McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM, Operator'S Manual

Page 1: ...BY CORNELIUS PHONE 800 238 3600 www cornelius com FOR SERVICE CALL COKE SMILE 1 800 241 COKE TABLE OF CONTENTS SAFETY Page 1 INTRODUCTION Page 4 PARTS IDENTIFICATION FUNCTION Page 5 OPERATION MODES Page 11 AUTOMATIC OPERATION Page 12 SEMIAUTOMATIC OPERATION Page 16 MANUAL OPERATION Page 18 MAJOR SUBSYSTEMS Page 23 DAILY START UP Page 39 CLOSING SANITATION PROCEDURES Page 41 DAILY CLEANING PROCEDUR...

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Page 3: ... COULD result in serious injury death or equipment damage CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS Carefullyreadandfollow allsafety messagesinthis manual andsafety signsontheunit Keepsafety signsingoodcondition and replacemissing or damaged items Learnhow tooperatetheunitandhowtouse thecontrolspr...

Page 4: ...e 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 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 CO2 gas leak is suspected particularly in a sm...

Page 5: ...he system depressurized prior to performing this service Failure to comply could result in serious injury death or damage to the equipment WARNING This unit must be grounded to avoid possible electrical shock to the operator The unit power cord is equipped with a three pronged plug If a three pronged grounded outlet is not available use an appropriate method to ground the unit Failure to comply co...

Page 6: ... Manual Auto button Don t pull cups from A B S Turret as damage may occur to cup tubes Locate a sleeve of cups and remove a cup Hold the cup under ice chute press EXTRA ICE Ice is dispensed Hold cup under nozzle press and hold desired flavor button Drink is dispensed Reinstall conveyor and return A B S unit to normal operation SAFETY Always disconnect CO2 or air pressure to unit before cleaning or...

Page 7: ...ption PRINTED ON RECYCLED PAPER 10 Post Consumer Content 40 Pre Consumer Content 1 620052935 Ventilation Grill 2 620516680 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 8: ...ption 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 5 20669 560002714 Water Deflector Conveyor Assembly 1 2 3 4 POSITION A SENSOR CUP POSTIONING BRACKET CUP HOLDER THUMB ...

Page 9: ...umber Number Description Ice Chute Assembly Components Diagram 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 Ice Chute Shield 7 620014801 Lid Holder Assembly 8 28076 560001589 Ice Chute Cleaning Brush Not Shown Ice Chute Assembly 1 2 3 6 5 4 7 ...

Page 10: ...p Tube Cover 12 21 oz 3 28377 569000199 42 Oz Cup Tube Kit N R 28373 569000172 12 Oz Cup Tube Assembly Kit Australian Small size N R 28374 569000173 16 Oz Cup Tube Assembly Kit Australian Medium size station 3 N R 28375 569000174 21 Oz Cup Tube Assembly Kit Australian Large size station 1 N R 569000175 30 32 Oz Kit Cup Tube 32 Oz ABS N R 569000159 21 Oz Cup Tube Assembly Kit Australian Large size ...

Page 11: ...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 12: ...trated Parts List 10 Automated Beverage System Ref CCUSA MFG Number Number Number Description Nozzle Assembly Components Diagram 161509 Complete Assembly 1 27940 560001545 Nozzle 2 27939 560001544 Diffuser 3 110677000 O Ring 6 325216000 Nozzle Brush Not Shown Nozzle Assembly 1 3 4 5 1 2 2A 2B DIFFUSER BODY DIFFUSER RING ...

Page 13: ...ay Drink Position Display Showing Drink Locations in Conveyor AN IS DISPLAYED WHEN A DRINK IS DISPENSED FROM THE A B S PANEL INSTEAD OF THE POS SYSTEM A IS DISPLAYED FOR ANY DRINK DISPENSED WITH EXTRA ICE COKE SPECIAL EXTRA ICE SPECIAL SPECIAL SPECIAL SPECIAL EXTRA ICE EXTRA ICE EXTRA ICE EXTRA ICE Fully Automatic Operation Operational Modes The A B S has three modes of operation Automatic Normal ...

Page 14: ...in the proper operation service and maintenance of the equipment With the unit in automatic mode the cus tomer 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 an...

Page 15: ...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 should slide off a cup it w...

