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McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM - User Manual

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OPERATOR’S MANUAL
This equipment chapter is to be inserted in
the Beverage Systems section of the
Equipment Manual.
AUTOMATED BEVERAGE SYSTEM
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
Printed In
The United States of America
This manual is for the exclusive use of licensees and employees of McDonald’s Systems, Inc.
MANUFACTURED
EXCLUSIVELY FOR
McDONALD’S
®
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 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

Table of Contents

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Summary

Safety Instructions Overview

Safety Overview

Overview of safety instructions and warning labels on the unit.

Recognize Safety Alerts

Understanding the safety alert symbol and its meaning.

Types of Safety Alerts

Explanation of DANGER, WARNING, and CAUTION alerts.

Safety Tips

Recommendations for safe operation and maintenance.

Operational Safety and Warnings

Qualified Service Personnel

Requirements for individuals servicing the unit.

Safety Precautions

General safety measures for operating the unit.

Shipping and Storage

Guidelines for safely shipping and storing the unit.

CO2 (Carbon Dioxide) Warning

Hazards and precautions related to CO2 gas.

Further Safety Warnings

Water and CO2 Safety

Warnings regarding water and CO2 depressurization.

Electrical Grounding Safety

Importance of proper grounding for electrical safety.

Unit Operation Safety Guidelines

CO2 and Pressure Safety

Safe handling of CO2 pressure and leaks.

Noise Level and Measurement

Information on unit noise levels and measurement.

Leveling and Temperature Limits

Unit leveling requirements and operating temperature range.

Introduction to the Automated Beverage System

ABS System Description

Description of the ABS for drive-thru applications.

ABS Modes of Operation

Overview of Automatic, Semiautomatic, and Manual modes.

Illustrated Parts List: Unit Access

Assembled Unit Diagram

Diagram showing major components of the assembled unit.

Illustrated Parts List: Conveyor Assembly

Conveyor;Cup Rest Assembly Diagram

Diagram of the conveyor and cup rest components.

Illustrated Parts List: Ice Chute Assembly

Ice Chute Assembly Components Diagram

Diagram of the ice chute components.

Illustrated Parts List: Cup Tube Assembly

Cup Tube Components Diagram

Diagram of various cup tube components.

Illustrated Parts List: Agitator Assembly

Ice Bin Components Diagram

Diagram of the ice bin and agitator components.

Illustrated Parts List: Nozzle Assembly

Nozzle Assembly Components Diagram

Diagram of the nozzle assembly components.

Fully Automatic Operation

Operational Modes Overview

Lists the three modes: Automatic, Semi-Automatic, and Manual.

Location and Display Diagram

Diagram showing conveyor positions and drink indicators.

Automatic Operation Details

P.O.S. Order Entry

Process of entering orders via the P.O.S. system.

Special Ice Drink Handling

Handling of special ice requests through P.O.S.

P.O.S. to Computer Signal

Order transmission from P.O.S. to store computer and ABS.

Automatic Operation Steps

Cup Turret Rotation

The cup turret moves to the extract position.

Cup Grabber Cycle

The cup grabber lifts, closes, and opens.

Automatic Operation Process

Conveyor Cup Movement

Conveyor moves cup to the ice chute.

Ice Dispensing

Ice gate opens to dispense ice.

Automatic Operation Beverage Dispensing

Cup to Dispensing Nozzle

Cup moves to nozzle for beverage fill.

Beverage Dispensing Process

Computer sends order; ABS dispenses drink.

Automatic Operation Serve Point

Cup Movement to Serve Point

Cup moves to serve position "D".

Crew Member Serves Drink

Crew member caps and serves the drink.

Semi-Automatic Operation

Selecting Cup Size

Select the desired cup size.

Selecting Flavor

Select the desired flavor.

Specifying Ice Requirements

Select EXTRA ICE or NO ICE if needed.

Semi-Automatic Operation Entry

Confirming Order and Dispensing

Press ENTER to dispense the drink.

