius Inc 37 Publication Number 621058590SER 4 current status of the messages show at right side as shown in Figure 71 Figure 71 Table 21 Step Action Figure ...

Page 44: ...ntil that cup is removed If No Ice was part of the drink order the cup will not be filled with ice NOTE The carousel will not operate if there is a cup or any other obstruction in the cup holder at Cup Serve Point A Figure 72 Carousel Reference Location INDEX SENSOR A sensor is located near edge of the sink drip tray near the cup drop area see Figure 72 This sensor detects metal bracket in each cu...

Page 45: ...ition is the extract position Therefore once a cup reaches Cup Serve Point A the ABS will stop operating until that cup is removed If for example there were cups at Cup Serve Positions A and B and the cup at Point A was removed the carousel would rotate one space until the cup that was at Point B moves to Point A then the ABS 2 0 would be stopped again The carousel mechanization assembly consists ...

Page 46: ...EL MOTOR The carousel is powered by a electric motor and gear box The motor and gear box are secured to the drip tray with four screws The screws are accessible from inside the ABS lower cabinet The motor is electrically connected to the Motion Control Board CUP SLIDE The cup slide must be installed with the oval rails up and with the Cup Positioning Bracket must be at the rear of the drip tray CU...

Page 47: ...f events that occur when a cup is to be pulled and placed in the carousel are as follows The cup turret rotates to place the correct cup at the extract position The cup lifter is raised up to the cup The cup grabber arms close onto the cup If the grabber arms do not encounter a cup and close completely a sensor will send an Empty Cup Tube message The cup grabber is lowered by the pneumatic cylinde...

Page 48: ...r until the ABS 2 0 unit has been shut down and the air CO2 has been shut OFF Serious injury could occur if the cup grabber activates during repair REPLACEMENT of CUP GRABBER PADS Remove the rubber pads from the picker arms by first cutting the edge of RTV at the base of the pads and then pulling the pads off the picker arms Install new pads by sliding them on to the picker arms making sure to ali...

Page 49: ...ivated by a command from the POS to the ABS 2 0 The cup turret rotates so that the correct cup size is at the cup drop position The cup is then pulled and placed into the carousel When the cup turret rotates to a selected cup size it will rotate in either direction clockwise or counterclockwise whichever distance is closest to the extract position CUP HOLDER DEFAULT POSITIONS The cup turret Holder...

Page 50: ... 1 Each cup dispenser has two mounting holes as shown in Figure 76 Figure 76 2 Attach the cup tube clip to the turret by fasten ing four screws as shown Figure 77 Figure 77 3 Assemble the base of the cup dispenser by hooking the key hole slot on hexagonal turret as shown in Figure 78 NOTE Assure proper mounting location Figure 78 ...

Page 51: ... through bottom opening and gradually lower the hand until the cups are supported Figure 80 6 Repeat the procedure for rest of the cup dispensers Table 23 CUP SIZE MATRIX Position Upper Lower 1 30oz 0 887 litre Large Plastic 21oz 0 621 litre Medium Paper 2 21oz 0 621 litre Medium Paper 16oz 0 473 litre Small Paper 3 30oz 0 887 litre Large Plastic 21oz 0 621 litre Medium Paper 4 12oz 0 355 litre Ch...

Page 52: ...SK The alignment disk attached with three screws to the shaft coupler interfaces with the turret position sensor and notifies the Motion Control Board of which cup tube is at the extract position The disk can only attach in one position TURRET POSITION SENSOR The turret position sensor is attached to the correct reads the holes in the disk sending position signals to the Motion Control Board The s...

Page 53: ... Sensor Magnet Bracket Enclosure Figure 82 ICE CHUTE COVER The ice chute directs the ice into the cup It can be removed for cleaning or replacement ICE CHUTE SENSOR There is a sensor that detects when the ice chute cover is on off The unit will not operate when off or installed incorrectly CYLINDER REPLACEMENT The cylinder can be replaced by manually shutting off the air CO2 supply Back of the uni...

Page 54: ...d Syrup in the case of a leaky solenoid etc Refer to the valve back block and removed section FLOW CONTROLS The flow controls are used to set the flow rates for the CW PW and all the syrups The flow rate is increased by turning the adjusting screw clockwise and decreased by turning it counterclockwise The flow controls are removable by removing the two retaining screws on each side of the control ...

