Cornelius ABS 2.0 Installation Manual
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Cornelius ABS 2.0 Installation Manual

Cornelius ABS 2.0 Installation Manual

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ABS 2.0
I
M
NSTALLATION
ANUAL
Release Date: July 25, 2019
Publication Number: 621058590INS
Revision Date: November 21, 2019
Revision: B
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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  • Page 1 ABS 2.0 NSTALLATION ANUAL Release Date: July 25, 2019 Publication Number: 621058590INS Revision Date: November 21, 2019 Revision: B Visit the Cornelius web site at www.cornelius.com for all your Literature needs.
  • Page 2 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...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Safety Instructions ............. . .1 Read and Follow ALL Safety Instructions .
  • Page 4 Moving Through the Menu ..........25 Entering The Technician Screen .

  • Page 5: Safety Instructions

    ABS 2.0 Installation Manual SAFETY INSTRUCTIONS ALL S EAD AND OLLOW AFETY NSTRUCTIONS Safety Overview ALL SAFETY INSTRUCTIONS • ead and follow in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). OSHA • ead and understand...

  • Page 6: Qualified Service Personnel

    ABS 2.0 Installation Manual NOTE: T MUST NOT he dispenser is not designed for a wash-down environment and be placed in an area where a water jet could be used. UALIFIED ERVICE ERSONNEL WARNING: nly trained and certified electrical, plumbing and refrigeration technicians are to service this unit.

  • Page 7: Sound Level

    ABS 2.0 Installation Manual OUND EVEL CAUTION: -weighted sound pressure level has been determined to be 91 d , uncertainty 3.16 d . The -weighted sound power level has been determined to be 77.7 d , uncertainty 3.16 d OCATION CAUTION: ppliance is not suitable for installation in an area where a water jet could be used.

  • Page 8: Checklist

    ABS 2.0 Installation Manual CHECKLIST HECK TEMS OMPLETED This check list is intended to permit you to be sure that all aspects of the installation have been completed. Please use this check list -- Don’t rely on memory. For experienced installers, this check list makes an easy guide and reminder of the steps to follow.

  • Page 9: Installation Kit

    ABS 2.0 Installation Manual INSTALLATION KIT The following installation kit contains the components required to install the ABS 2.0. This description is designed to assist you in identifying the components and checking the inventory. Table 1. List of component in installation kit Sl.

  • Page 10: General Introduction

    When a beverage is ordered from the P.O.S. register, the ABS 2.0 automatically drops a cup, fills it with ice and dispenses the correct amount and type of any syrup-based beverage. The finished drink is then moved by the Carousel to the pick-up sta- tion and the drink description is displayed on the panel.

  • Page 11: Features

    629097799 ICEMAKER ADAPTER ABS 2.0 HOSHIZAKI 629097800 PRE - CHILLER 120V /60Hz 560000270 PRE - CHILLER 230V /50Hz 560002730 UPPORTED AKER Table 5. List of ice maker compatible with ABS 2.0 SL NO. BRAND MODEL MANITOWOC IB0620C-161 MANITOWOC IB0820C-161 MANITOWOC...

  • Page 12: Unit Drawing

    ABS 2.0 Installation Manual UNIT DRAWING Figure 1. Dimension units in [mm]. Publication Number: 621058590INS - 8 - © 2019, Cornelius Inc.

  • Page 13: Installation Prerequisites

    Inspect the unit for damage or irregularities upon delivery. If any damage is found Immediately report problems to the delivering carrier and file a claim with that carrier. NOTE: Cornelius is not responsible for damaged freight. If damage is found, you must save all packaging material and contact the freight carrier.

  • Page 14: Installation Requirements

    ABS 2.0 Installation Manual INSTALLATION REQUIREMENTS OOLS EQUIRED 1. Phillips screwdriver. 2. Pliers. 3. Tube cutters. 4. Oetiker crimper. 5. Ratio Cups. LECTRICAL EQUIREMENTS Refer to the nameplate to determine the power requirements before connecting electrical power to the unit. All of...

