McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM Operator's Manual

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This equipment chapter is to be inserted in

the Beverage Systems section of the

Equipment Manual.

MANUFACTURED

EXCLUSIVELY FOR

McDONALD'S

CORNELIUS

PHONE (800) 238-3600

www.cornelius.com

FOR SERVICE CALL

COKE SMILE

1-800-241-COKE

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 Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 44

MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 45

Quarterly Cleaning/Sanitation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 46

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 50

WIRING & PNEUMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 55

Part No. 569000181OPR

April 21, 2004

Revision: L

Revised: March 20, 2018

This manual is for the exclusive use of licensees and employees of McDonald's Systems, Inc.

OPERATOR'S MANUAL

AUTOMATED BEVERAGE SYSTEM

Printed In

The United States of America

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Summary of Contents for McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM

Page 1 OPERATOR’S MANUAL AUTOMATED BEVERAGE SYSTEM This equipment chapter is to be inserted in the Beverage Systems section of the Equipment Manual. MANUFACTURED EXCLUSIVELY FOR ® McDONALD’S CORNELIUS PHONE (800) 238-3600 www.cornelius.com FOR SERVICE CALL COKE SMILE 1-800-241-COKE TABLE OF CONTENTS SAFETY.
Page 3 Automated Beverage System SAFETY INSTRUCTIONS ALL S EAD AND OLLOW AFETY NSTRUCTIONS 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.
Page 4 Automated Beverage System UALIFIED ERVICE ERSONNEL WARNING: 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. AFETY RECAUTIONS This unit has been specifically designed to provide protection against personal injury.
Page 5 Automated Beverage System Failure to comply could result in serious injury, death or damage to the equipment. WARNING: Water and CO to the system must be turned off and the system depressurized prior to performing this service. Failure to comply could result in serious injury, death or damage to the equipment.
Page 6 Automated Beverage System SAFETY INTRODUCTION Always disconnect CO or air pressure to unit The Automated Beverage System (A.B.S.) is before cleaning or servicing grabber arm or an automated cold beverage dispenser for ice chute. Disconnect switch for ice gate is drive-thru applications.
Page 7 Automated Beverage System Illustrated Parts List A.B.S. Unit Access TURRET FLAVOR DISPLAY CUP GRABBER ON/OFF SWITCH CONTROL PANEL OPTIONAL PRECHILLER Assembled Unit Diagram Automated Beverage System — CCUSA MFG. Number Number Number Description 1 ........620052935 ..Ventilation Grill 2 ........620516680 ..Access Hole Cover PRINTED ON RECYCLED PAPER 10% Post-Consumer Content 3 ....
Page 8 Automated Beverage System Illustrated Parts List Conveyor Assembly THUMB SCREWS CUP HOLDER CUP POSTIONING BRACKET POSITION “A” SENSOR Automated Beverage System — Conveyor/Cup Rest Assembly Diagram CCUSA MFG. Number Number Number Description 1 27921 ..560000320Conveyor Cover 1 ....27921... 560000320 ..Conveyor Cover 2 ....
Page 9 Automated Beverage System Illustrated Parts List Ice Chute Assembly Ice Chute Assembly Components Diagram Automated Beverage System — CCUSA MFG. Number Number Number Description 1 ........560000392 ..Ice Chute Gasket 2 ........560000344 ..Ice Chute Mounting Plate 3 ....27926..560000346 ..Ice Chute 4 ....
Page 10 Automated Beverage System Illustrated Parts List Cup Tube Assembly Automated Beverage System — Cup Tube Components Diagram CCUSA MFG. Number Number Number Description 1 ....27916 ..560000207 ..5” Cup Tube Cover (30/32 - 42 oz.) 2 ....27915 ..560000206 ..4” Cup Tube Cover (12 - 21 oz.) 3 ....28377 ..569000199 ..42 Oz.
Page 11 Automated Beverage System Illustrated Parts List Agitator Assembly Ice Bin Components Diagram Automated Beverage System — CCUSA MFG. Number Number Number Description 1 ....15346........ Agitator Assembly 1 ...........15346 ...... Agitator Assembly 2 ....52887........ Lid 2 ...........52887 ...... Lid 3 ....
