Cornelius ABS Operator’s Manual
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
®
BY
IMI CORNELIUS
PHONE (800) 238-3600
www.cornelius.com
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
AUTOMATIC OPERATION..................................................................................................Page 12
SEMIAUTOMATIC OPERATION .........................................................................................Page 17
MANUAL OPERATION........................................................................................................Page 19
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.............................................................................................................Page50
WIRING & PNEUMATIC DIAGRAMS ......................................................................................Page 55
Part No. 569000181OPR
April 21, 2004
Revision: D
Revised: July 29, 2005
This manual is for the exclusive use of licensees and employees of McDonald’s Systems, Inc.
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
Printed In
The United States of America
Automated Beverage System
McDonald’s Automatic Beverage System
WARRANTY, DISCLAIMER OF WARRANTY AND LIMITATION OF REMEDY
Products covered by this Warranty include only Automatic beverage Dispenser (“ABS”) manufactures or sold by Cornelius after the date hereof (herein “Products”). THE TERM “PRODUCTS” DOES NOT INCLUDE, AND THIS WARRANTY IN NO EVENT EXTENDS TO,
ITEMS NOT MANUFACTURED OR SOLD BY CORNELIUS, SUCH AS ANY POS SYSTEMS (INCLUDING CABLE CONNECTING THE POS TO THE ABS) AND ANY
RECIRCULATING SYSTEM SUPPLYING CO2 WATER, WATER OR SYRUP TO THE
ABS.
WARRANTY
IMI Cornelius Inc., (Cornelius”) warrants to the original McDonald’s purchaser with respect
to each product purchased that:
1. For the lesser of (i) two (2) years from the date of installation or (ii) twenty seven (27) months from the date
of shipment by Cornelius, all parts comprising such Product (except Excluded Parts as defined below and
the refrigeration system of the precooler) are free from defects in materials;
2. For the lesser of five (5) years from the date of installation or sixty-three (63) months from the date of shipment by Cornelius (and subject to the service limitation set forth below), the parts (except Excluded Parts)
comprising the refrigeration system of the precooler of such Product, being only the compressor, evaporator,
condenser, and interconnecting tubing (but not access valves or any other part) are 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, government, or professional organizations standards to the extent expressly set forth in written product information disclosures in Cornelius
product literature and documentation;
Provided that the foregoing shall not apply to any warranty claim not made as promptly as possible and in any
event within thirty (30) days after the discovery thereof to the Cornelius Service Department at 101 Broadway
Street West, Osseo, MN, (800) 238-3600.
For the purposes of the foregoing warranties, “Excluded Parts” include all water filter cartridges, coin mechanisms, light bulbs, fuses, glass diaphragms, seals, o-rings, silicone or rubber parts, parts in contact with water or
the product dispensed and which become inoperative due to scale or chemical change, as well as normal maintenance items.
All service warranty claims above $400 require Cornelius authorization prior to repair/replacement. If service
occurs outside the standard Cornelius business hours, claim will be denied if part(s) are not returned and/or
returned are not found to be defective upon further inspection. See next paragraph.
It is not a defect, and thus these warranties do not apply to, repair, replacement or other service required by or
loss or damage resulting from (i) other that normal and proper use and service conditions with respect to such
Product, (ii) use of the product other that exclusively with soft drinks, soft drink syrup, or iced tea identified in
wring by Cornelius, (iii) improper voltage, (iv) inadequate wiring, (v) abuse, (vi) accident, (vii) alteration, (viii)
risk of transportation, (ix) misuse, (x) neglect, (xi) unauthorized repair, (xii) fire, flood or other acts of God, (xiii)
improper cleaning, or failure to follow installation, operating, or maintenance instructions, nor does these Warranties cover normally prescribed maintenance, cleaning, and adjustments.
IMI CORNELIUS
www.cornelius.com
2
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
Disclaimer of Warranty
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABLITY AND FITNESS FOR A PARTICULAR PURPOSE, ALL
OF WHICH OTHER WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED.
Remedy, Limitation of Remedy and Disclaimer of Liability
The remedy for any breach of this Warranty is limited to the repair or replacement or the defect part or the Product in which it is included, at the option of Cornelius. to the extent that, in the judgement of Cornelius, repair or
replacement should be performed through on-site service, such service is included in the Warranty for the lesser
of two (2) years from the date of installation or (ii) twenty seven (27) months from the date of shipment by Cornelius, and even then only to the extent of scheduled straight time labor to repair or replace the defective part and
travel time to destination ($40 per claim maximum). Such service is to be performed by a service agency authorized by Cornelius. Time and rate schedules for labor compensation will be published periodically by Cornelius.
Additional expenses including, but not limited to truck charges, overtime charges, material costs, are not the
responsibility of and will not be paid by Cornelius. Neither any part alleged to be defective and covered by this
warranty or the product in which it is included shall be returned to Cornelius without authorization from the Cornelius Service Department. The instructions for return will be given with any such authorization. All returned
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 Francisco, respectively. Cornelius will not accept collect shipments. Replaced products or parts become property of Cornelius. Any product or parts returned to Cornelius
under the terms of this Warranty must be accompanied by a Returned Goods Authorization Number.
THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY OBLIGATION OF CORNELIUS
AND THE SOLE REMEDIES FOR CORNELIUS’ LIABILITY OF ANY KIND (INCLUDING LIABILITY FOR NEGLIGENCE) WITH RESPECT TO THE PRODUCTS AND RELATED SERVICES
SHALL BE THE REMEDY SET FORTH HEREIN, OR IF NO SUCH REMEDY APPLIES, THEN TO
USE REASONABLE EFFORTS TO PROMPTLY CURE SUCH BREACH.
IN NO EVENT SHALL CORNELIUS’ LIABILITY OF ANY KIND INCLUDE ANY SPECIAL, INDIRECT, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE, EVEN IF CORNELIUS SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH POTENTIAL LOSS OR
DAMAGE.
CORNELIUS CUMULATIVE LIABILITY FOR DAMAGES UNDER OR IN RELATION TO A PRODUCT AND RELATED SERVICES FOR ANY CAUSE WHATSOEVER, AND REGARDLESS OF THE
FORM OF ACTION; WHETHER IN CONTRACT ON IN TORT INCLUDING NEGLIGENCE, SHALL
BE LIMITED TO THE COST OF SUCH PRODUCT.
No alteration or modification of the terms and conditions of this Warranty shall be valid unless expressly agreed
to in writing by Cornelius. Any different, additional, or conflicting terms or condition set forth in any order confirmation of other writing are expressly objected to by Cornelius and the terms of this Warranty shall exclusively
govern warranties and remedies with respect to the Products.
IMI CORNELIUS
www.cornelius.com
3
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
INTRODUCTION
The Automated Beverage System (A.B.S.) is
an automated cold beverage dispenser for
drive-thru applications. When a cold beverage
is ordered from the P.O.S. register, the A.B.S.
will automatically drop the cup, fill it with ice,
and dispense the correct amount and type of
any syrup-based cold beverage. The finished
drink is then moved by the conveyor to the
pick-up station and the drink description is
displayed on the panel.
The Automated Beverage System has three
modes of operation:
• Automatic Mode
In automatic mode, the customer places an
order at the drive-thru and the A.B.S.
automatically produces the order. If extra or
no ice drinks are ordered, they are entered
from the P.O.S. as a “grill order” and the
A.B.S.automatically produces the drink as
ordered.
• Semiautomatic Mode
While in automatic mode, the operator
presses the desired cup size button, the desired
flavor button and ENTER, then the drink is
dispensed. If extra ice or no ice is required,
the EXTRA ICE or NO ICE button is pressed
after the flavor button has been pressed before
ENTER, then the drink is dispensed.
• Manual Mode
A drink can also be dispensed in manual
mode. Remove the conveyor. Enter the manual 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.B.S. unit to normal operation.
SAFETY
To avoid possible fatal electrical shock or serious injury to the Operator, it is highly recommended that a G.F.I. (ground fault circuit
interrupter) be installed in the electrical power
circuits to the unit.
Always disconnect power before cleaning or
servicing the unit. Do not use metal scrapers,
sharp objects or abrasives on the ice storage
hopper, top cover and the agitator disk, as
damage may result.
Always disconnect CO2 or air pressure to the
unit before cleaning or servicing the grabber
arm or ice chute. A disconnect switch for the
ice gate is located on the control box behind
the cup lid holder panel.
Insure that the unit is in manual mode before
removing or replacing the conveyor assembly
to avoid pinching fingers in the drain area.
The dispenser is very top heavy. To prevent
serious injury, exercise caution when moving
or setting the dispenser in place.
© 2004 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
4
Automated Beverage System
Illustrated Parts List
A.B.S. Unit Access
TURRET
FLAVOR DISPLAY
CUP GRABBER
ON/OFF SWITCH
1
2
CONTROL PANEL
OPTIONAL PRECHILLER
3
4
Automated Beverage System —
Assembled Unit Diagram
Ref CCUSA MFG.
Number Number Number Description
1 .................... ................ 560000260.....Ventilation Grill
PRINTED ON RECYCLED PAPER
2 .................... ................ 560000245.....Access Hole Cover
10% Post-Consumer Content
3 .................... ................ 560000291.....Air Filter
40% Pre-Consumer Content
4 .................... ................ 560000289.....Front Panel (Built before Serial No. 56A0019AB102)
...................... ................ 560002774.....Front Panel (Serial No. 56A0019AB102 and after)
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
5
Automated Beverage System
Illustrated Parts List
Conveyor Assembly
1
THUMB SCREWS
2
3
4
5
CUP HOLDER
CUP POSTIONING BRACKET
POSITION “A” SENSOR
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
1 27921 ...... 560000320Conveyor Cover
1 ................ 27921........... 560000320 ...... Conveyor Cover
2 .............. 27922...................560000325 ..............Conveyor Assembly
2 ................ 27922........... 569000295 ...... Conveyor Assembly
3 .............. .............................560000315 ..............Cup Rest
3 ................ .....................560000315 ...... Cup Rest
4 .............. .............................560000306 ..............Drip Tray Assembly
4 ................ .....................560000306 ...... Drip Tray Assembly
5 ................ 20669........... 560002714 ...... Water Deflector
Conveyor/Cup Rest Assembly Diagram
6
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
Illustrated Parts List
Ice Chute Assembly
7
1
5
4
3
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
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 Components Diagram
2
6
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
7
Automated Beverage System
Illustrated Parts List
Cup Tube Assembly
2
2
1
2
1
3
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
1 ..............27916 ..........560000207 .......5” Cup Tube Cover (32 - 42 oz.)