ABS Float Dispensing

Dispensing drinks without ice for "FLOAT" drinks.

Ordering a Float Drink

Steps to order a float drink.

Manual Operation Mode

Entering Manual Mode

Procedure to enter manual mode.

Conveyor Removal

Steps to remove the conveyor for manual operation.

Cup Turret Removal Warning

Warning about manually removing cups from turret.

Manual Operation Dispensing

Dispensing Ice Manually

Holding cup under ice chute and pressing EXTRA ICE.

Troubleshooting Ice Dispensing

Troubleshooting for ice not dispensing.

Dispensing Beverage Manually

Holding cup under nozzle to dispense beverage.

Manual Operation Return to Auto

Returning to Normal Operation

Reinstalling the conveyor to return to normal operation.

Clearing P.O.S. Order Buffer

Clearing the P.O.S. buffer in manual mode.

Returning to Automatic Mode

Automatic Mode Return Procedure

Procedure to return the unit to automatic mode.

ABS Unit Major Subsystems Overview

List of ABS Components

List of major components of the ABS unit.

ABS Control Panel and Display

Control Panel Button Functions

Explanation of buttons on the touch panel.

ABS Display Message Guide

Explanation of the ABS display messages.

ABS Touch Panel and Display Details

Touch Panel Button Descriptions

Detailed description of each touch panel button.

Display Functionality

How the display guides the user and shows status.

ABS Drink Position Display

Drink Position Display Explanation

How the display shows drink pickup positions and details.

ABS Drink Indicators

Special Drink Indicator

Indication of drinks dispensed from touch panel.

Extra Ice Indicator

Indication for drinks with special ice requirements.

Float Drink Indicator

Indication for drinks prepared as a "FLOAT".

ABS Turret, Extractor, and Conveyor

Cup Turret Components Diagram

Diagram of cup turret components.

Cup Conveyor Components Diagram

Diagram of cup conveyor components.

ABS Conveyor Details

Cup Tube Configuration Options

How cup tubes are configured for different sizes.

Rotating Cup Turret for Installation

Rotating the turret for easy cup tube filling.

Alternative Cup Tube Configurations

Options for configuring four or five cup sizes.

ABS Conveyor Operation

Cup Grabber Assembly Components

Components of the cup grabber.

Cup Grabber Operational Cycle

Steps involved in the cup grabber's operation.

Managing Cup Jam Errors

Handling of a "CUP JAM" error message.

ABS Conveyor Components

Conveyor System Description

Description of the conveyor and its sensors.

Cup Rest Installation Procedure

Proper installation of the cup rest.

Water Deflector Installation Check

Ensuring the water deflector is installed correctly.

ABS Conveyor Positioning

Cup Positioning Bracket Function

Function of the cup positioning bracket.

Cup Position A Sensor

Function of the sensor for cup position "A".

Conveyor Reinstallation Steps

Steps for reinstalling the conveyor.

ABS Ice Dispenser Operation

Ice Gate Mechanism

Description of the pneumatically operated ice gate.

Ice Dispensing Cycle Steps

Steps of the ice dispensing process.

Low Ice Warning Alarm

Warning for low ice levels in the bin.

ABS Ice Dispenser Functions

Auto-Agitate Functionality

How the agitator maintains ice on the coldplate.

Ice Chute Access and Function

Function and access for the ice chute.

Ice Chute Removal and Replacement

Steps for removing and replacing the ice chute.

ABS Ice Chute Service

Manual Ice Gate Switch Warning

Warning to shut off the manual ice gate switch.

Sliding Ice Gate Out

Procedure for sliding the ice gate out.

Using Ice Chute Release Mechanism

Using the release mechanism to turn the chute.

ABS Ice Chute Reinstallation

Rotating and Pulling Ice Chute Down

Steps for rotating and pulling the ice chute.

Returning Unit to Normal Operation

Returning the ABS unit to normal operation after service.