Page 12 Automated Beverage System Illustrated Parts List Nozzle Assembly DIFFUSER BODY DIFFUSER RING Automated Beverage System — Nozzle Assembly Components Diagram CCUSA MFG. Number Number Number Description ....161509 ....Complete Assembly 1....27940 560001545 ..Nozzle 2....27939 560001544 ..Diffuser 3....110677000 ..
Page 13 Automated Beverage System Fully Automatic Operation Operational Modes The A.B.S. has three modes of operation: • Automatic (Normal Operation) • Semi-Automatic (while in Auto) • Manual *Drink Position Display Cup Extraction Position Ice Fill Position Beverage Fill Position Conveyor Positions SPECIAL SPECIAL SPECIAL...
Page 14 Automated Beverage System Automatic Operation Order Entered On P.O.S. Operation of the ABS is restricted to employ- ees and service personal that have been trained and certified 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.
Page 15 Automated Beverage System Automatic Operation Cup Turret Rotates The cup turret rotates to move the proper size cut to the extract position. Cup Grabber Rises & Closes The cup grabber is lifted by a pneumatic cyl- inder up to the cup. The travel is sensed by the full travel sensor.
Page 16 Automated Beverage System Automatic Operation Conveyor Operates Sensors check for a cup in position “A.” If the sensor is clear, the conveyor rotates clock- wise to move the cup to the ice chute. This is based on only one drink being ordered.
Page 17 Automated Beverage System Automatic Operation Cup To Dispensing Nozzle Sensors check for a cup in position A. If the sensor is clear, the conveyor 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.
Page 18 Automated Beverage System Semiautomatic Operation (Unit in Automatic) Cup Is Moved To Cup Serve Point Sensors 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”.
Page 19 Automated Beverage System Semiautomatic Operation (Unit in Automatic) Press Cup Size Operation of the ABS is restricted to employ- ees and service personal that have been trained and certified 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.
Page 20 Automated Beverage System Manual Operation When Correct, Press Enter Sequence of pressing the cup size, flavor, and special ice buttons is not important. At any time, pressing any button changes the selec- tion of the drink to be dispensed. When the correct order is displayed, press ENTER and the drink is dispensed.
Page 21 Automated Beverage System Manual Operation Enter Manual Mode Operation of the ABS is restricted to employ- ees and service personal that have been trained and certified in the proper operation, service and maintenance of the equipment. Enter the manual mode by pressing the Man- ual/AUTO button.
Page 22 Automated Beverage System Manual Operation Dispense Ice Hold the cup under 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.
Page 23 Automated Beverage System Manual Operation Return The A.B.S. To Normal Operation Reinstall the cup conveyor by aligning the drive pin on the left side of the conveyor assembly so that the conveyor seats properly. The conveyor drive pin must engage the drive socket on the gear box.
Page 24 Automated Beverage System Manual Operation 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. © 2004-2018 The Coca-Cola Company, Cornelius and McDonald’s Corporation.
Page 25 Automated Beverage System A.B.S. Unit Major Subsystems CUP TURRET & CUP TUBE ASSEMBLY CUP LID RACK CONTROL PANEL DISPENSING VALVE ICE DISPENSER CUP EXTRACTOR CONVEYOR PRE-CHILLER Components of the A.B.S. • Turret • Cup Lid Rack • Ice Dispenser • Control Panel •...
Page 26 Automated Beverage System A.B.S. Unit Major Subsystems Major Subsystems ARROW (CURSOR) DOWN/FLOAT OPTION-Used to move the selection to the down when in man- ARROW (CURSOR) DOWN/FLOAT OPTION-Used to move the selection to the down when in manual mode, used to ual mode, used to add float to ordered drink in Automatic mode.
Page 27 Automated Beverage System A.B.S. Unit Major Subsystems Touch Panel Description Each button on the Touch Panel is described in detail in the Touch Panel Diagram on page XX. Whenever any button is pressed, there is an audible Beep. If the button is incorrect and cannot function, there will be a triple Beep indicating an error.