2 ..............27915 ..........560000206 .......4” Cup 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 .......32 Oz. Cup Tube Assembly Kit
N/R ......... ....................569000159 .......21 Oz. Cup Tube Assembly Kit (Australian “Large” size, station 2)
N/R ......... ....................569030035 .......Medium Cup Tube Assembly Kit Station 5, (Australian ABS only)
8
Cup Tube Components Diagram
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
Illustrated Parts List
Agitator Assembly
2
4
3
1
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
1 ............... ............................15346 ...................... Agitator Assembly
1 .............. 15346................................Agitator Assembly
2 ............... ............................52887 ...................... Lid
2 .............. 52887................................Lid
3 ............... ............................53227 ...................... Disk
3 .............. 53227................................Disk
4 ............... ............................15087 ...................... Agitator Retainer
4 .............. 15087................................Agitator Retainer
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Ice Bin Components Diagram
9
Automated Beverage System
Illustrated Parts List
Nozzle Assembly
3
4
2
1
1
2A
2B
DIFFUSER BODY
DIFFUSER RING
5
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
.................. 161509 ................Complete Assembly
1................27940 560001545 .......... Nozzle
2................27939 560001544 .......... Diffuser
3................ 110677000 ..........O-Ring
6................ 325216000 ..........Nozzle Brush (Not Shown)
Nozzle Assembly Components Diagram
10
© 2004-2005 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Operational Modes
The A.B.S. has three modes of operation:
• Automatic (Normal Operation)
• Semi-Automatic (while in Auto)
•Manual
Automated Beverage System
Fully Automatic Operation
*Drink Position Display
Cup Extraction Position
Ice Fill Position
Beverage Fill Position
Conveyor Positions
*Drink Position Display - Showing Drink Locations in Conveyor
AN * IS DISPLAYED WHEN A
SPECIAL
DRINK IS DISPENSED FROM THE
A.B.S. PANEL INSTEAD OF THE
POS SYSTEM.
*
COKE
EXTRA ICE
A
B
C
D
SPECIALSPECIAL
EXTRA ICE
AB
EXTRA ICE
SPECIAL
COKE
EXTRA ICE
C
SPECIAL
EXTRA ICE
#
SPECIAL
EXTRA ICE
D
A # IS DISPLAYED
FOR ANY DRINK DISPENSED
WITH EXTRA ICE.
Location Diagram
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
11
Automated Beverage System
Automatic Operation
Order Entered On P.O.S.
With the unit in automatic 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 automatically 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.
12
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
Cup Turret Rotates
The cup turret rotates to move the proper size
cut to the extract position.
Automatic Operation
Cup Grabber Rises & Closes
The cup grabber is lifted by a pneumatic cylinder 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 would
be detected by the cup sensor.
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
13
Automated Beverage System
Automatic Operation
Conveyor Operates
Sensors check for a cup in position “A.” If the
sensor is clear, the conveyor rotates clockwise
to move the cup to the ice chute.
This is based on only one drink being ordered.
If a second drink 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 cylinder for the time needed to dispense the
selected ice portion. Correct operation is
insured by the ice gate full travel sensor.
14
The agitator continues to operate for the set
refill time to refill the ice chute.
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
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.
Automatic Operation
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 portion will be dispensed. After a delay, the balance of the drink will be dispensed.
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
15
Automated Beverage System
Automatic Operation
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.”
Crew Member Serves Drink
A crew member caps the drink while still on
the conveyor and serves it with the remainder
of the order.
16
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
Automated Beverage System
Semiautomatic Operation (Unit in Automatic)
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.
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.
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
17
Automated Beverage System
Semiautomatic Operation (Unit in Automatic)
When 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.
The word “FLOAT” will
appear when the float option
The word “FLOAT” will appear
when the float option is applied
is applied to the drink order.
to the drink order.
This button oper-
This button op
ates as the
erates as the
DOWN arrow key
DOWN arrow
in the manual
key in the manual
mode, and as the
mode, and as the
“FLOAT” key
“FLOAT” key
while the unit is
in automatic.
while the unit is
in automatic.
Any drink entered in this manner will display
an illuminated asterisk in the SPECIAL section of the Drink Position Display identifying
the semiautomatic drink selected at the A.B.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
18
© 2004-2005 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
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