Cornelius ABS 2.0 User manual

ABS 2.0
Service Manual
Release Date: December 16, 2019
Publication Number: 621058590SER
Revision Date: December 16, 2019
Revision: B
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi-
ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the per-
son(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warranty applicable to this Product and is sub-
ject to all of the restrictions and limitations contained in the 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
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per-
sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, oper-
ating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con-
tact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
This document contains the original instructions for the unit described.
CORNELIUS INC
101 Regency Drive
Glendale Heights, IL
Tel: + 1 800-238-3600
Printed in U.S.A.
RECYCLE
Correct Disposal of this Product
This marking indicates that this product should not be disposed with other household wastes throughout the EU.
To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle it respon-
sibly to promote the sustainable reuse of material resources. To return your used device, please use the return
and collection systems or contact the retailer where the product was purchased. They can take this product for
environmental safe recycling.

-I-
TABLE OF CONTENTS
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Read And Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types Of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Supported Ice-Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
E-Box Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Initializing and Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clear The Pos Order Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Semi-automatic Drink Order Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introduction to Abs 2.0 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Default Settings/Restoring Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Display Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Entering the Technician Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Carousel Assembly / Splash Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Carousel Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Splash Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nozzle Diffuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Multi-flavor Valve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Disassembly Of An MFV Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Reassembly of MFV Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ice Chute cover Removal / replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Water & Syrup Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Product to the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Set Flow Rate and Valve Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Adjusting Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Set Overall Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting for water valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjust the Syrup Ratio (Brand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
U.S.A. Follow The Procedure Below: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Australia Follow The Procedure Below: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

-II-
Syrup Mapping (Brand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Syrup Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brand Mapping Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mapping – First Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mapping – Second Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drink List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjustment Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Saving the Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cup Carousel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Description Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Index Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Last Cup Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Carousel Drive Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Carousel Belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Carousel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cup Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cup Positioning Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cup Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Empty Cup Tube Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement of Cup Grabber Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement of Cup Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cup Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cup Holder Default Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cup Holders Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Turret Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Turret Gear Box & Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Encoder Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Turret Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shaft Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Ice Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Ice Gate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ice Chute Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ice Chute Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ice Gate Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Dispensing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shut-off Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flow Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Picker Control and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

-III-
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Mechanical Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Beverage / Ice related Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
POS Related Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Plumbing Diagram (Air/CO2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

-IV-

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 1 - Publication Number: 621058590SER
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
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.
Recognition
DIFFERENT TYPES OFALERTS
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, 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
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Unit must be located in an area with nearest access to floor drain port, preferably under the foot print of
unit.
• DO NOT Let anyone operate the unit without proper training. This appliance is not intended for use by
children. Children should be supervised to ensure that they do not play with the appliance.
• The appliance is not to be used by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
• This unit must be installed and used as per the requirement in the specification section of this manual.
• If freezing occurs, move the unit to a location maintained at ambient called in specification section of this
manual.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
!

ABS 2.0 Service Manual
Publication Number: 621058590SER - 2 - © 2019, Cornelius Inc.
NOTE:The dispenser is not designed for a wash-down environment and MUST NOT be placed in an
area where a water jet could be used.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians are to 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.
SAFETY PRECAUTIONS
• This unit has been specifically designed to provide protection against personal injury. To ensure
continued protection observe the following:
• Access to the service area is restricted to persons having knowledge and practical experience of the
appliance, in particular as far as safety and hygiene are concerned.
!
WARNING:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user.
Verify all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment Damage.
CAUTION:
!
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
CAUTION:
!
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be
drained from the system. Afreezing ambient environment will cause residual sanitizing solution or water remaining
inside the unit to freeze resulting in damage to internal components.
!
WARNING:
It is the responsibility of the installer to ensure that the water supply to the dispensing equipment is provided with
protection back flow by an air gap as defined in ANSI A 112.1.2-1979; or an approved vacuum breaker or other
such method as proved effective by test and must comply with IEC 61770 and all federal, state and local codes.