  • Page 15: Environmental Requirements

    Figure 2. ABS Clearance Requirement 3. Clearance above top of the ABS 2.0 unit must be open above the unit and the front of the unit stand must be open to the room. These clearances be provided to allow for proper air flow through the Pre-Cooler refrigera- tion system and to allow access to the ice bin for refilling.

  • Page 16: Installation

    ABS 2.0 Installation Manual INSTALLATION WARNING: isconnect power to the unit before servicing. ollow all lock out/tag out procedures established by the user. erify all power is off to the unit before performing any work. ailure to comply could result in serious injury, death or damage to the equipment.

  • Page 17: Step 1 - Installing Legs

    Place ABS 2.0 unit in it’s final operating location allowing clearance as specified previously. Figure 2. ABS Clearance Requirement on Page 11 Once the ABS 2.0 unit is in place, use a 2i level to level it using the leveling legs. The unit must be level side to side and front to rear.

  • Page 18: Step 2 - Power And Communication Connection

    If the communications cable has not been previously routed from POS system to the ABS 2.0 location, do that now. The Ethernet cable must be routed with the ABS 2.0 unit. Then connect the cable to the ABS 2.0 unit.

  • Page 19: Step 3 - Inlet Water/Syrup Connection

    Plain water). Figure 9. NOTE: When connecting the bundle syrup tubing to the syrup tubing from the ABS 2.0 unit, keep a record of what syrup is connected to what valve number. This record will be important when setting up the syrup mapping.

  • Page 20: Step 4 - Inlet Air Or Co2 Connection

    ABS 2.0 Installation Manual 4 – I NLET IR OR ONNECTION Table 10. Step Action Figure A. Remove the highlighted screws and take out the side access panel as shown in Figure 10. B. Route the compressed air tube through the hole from top of the unit.

  • Page 21: Step 5 - Unit Drain Assembly Connection

    ABS 2.0 Installation Manual 5 – U RAIN SSEMBLY ONNECTION Follow the installation procedure step by step to avoid damages to unit. Table 11. Step Action Figure Assemble the drain tubes to the unit drain shown in Figure 13. using the fittings, clamps, and insu- lation provided with the dispenser.

  • Page 22: Step 6 - Clean And Sanitize The Ice Bin And Ice Chute (Prior To Mounting The Ice Maker)

    ABS 2.0 Installation Manual 6 – C and S the I LEAN ANITIZE IN AND HUTE to M the I RIOR OUNTING AKER Table 12. Step Action Figure R e m ov e th e a g i ta t o r a s s e m b l y b y...
  • Page 23 ABS 2.0 Installation Manual Table 12. (Continued) Step Action Figure Remove the ice chute cover from the unit. Figure 19. Clean the inside of the ice chute and ice chute cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent.

  • Page 24: Step 7 - Pre-Cooler Installation (If Applicable)

    Nozzle Housing Screws Figure 22. A. Place the Pre-Cooler unit in the ABS 2.0 lower cabinet. If the electrical outlets are behind the ABS, plug the power cords in before the Pre-cooler is installed. When sliding the Pre-Cooler into the ABS 2.0 dis-...
  • Page 25 IMPORTANT: Before connecting the carbonated and the plain water tubing to the Pre-Cooler, the Pre- Cooler must be pulled out of the ABS 2.0 dispenser lower cabinet to the stops. The water tubing is the correct length and does not need to be cut to fit. The carbonated and the plain water tubing should properly coil when the Pre-Cooler is pushed back in place inside the ABS 2.0 dispenser cabinet.

  • Page 26: Step 8 - Preparing The Dispenser For Operation

    4. Install Pre-Cooler water fill hole cover and secure with two wing nuts. Very carefully, push the Pre-Cooler back inside the ABS 2.0 dispenser lower cabinet. Make sure the carbonated and plain water tubes are not kinked and not contacting the refrigeration compressor, compressor discharge tube, or the agitator motor.