Page 55: ...while servicing the assembly It is also ensure the Unit function working properly PICKER CONTROL AND FEEDBACK Table 24 Step Action Figure 1 From the Technician Menu page select the Diagnostics Icon as shown in Figure 84 Figure 84 2 From the Diagnostics menu page select Picker Control Feed Back button to entering the menu as shown in Figure 85 Figure 85 3 In the menu it is have the input and out pu...

Page 56: ...nd the sensor highlight in green as shown in Figure 87 If the position is not correct the sensor will Highlight in red the sensor input data is missing B Same as check the other position of sensor Figure 87 5 Same way the cup are select and pick by using the Gripper at different cup size at different position Figure 88 Table 24 Continued Step Action Figure ...

Page 57: ...trical board driver circuit is defec tive E Gear motor has open circuit F Reed switch is not activated improper assembly of upper ice chute to lower chute G Broken wire in the 2 wire harness lead ing to the reed switch H Bad connection at main control board I Door not closed or not making switch connections to lid A Restore power or plug in unit B Check the upper ice chute assembly for proper asse...

Page 58: ...mount cup tubes Loose or missing Hardware Check each cup tube to insure all hard ware is present on the cup tube Replace any missing hardware Cups Cups are packed together and will not separate NO CUP EXTRACTED The gripper did not or could not extract a cup from the cup tube Check cup supply at the extract station and make sure the cups are not stuck Make sure the gripper pads are not damaged No c...

Page 59: ...ENOUGH A Empty B I B container B Valve ratio requires adjusting Replace Call for service BEVERAGE NOT COLD A No ice in hopper B Drains plugged and water standing on cold plate C Master Cooling system not cooling Fill ice bin Clean ice bin and flush drain with warm water Call for service DRINKS FOAMY A Nozzle Syrup diffuser not clean B Bulk coke tank needs to be sanitize C Lower or out of CO2 D No ...

Page 60: ... Reboot power to the ABS 2 0 unit ABS UNIT WILL NOT DIS PENSE A DRINK WITHOUT ICE OR WITH EXTRA ICE For no ice you must have to check ice chute sensor or pneumatic For extra ice you must have the modify ice dispense time ABS UNIT IS DISPENSING THE WRONG SIZE OR BRANDS Make sure that the order in which the brands and size are the same in brand Setup and size Setup in the Drink dispenser as it is on...

Page 61: ...tes a non polarized connection Indicates an optional kit Cleaning Pump Valve 620049798 001 Turret Motor 620065922 Turret Sensor 620065928 Turret Assembly Agitator Motor 620068668 Agitator Heater 620065035 Carousel Capacitor 3 5 uF 250VAC Turret Capacitor 6 0 uF 250VAC Fuse 5 AMP V2 12V V1 30V UI 620066501 RE D BLK W HT BLK GRN BLK BLU BLK RE D BLK K K W HTW BLK GRN BLK K BLU BLK Water Valve Block ...

Page 62: ...071054 Turret Sensor 620065928 Turret Assembly Agitator Motor 620071056 Agitator Heater 620058352 004 Carousel Capacitor 620069546 0 8 uF 450VAC Turret Capacitor 620069547 1 5 uF 450VAC Fuse 5 AMP V2 12V V1 30V UI 620066501 RE D BLK W HT BLK GRN BLK BLU BLK RE D BLK K K W HTW BLK GRN BLK K BLU BLK Water Valve Block 2x2 Syrup Valve Block 1 2 x 2 620066712 003 Flavor Valve Block 2 x 2 620058545 003 ...

Page 63: ...6 CO2 SOLD OUT 620313290 CI 441MPa 64PSI CO 379MPa 55PSI ICE CHUTE SOLENOID 620057548 PRESSURE REGULATOR 620057079 001 241MPa 35PSI EXH A B CLEAR DRAIN TO DRIPTRAY 1 2 3 AIR CO2 IN A B A B A B A B A B A B PICKER 620066477 Ø0 419mm Ø 0165 ORIFICE EXH 2A 2A 2A EXHAUST EXHAUST PRESSURE 1A EXHAUST 1A PRESSURE 2B 2B 2B PRESSURE PRESSURE EXHAUST 1B PRESSURE 1B EXHAUST 3B 3B 3B EXHAUST PRESSURE PRESSURE ...

Page 64: ...ABS 2 0 Service Manual Publication Number 621058590SER 58 2019 Cornelius Inc ...

Page 65: ...ABS 2 0 Service Manual 2019 Cornelius Inc 59 Publication Number 621058590SER ...

Page 66: ...ABS 2 0 Service Manual Publication Number 621058590SER 60 2019 Cornelius Inc ...

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Page 68: ...Cornelius Inc www cornelius com ...

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