Page 28 Automated Beverage System 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 Automated Beverage System A.B.S. Unit Major Subsystems 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 EXTRA ICE, the # will be illuminated in the display.
Page 30 Automated Beverage System A.B.S. Unit Major Subsystems Major Subsystems Turret, Cup Extractor, & Conveyor Cup Turret Components – Location Diagram Cup Turret Components – Location Diagram Cup Conveyor Components – Location Diagram Cup Conveyor Components –Location Diagram © 2004 -2018 The Coca-Cola Company, Cornelius and McDonald’s Corporation.
Page 31 Automated Beverage System A.B.S. Unit Major Subsystems Conveyor Cup Tube Configuration The cup tube configuration is 1 – Small; 1 – Child; 1 – Large; 1 – Medium; 1- XL. The cup tube configuration for Australia is 1 – Small; 2 – Large; 2 – Medium. The hole mounting pattern is such that the cup tubes will only mount in one location.
Page 32 Automated Beverage System A.B.S. Unit Major Subsystems Conveyor Cup Grabber Assembly The cup grabber consists of two cup grabber arms actuated by a pneumatic cylinder, an ele- vating mechanism operated by a pneumatic cylinder, two guide rods, a Travel sensor and a Cup Empty sensor.
Page 33 Automated Beverage System A.B.S. Unit Major Subsystems Conveyor Conveyor The conveyor contains nine equally spaced cup holders. Each cup holder contains a ceramic magnet. A sensor located in the drip pan at the cup grabber detects the cup holders and thereby controls the movement of the conveyor and the position of the cup holders.
Page 34 Automated Beverage System A.B.S. Unit Major Subsystems Conveyor Cup Positioning Bracket 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.
Page 35 Automated Beverage System A.B.S. Unit Major Subsystems Ice Dispenser Ice Gate Description The ice gate is a pneumatically operated “gate” that is controlled by the Beverage Interface Board. The time the gate is open is very precise and determines the portion of ice dispensed.
Page 36 Automated Beverage System A.B.S. Unit Major Subsystems Ice Dispenser Auto-Agitate Ice from the bin is used for the coldplate. If the A.B.S. unit is idle for a period (pro- grammed during setup), the agitator will agi- tate for a preset period to maintain ice on the coldplate.
Page 37 Automated Beverage System A.B.S. Unit Major Subsystems Ice Dispenser 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”. ©...
Page 38 Automated Beverage System A.B.S. Unit Major Subsystems Ice Dispenser 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.
Page 39 Automated Beverage System A.B.S. Unit Major Subsystems Beverage Dispenser Valve Description The dispensing valve is located behind the touch panel and is made up of five blocks, each containing two solenoids, two flow con- trols, and two shutoffs. The blocks are per- manently manifolded together to supply a single outlet nozzle.
Page 40 Automated Beverage System A.B.S. Unit Major Subsystems Pre-Chiller Optional Pre-Chiller An optional pre-chiller must be installed if carbonated water and plain water are not chilled in a backroom package. © 2004 -2018 The Coca-Cola Company, Cornelius and McDonald’s Corporation. All Rights Reserved.
Page 41 Automated Beverage System Daily Start-Up Procedures Fill Ice Bin Preventing a Freeze Up To prevent freeze up, make sure the area where the unit is located is kept above freezing tem- peratures. Recovery from a Freeze Up In the event of a freeze up, turn off power and supply lines to the unit. Allow the machine to defrost (one hour minimum).
Page 42 Automated Beverage System Daily Start-Up Procedures Filling Cup Tubes Rotating The Cup Turret Place the unit in the manual mode – press the Cup Size button corresponding to the cup tube you wish to fill. The turret will rotate until the correct turret face is forward, allow- ing easy filling of the cup tube.
Page 43 Automated Beverage System Closing/Sanitation Procedures CAUTION: Do not use sharp objects, metal devices or abrasives on the ice hopper, top cover, ice chute or agitator disc, repairable damage may result. Do NOT use solvent or other cleaning agents as they may attack the plastic material. CAUTION: The ABS equipment or any of its components may not be cleaned using water jet cleaning equip- ment.