  • Page 27: Step 9 - Set-Up And Programming

    ABS 2.0 Installation Manual 9 – S and P ROGRAMMING & E OUCH ANEL AYOUT XPLANATION Cup Size Water PW/CW Used to Dispense Ice Amount SCREEN 1 ENTER- SCREEN 2 Used to select o Refer Figure 38. confirm a selection.

  • Page 28: Display Explanation

    ABS 2.0 Installation Manual ISPLAY XPLANATION The screen displays represented in the following illustrations are samples of the screen data. Figure 28. 1. Software Version. 2. Page/Menu. 3. Order Queue. 4. Cup Refill. 5. Automatic/ Manual (Dark is Selected). -Currently in Automatic Mode 6.

  • Page 29: Moving Through The Menu

    ABS 2.0 Installation Manual OVING HROUGH THE As the following instructions will indicate, you can move through the menu items by selecting the ICON from the touch screen. The partial menu below shows the use of BACK button to move back to a previous menu and HOME button to move back to the starting screen.

  • Page 30: Entering The Technician Screen

    ABS 2.0 Installation Manual HOME USE OF BUTTON SELECT MENU 3 MENU 1 Figure 30. NTERING ECHNICIAN CREEN Table 14. Step Action Figure Select the Menu left top corner shown in Figure 31. Figure 31. Select the Technician Icon at left bottom corner shown Figure 32.

  • Page 31: Explanation Of Carousel Positions

    ABS 2.0 Installation Manual Table 14. (Continued) Step Action Figure Close the Clear the Enter the pass code (9876) then select green Keypad entry arrow as shown Figure 33. Figure 33. See the Technician Screen as shown Figure 34. Figure 34.

  • Page 32: Initial Set-Up, Programming

    NITIALIZING AND Turn ON the ABS 2.0 unit at the ABS 2.0 ON/OFF switch located on the left top corner of the unit front (see Figure 35.). During the power-up sequence the Self Test and Initializing messages will be displayed as each test is being made.

  • Page 33: Ip-Address Set Up

    ABS 2.0 Installation Manual IP-A DDRESS Table 15. Step Action Figure From the Technician Screen Select Unit set up icon as shown Figure 38. Refer Table 14. for entering the Technician Screen Figure 38. Select the NP6 Server Setup icon form unit set up screen as shown Figure 39.

  • Page 34: Initial Set- Up Adjustments

    ABS 2.0 Installation Manual NITIAL DJUSTMENTS Important Start-up Information NOTE: All CO (air), syrup and water products must be connected and operational before the Start-Up sequence can be started. The cup holders must be in place and filled with cups. The bin must be full of ice.
  • Page 35 ABS 2.0 Installation Manual Table 16. (Continued) Step Action Figure Fill Cup’s in the cup holder. Spin Turret by hand for all other size. Ensure the cup size with holder cup size mark see Figure 44. C. Load from top only.

  • Page 36: Adjustments

    ABS 2.0 Installation Manual DJUSTMENTS ETTING APPING Table 17 Step Action Figure Select Map Cup Type to Tubes button from Unit Set up Menu as shown in Figure 46. Figure 46. Select the cup position from right side as shown Figure 47.

  • Page 37: Syrup Mapping (Brand)

    ABS 2.0 Installation Manual YRUP APPING BRAND Syrup Map The table below, shows all the brand names that are resident in the ABS 2.0 system. The shaded area is the default brands. Table 18. DEFAULT SETTINGS POS PROGRAMMING DATA VALVE...

  • Page 38: Accessing Brand Mapping

    Figure 52. Syrup Map Explanation 1 Drink List Create a drink list showing the exact position of each drink in the ABS 2.0 system and hand over the list to GM or keep at the unit (Behind screen).Refer Table 18. on Page 33...