ABS Beverage Dispenser

Dispensing Valve Description

Description of the dispensing valve and its components.

Beverage Dispensing Process Steps

How the valve dispenses syrup and water.

ABS Optional Pre-Chiller

Pre-Chiller Installation Requirement

When an optional pre-chiller is required.

Daily Start-Up Procedures

Preventing and Recovering from Freeze-Up

Ensuring the unit area is above freezing temperatures.

Filling the Ice Bin

Instructions for filling the ice bin.

Daily Start-Up: Filling Cup Tubes

Rotating Turret for Cup Tube Filling

Rotating the turret for easy cup tube filling.

Cup Tube Filling Process

Steps to fill the cup tubes and cover them.

Closing and Sanitation Procedures

Cleaning Cautions and Tasks

Warnings against improper cleaning methods.

Removing Conveyor and Cup Rest

Steps to remove and clean conveyor and cup rest.

Closing;Sanitation: Surface Cleaning

Cleaning Drip Tray and Exterior

Cleaning drip tray and external surfaces.

Reinstalling Cup Rest and Conveyor

Steps to reinstall the cup rest and conveyor.

Closing;Sanitation: Nozzle and Unit Wipe

Cleaning Nozzle and Diffuser

Steps to clean the nozzle and diffuser.

Wiping Down the ABS Unit

Wiping down the unit exterior with sanitizing solution.

Daily Cleaning: Sensor Maintenance

Cleaning Conveyor Thru-Beam Sensor

Cleaning the conveyor thru-beam sensor.

Monthly Cleaning;Sanitation: Ice Bin

Ice Bin Cleaning Cautions and Solutions

Warnings and preparation of cleaning solutions.

Ice Bin Cleaning Procedure

Detailed steps for cleaning the ice bin.

Quarterly Cleaning: Syrup System Prep

Quarterly Syrup System Sanitation Overview

Overview of quarterly syrup system sanitation.

Syrup System Preparation Steps

Steps to disconnect supplies and prepare detergent.

Quarterly Cleaning: Syrup System Flush

Flushing Syrup System with Detergent

Flushing the syrup system with detergent.

Flushing Syrup System with Water

Flushing the system with water after detergent.

Quarterly Cleaning: Syrup System Sanitize

Sanitizing the Syrup Systems

Preparing and applying sanitizing solution.

Flushing Sanitizer from Syrup Systems

Flushing the system with water after sanitizing.

Quarterly Cleaning: Restore Operation

Purging Water from Syrup Systems

Purging water to restore unit operation.

Troubleshooting Overview

Service Personnel and Contact

Importance of qualified personnel and service contact.

Troubleshooting Chart Reference

Reference to the troubleshooting chart.

Troubleshooting Common Issues

Electrical and Gate Problems

Troubleshooting blown fuses, gates, and agitators.

Dispensing and Beverage Quality Issues

Issues with ice, beverage dispensing, sweetness, and temperature.

Troubleshooting Alarm Messages

Understanding Alarm Messages

Explanation of alarm messages and corrective actions.

Common Error Message Handling

Handling of specific errors like CUP OUT, SYRUP OUT, JAM.

Troubleshooting Specific Problems

Insufficient Ice or No Ice Dispensing

Causes and solutions for ice dispensing issues.

Foamy Drinks and Pouring Issues

Addressing foamy drinks and pouring problems.

System Diagrams: 115 V Wiring

115 V Wiring Diagram

Electrical wiring diagram for 115V units.

115 V Wiring Diagram Details

115 V Diagram Component Labels

Labels and connections in the 115V wiring diagram.

System Diagrams: 230 V Wiring

230 V Wiring Diagram

Electrical wiring diagram for 230V units.

System Diagrams: Air Compressor

Air Compressor System Diagram

Diagram of the air compressor system.

McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM Specifications

General IconGeneral
BrandMcDonald's
ModelCORNELIUS AUTOMATED BEVERAGE SYSTEM
CategoryBeverage Dispenser
LanguageEnglish