Page 44 Automated Beverage System Closing/Sanitation Procedures Clean Drip Tray & Exterior Surfaces Clean drip tray and all exterior surfaces with warm soapy solution and rinse with clean potable water. Pour warm (NOT HOT) water down the drip tray drain to flush drain line. Inspect water deflector after cleaning to check for proper installation.
Page 45 Automated Beverage System Closing/Sanitation Procedures Clean Nozzle & 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.
Page 46 Automated Beverage System Daily Cleaning/Sanitation Procedures Daily 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.
Page 47 Automated Beverage System Monthly Cleaning/Sanitation Procedures Monthly Cleaning/Sanitation of the Ice Bin CAUTION: Do not use sharp objects, metal devices or abrasives on the ice hopper, top cover, ice chute or agitator disc, or irreparable damage may result. Do NOT use solvent or other cleaning agents as they may attack the plastic material.
Page 48 Automated Beverage System Quarterly Cleaning/Sanitation Procedures Quarterly Sanitation of Post-Mix Syrup System IMPORTANT: Only qualified service personnel should perform the sanitizing procedure on the post-mix syrup systems. The post-mix syrup systems should be sanitized every 90 days using a non-scented household liquid bleach containing a 5.25% sodium hypochlorite concentration.
Page 49 Automated Beverage System Quarterly Cleaning/Sanitation Procedures Quarterly Cleaning/Sanitation Procedures 6. Flush 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 syrup is expelled and water fills the tubing.
Page 50 Automated Beverage System Quarterly Cleaning/Sanitation Procedures Step 3: Sanitize the Syrup Systems 14. Using a clean syrup tank (syrup tank system) or a five gallon container (bag-in-box sys- tem), prepare sanitizing solution using 70 F (21 C) to 100 F (38 C) potable water and 5 oz.(15 ml) of non-scented household liquid bleach that contains a 5.25% sodium hypo- chlorite concentration to one gallon of potable water.
Page 51 Automated Beverage System Quarterly Cleaning/Sanitation Procedures B. Place the ABS unit in the TEST/VALVE TEST mode and press each flavor button until all the sanitizer is expelled and water fills the tubing. Activate the dispensing valve for one minute to purge all the sanitizing solution out of the syrup system and the dispensing valve.
Page 52 Automated Beverage System 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 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 Automated Beverage System 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. © 2004-2018 The Coca-Cola Company, Cornelius and McDonald’s Corporation. All Rights Reserved.
Page 54 Automated Beverage System Troubleshooting Alarm & Warning Messages When an alarm occurs, press the Silence/Alarm button to silence the alarm. Read the display to determine the problem so that the appropriate corrective action can be taken. LEFT and RIGHT arrow are used to scroll the alarm list and the number of unresolved warn- ings and alarms are displayed with direction cues to scroll.
Page 55 Automated Beverage System Troubleshooting Problem Probable Cause Corrective Action A. Short circuit in wiring Call for service. Blown fuse or circuit breaker B. Defective agitator motor. Call for service A. No power or CO A. Plug in unit. Gate does not open. Agitator does Replace CO not turn.
Page 56 Automated Beverage System Troubleshooting Problem Probable Cause Corrective Action A. Ice bin empty. A. Fill ice bin. B. Defective gate cylinder. B. Call for service. C. CO2 supply disconnected or C. Reconnect CO depleted. Replace CO cylinder. Not enough ice in the cup. Call for refill (bulk) Call for service D.
Page 58 Automated Beverage System System Diagrams Wiring Diagram 230V (Before 10/15/08 and after 03/20/18) © 2004 -2018 The Coca-Cola Company, Cornelius and McDonald’s Corporation. All Rights Reserved.

McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM Operator's Manual

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