  • Page 39: Mapping - Second Step

    ABS 2.0 Installation Manual APPING ECOND Table 20. Step Action Figure From unit setup Menu select the Map Brands to Valves as shown in Figure 53. Figure 53. Brand mapping menu as shown in Figure 54. Figure 54. Select the Valve’s as shown in Figure 55.

  • Page 40: Drink List

    ABS 2.0 Installation Manual Table 20. (Continued) Step Action Figure Select the brand to assign the valve by scroll- ing through brand’s using the up/down arrow as shown in Figure 56. Figure 56. Save the Mapping and back to home or previ- ous menu Figure 57.

  • Page 41: Valve Purge

    ABS 2.0 Installation Manual ALVE URGE The Table 22. below shows water and syrup valve purging procedure. Table 22. Step Action Figure Log in to the technician screen and select UNIT SETUP shown in Figure 58. Figure 58. Select Water Valve Purging from screen as shown Figure 59.
  • Page 42 ABS 2.0 Installation Manual Table 22. (Continued) Step Action Figure Syrup Valve Purging menu open as shown in Figure 62. Figure 62. While in this mode, press each syrup brand button, SODA and WATER until all air is purged from the tubing.

  • Page 43: Set Flow Rate And Valve Ratio

    ABS 2.0 Installation Manual ATE AND ALVE ATIO NOTE: Cold plate should have ice on it and should be cold. Remove the Carousel assembly to allow easy access to the area under the valve for the ratio cup. Table 23.

  • Page 44: Adjusting Water Flow Rate

    DJUSTING ATER Overview: The ABS 2.0 uses 2 MFV water valves for both carbonated water (CW1 & CW2) and plain water (PW1 & PW2). Each valve module has a high-flow orifice and a low-flow orifice. The high-flow orifice provides approximately 75% and the low-flow orifice provides approximately 25% of the total flow-rate. During a beverage dispense, both valves are activated and together provide the total water flow-rate required.

  • Page 45: Set Overall Water Valve

    ALVE Important: This is the step that adjusts the pour times of all beverages dispensed from the ABS 2.0. If this step is not completed, then drinks will either over or under-pour depending on the flow-rate adjustment of the valves Table 24.

  • Page 46: Troubleshooting For Water Valve

    ABS 2.0 Installation Manual ROUBLESHOOTING FOR ATER ALVE • If drinks overfill, this means the dispense times are too high for the flow-rate that the valves have been adjusted to. Repeat the above steps and increase volume entered. This will shorten the dispense time prevent overfilling.

  • Page 47: Follow The Procedure Below

    ABS 2.0 Installation Manual U.S.A. F OLLOW THE ROCEDURE ELOW 1. Hold the ratio cup water compartment below the valve and select the Plain Water button if adjusting a non- carbonated drink or the carbonated water button if adjusting a carbonated water drink.

  • Page 48: Adjust Ice Portion

    ABS 2.0 Installation Manual DJUST ORTION Install the Carousel assembly before beginning the next procedure. Place the measuring cup under the ice. Table 26. Step Action Figure Place the measuring cup under the ice dis- penser.Select the “Ice Dispense Calibration”...

  • Page 49: Top-Off Explanation

    ABS 2.0 Installation Manual XPLANATION Drink brands that tend to pour with excessive foam have been adjusted so 70% of the drink pours and then after a delay the remainder of the drink pours. DJUSTING THE Table 27. Step Action Figure Select the “Dispense Time Setup”...

  • Page 50: Brand Flush Setting

    ABS 2.0 Installation Manual RAND LUSH ETTING Table 28. Step Action Figure From the Unit setup menu select Brand Attri- bute Edit Button. as shown in Figure 78. Figure 78. A. Select the brand or water type. B. select YES green button for flush before drink or select NO red button for without flush drink.

  • Page 51: Saving The Set-Up

    In the MANUAL mode, POS data is updated and ALARM messages are displayed. In MANUAL mode the highlight flashes to alert operator that the ABS 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.