Page 16: ...k had been ordered the conveyor 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 ice...

Page 17: ... 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 be dispen...

Page 18: ...sors check for a cup in position A If the sensor is clear the conveyor moves the cup to cup serve position D The display will indicate the flavor of the beverage 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 Semiautomatic Operation Unit in Automatic ...

Page 19: ...in the proper operation service and maintenance of the equipment 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 Press Special Ice Requirement If Requested If extra ice is desired press the EXTRA ICE button If no ice is required press the NO ICE button If normal ice is desired no button is pressed ...

Page 20: ...S panel ABS Float Dispensing ABS Float Dispensing allows for the ABS to dispense drinks without ice that are only a pre set portion full Ice cream can then be added after the dispense to make it into a FLOAT drink Ordering a Float Drink 1 Place the unit in AUTOMATIC MODE 2 Select the CUP SIZE 3 Select the FLAVOR 4 Press the DOWN ARROW FLOAT KEY 5 Press ENTER The word FLOAT will appear when the flo...

Page 21: ...tion service and maintenance of the equipment Enter the manual mode by pressing the Man ual 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...

Page 22: ...nder 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 23: ...ats 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 M...

Page 24: ...nelius 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 25: ...ights Reserved 23 A B S Unit Major Subsystems Components of the A B S Turret Cup Lid Rack Ice Dispenser Control Panel Cup Extractor Conveyor Beverage Dispenser Pre Chiller Optional CUP LID RACK CONTROL PANEL DISPENSING VALVE CONVEYOR CUP TURRET CUP TUBE ASSEMBLY ICE DISPENSER CUP EXTRACTOR PRE CHILLER ...

Page 26: ...Unit Major Subsystems 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 man ual mode used to add float to ordered drink in Automatic mode ...

Page 27: ... pressed there 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 win dow in the Touch Panel is the message cen ter 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 tell...

Page 28: ...s Corporation All Rights Reserved 26 A B S Unit Major Subsystems Major Subsystems 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 29: ...ms A drink that is dispensed from the touch panel and not from the P O S will be indi cated as a SPECIAL This will be indicated by the being illuminated in the display If the drink has the special ice requirements EXTRAICE the will be illuminated in the display If the drink is a FLOAT drink F will be illu minated in the display ROOT BEER FL F ...

Page 30: ...onald s Corporation All Rights Reserved 28 A B S Unit Major Subsystems 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 ...

Page 31: ...sh to install The turret will rotate until the correct turret face is forward allowing easy mounting of the cup tube In the stan dard configuration 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 ...

Page 32: ...r during the lift motion Asignal is sent that the grabber is in position and then a pneu matic cylinder closes the grabber arms If the arms close fully indicating No Cup the con trol system attempts to pull a cup from a second tube of same size cup if present If no cup is available a SOLD OUT message is dis played If a cup is available the cup grabber is lowered and the cup pulled from the cup tub...

Page 33: ...p holders and thereby controls the movement of the conveyor and the position of the cup holders Note The conveyor does 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 Check for the presence of a cup locator spring Water Def...

Page 34: ...l cups will be in the same position 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 conveyo...

Page 35: ...loses under pneumatic pressure The 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 for 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...

Page 36: ...d 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 Ice Chute Removal Replacement 1 With the unit in manual mod...

Page 37: ...04 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 35 2 WARNING Shut off the manual ice gate switch 3 Slide the gate out of the chute 4 Pull the ice chute release mechanism out and turn the chute clockwise 1 Ice Dispenser ...

Page 38: ... s Corporation All Rights Reserved 36 5 Holding the ice chute release mecha nism 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 proce dures in reverse order 6 Return the A B S unit to normal opera tion Ice Dispenser ...

Page 39: ...containing two solenoids two flow con trols and two shutoffs The blocks are per manently 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 b...

Page 40: ...systems 2004 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 38 Optional Pre Chiller An optional pre chiller must be installed if carbonated water and plain water are not chilled in a backroom package Pre Chiller ...

Page 41: ...ines to the unit Allow the machine to defrost one hour minimum When all the ice and condensation has evaporated or been removed turn on the power and supply lines access the service test mode and confirm that all components are functioning properly before placing the unit back into service Refer to installa tion manual 569000179INS for service mode access details Fill Ice Bin Remove the ice bin li...