  • Page 52: Automatic Mode Operation

    UTOMATIC PERATION In automatic mode the beverage dispense automatically from the input of POS system. By default ABS 2.0 System is setup to Automatic operation mode. If alarm conditions are present (but previously acknowledged) the ABS 2.0 status will indicate Warning. While the Warning status is present.

  • Page 53: Semi-Automatic Drink Order Entry

    ABS 2.0 Installation Manual AUTOMATIC RINK RDER NTRY Manual order entry can be made without entering the drink at the POS. This is normally done to correct an error in entry, to pour a replacement drink or to accommodate a customer special request.

  • Page 54: Alarm And Warning Messages

    ABS 2.0 Installation Manual LARM AND ARNING ESSAGES To view warnings, follow the steps. Table 30 Step Action Figure From the starting page select the Menu page Icon as shown in Figure 87. Figure 87. From the menu page select “Alarm Logging”...

  • Page 55: Schematics

    ABS 2.0 Installation Manual SCHEMATICS IRING IAGRAM A C TL B CTL DOOR LOCK PKR CTL TURRET SENSOR W HT O RG Y EL RE D RE D CO2 OUT STILL OU T LAST CUP CHUTE FIRST CUP SYRUP OUT CARB OUT...

  • Page 56: B Ctla C Tl

    ABS 2.0 Installation Manual A C TL B CTL DOOR LOCK PKR CTL TURRET SENSOR W HT O RG Y EL RE D RE D STILL OU T CO2 OUT CHUTE LAST CUP FIRST CUP SYRUP OUT CARB OUT LOW ICE...

  • Page 57: Plumbing Diagram (Air/Co2)

    ABS 2.0 Installation Manual PLUMBING DIAGRAM (AIR/CO AIR/CO2 PICKER POSITIONS PRESSURE EXHAUST EXHAUST FILTER & REGULATOR UNIT 560000391 PRESSURE PRESSURE EXHAUST MIDDLE: .358 Mpa (52PSI) EXHAUST PRESSURE PRESSURE DOWN: 1A EXHAUST 1B PRESSURE OPEN: 1A PRESSURE 1B EXHAUST CLOSE: Ø0.419mm (Ø...

  • Page 58: Troubleshooting

    ABS 2.0 Installation Manual TROUBLESHOOTING ECHANICAL SSUES Table 31 Message Explanation Correction Remove all cups from the Carousel Cup(s) is jammed in the Carousel at the cup holders at the Extract Position cup extraction position and the Carou- before pressing the ENTER button.

  • Page 59: Beverage / Ice Related Issues

    ABS 2.0 Installation Manual EVERAGE CE RELATED SSUES Table 32 Message Explanation Correction A. Ice Chute not installed correctly. Reinstall Ice Chute. B. Bad solenoid valve. Call for service. C. Plugged orifice. NO ICE DISPENSE Call for service. D. No / Low CO Call for service.

  • Page 60: Pos Related Issues

    Make sure that the order in which the brands and size are the same in brand ABS UNIT IS Setup and size Setup in the Drink dispenser as it is on the ABS 2.0 System. DISPENSING THE Coca-Cola will provide the brand Position Guide for POS programming.
  • Page 61 ABS 2.0 Installation Manual © 2019, Cornelius Inc. - 57 - Publication Number: 621058590INS...

  • Page 62: Tear-Out Reference Chart - Brand Line-Up

    RAND NOTE: This reference chart is to be used by the POS programmer to properly set the POS system to agree with the ABS 2.0 set-up. The syrup map must also be adjusted to agree with this form as described.
  • Page 63 ABS 2.0 Installation Manual © 2019, Cornelius Inc. - 59 - Publication Number: 621058590INS...
  • Page 64 ABS 2.0 Installation Manual Publication Number: 621058590INS - 60 - © 2019, Cornelius Inc.
  • Page 66 Cornelius Inc. www.cornelius.com...

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