Page 42: ...ish to fill The turret will rotate until the correct turret face is forward allow ing 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 overfill the cup tubes Damage may result to the cup tubes or may result in cup jams When all tubes have been filled return to au...

Page 43: ...f the ABS unit Daily Cleaning Sanitizing Tasks At close the following tasks should be per formed Put in manual mode do not shut off main power Remove and clean the conveyor and cup rest Clean drip tray and exterior surfaces Pour warm NOT HOT water down the drip tray drain Check for water deflector If missing use the spare located behind the lid holder panel Reinstall cup rest and conveyor Remove a...

Page 44: ...acket must be at the rear of the drip 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 dri...

Page 45: ...ozzle Diffuser Remove the nozzle by twisting clockwise Then pull the diffuser straight down Separate the diffuser 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 san itizing solution ...

Page 46: ...aily Cleaning Conveyor Thru Beam Last Position Sensor The thru beam Position A sensor requires cleaning If not clean the sensor may work intermittently With the conveyor off wet a clean napkin with carb water and carefully wipe the lens of the thru beam sensor emitter and the receiver Note Don t use cleaning towel on sensor it may leave film on sensor lens ...

Page 47: ... the plastic cold plate access cover B Locate and remove any debris from the drain trough and cold plate Make sure the drain holes are not clogged C Reinstall the cold plate access cover and splash panel 5 Remove the agitator retainer and the ice agitator assembly 6 Using a long handled nylon bristle brush clean the interior of the hopper top cover agita tor agitator cover and cold plate with a wa...

Page 48: ...o not attempt to remove the syrup tank cover until CO2 pressure has been released from the system 3 Using a clean syrup tank syrup tank system or a five gallon container bag in box sys tem prepare 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 solu...

Page 49: ...ystems 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 B I B 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 dispensing valve as follows A Place a waste container under the...

Page 50: ...ate the dispensing valve for one minute to purge all water out of and install sanitizing solution into the syrup system and dispensing valve C Continue to activate each dispensing valve in cycles ON for 15 seconds OFF then ON for 15 seconds Repeat ON and OFF cycles for 15 cycles 18 Repeat Steps 15 16 and 17 to flush water out of and install sanitizing solution in the remaining syrup systems and di...

Page 51: ...rge 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 containing the syrup into the syrup systems 28 Bag In Box Syrup System A Remove all bag valves from syrup outlet tubes B Connect bag in box syrup container...

Page 52: ...ights Reserved 50 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 authorized Coca Cola Service Agent Call 1 800 241 COKE If the A B S unit does not dispense check the Troubleshooting chart on pages 54 56 ...

Page 53: ...em Troubleshooting 2004 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 51 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 ...

Page 54: ...r this flavor LOW ICE REFILL SOON A Ice level in the ice bin is too low A Refill the ice bin with ice Press ENTER CLEAR CUP JAM A Cup s jammed in the conveyor at the cup extraction position and the conveyor and turret are unable to operate A Remove all cups from the con veyor cup holders at the Extract Position before pressing the ENTER button Another cup is extracted and dispensing contin ues NO ...

Page 55: ...for service Beverages too sweet A Carbonator not working B No CO2 pressure in carbonator C Valve ratio requires adjusting A Call for service B Call for service C Call for service Beverages not sweet enough A Empty B I B container B Valve ratio requires adjusting A Replace B Call for service Beverages not cold A No ice in hopper B Drains plugged and water standing on coldplate A Fill ice bin B Clea...

Page 56: ...Call for refill bulk Call for service D 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 A Fill ice bin B Call for service C Reconnect CO2 Replace CO2 cylinder Call for refill bulk Call for service D Call for service Drinks too foamy A Carbonator pressure too high Normal operating ...

Page 57: ...Automated Beverage System System Diagrams 2004 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 55 Wiring Diagram 115V Before 10 15 08 and after 03 20 18 ...

Page 58: ...Automated Beverage System System Diagrams 2004 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 56 Wiring Diagram 230V Before 10 15 08 and after 03 20 18 ...

Page 59: ...Automated Beverage System System Diagrams 2004 2018 The Coca Cola Company Cornelius and McDonald s Corporation All Rights Reserved 57 Air Compressor System ...