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 3 - Publication Number: 621058590SER
GENERAL INFORMATION
SYSTEM OVERVIEW
The Automated Beverage System ABS 2.0 is an upgraded version of ABS. The ABS 2.0 is designed for drive-
through area installation or other restricted area that is accessible to authorized personnel only. 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 station
and the drink description is displayed on the touchscreen.
Operation of the ABS 2.0 is restricted to employees and service personnel that have been trained and certified in
the proper operation, service and maintenance of the equipment.
SPECIFICATION
Table 1.Product Specification
Unit Dimen-
sions
Length 911.86 mm [35.9 inch]
Width 901.70 mm [35.5 inch]
Height 1905 mm [75.0 inch]
Unit weight
Dry weight 267.62 kg [590 lbs] (Dry)
Operational weight
(With ice, water, etc.) 362.87 kg [800 lbs]
Cooling
method
Method of product
cooling Cold plate & on board chiller for condition “C”
Ice storage
capacity W/o bin extender 61.24 kg [135 lbs]
Electrical
Line voltage 621058590: 115 ± 10% VAC, 60 Hz, 1 Phase
621058773: 220-240 VAC, 50-60 Hz, 1 Phase
Current 3A
Connection method 115V/60Hz (North America): IEC-NEMA 5-15P
220-240V, 50-60Hz (Rest of World)
Water Supply pressure 0.55 ±0.10 MPa [90 ±15 psi] static
Supply method 12.7 mm [1/2 inch] ID tube (Python)
Syrup Supply pressure 0.44 ±0.14 MPa [65 ±20 psi] Optimal
Supply method 9.52 mm [3/8 inch] ID tube (Python)
Temperature
Water & Syrup Max 1.7°C (35°F) Water & 3.3°C (38°F) Syrup
Ambient Operating
Temperature 18°C (65°F) to 35°C (95°F)
Air and CO2
Supply pressure CO2/Compressed Air: 0.55 ±0.07 MPa
[90 ± 10 psi]
Supply method 9.52 mm [3/8 inch] ID tube
Clearance
Requirement
Top
No ice Maker:1905mm [75 inch] + 304.8 mm [12 inch]
refill area = 2209.8 mm [87 inch]
With ice Maker: 2501.9 mm [98.5 inch]
Back 25.4 mm [1 inch] clearance to wall (min)

Table 3.Accessories compatible with ABS 2.0
SL NO. Accessories Part No:
1. ICEMAKER ADAPTER KIT ABS 2.0 MANITOWOC/SCOTSMAN 629097799
ICEMAKER ADAPTER ABS 2.0 HOSHIZAKI 629097800
2. PRE - CHILLER 120V /60Hz 560000270
PRE - CHILLER 230V /50Hz 560002730
ABS 2.0 Service Manual
Publication Number: 621058590SER - 4 - © 2019, Cornelius Inc.
FEATURES
Table 2. Product features
Mounting type (leg/caster) 4 legs mounted
UI interface type and size Two 177.8 mm [7 inch] touch screen dis-
play
Number of Brands 8
Cup storage 6 cup dispenser
Lid Storage 8 lid compartment
Ice dispensing 1 portion controlled ice dispenser
Product dispensing Cornelius Multi Flavor Valve
Automatic cleaning Wand type cleaning nozzle Kit.
No of stage drinks 6
ACCESSORIES
SUPPORTED ICE-MAKER
Table 4. List of ice maker compatible with ABS 2.0
SL NO. BRAND MODEL
1MANITOWOC IB0620C-161
2MANITOWOC IB0820C-161
3MANITOWOC IB1020C-161
4MANITOWOC 1B0694YC-161
5MANITOWOC IB0894YC-161
6MANITOWOC IB1094YC-161
7SCOTSMAN EH222
8SCOTSMAN ECC1410
9HOSHIZAKI KMS-1122MLH
10 HOSHIZAKI KMS-1122MLJ

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 5 - Publication Number: 621058590SER
UNIT DRAWING
Figure 1.
Dimension Unit in [mm].

ABS 2.0 Service Manual
Publication Number: 621058590SER - 6 - © 2019, Cornelius Inc.
E-BOX CONFIGURATION
!
WARNING:
Disconnect power to the unit before accessing the E-box.
Figure 2.
[1] MCB.
[2] 12V DC/ 24V DC power supply.
A. 12V DC - for screen.
B. 24V DC - Power for all sensor.
[3] 30V DC Power supply for Valve bank.
[4] A. Turret motor capacitor.
B. Agitator motor capacitor.
C. Carousel motor capacitor.
[5] Circuit breakers as follows.
C. 4A - 12V DC.
D. 4A - 24V DC.
E. 3A - 30V DC.
[6] AC Power Inlet.
[5] 3A-30V
[5] 4A-24V
[5] 4A-12V
[2] 24V DC
[2] 12V DC
POWER SUPPLY POWER SUPPLY
[6] AC Power Inlet
[3] 30V DC Power Supply for Valve Bank.
[1]MCB
[4] Carousel motor capacitor
[4] Turret motor capacitor
[4] Agitator motor capacitor

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 7 - Publication Number: 621058590SER
INITIALIZING and SELF TEST
Turn ON the ABS 2.0 unit at the ABS 2.0 ON/OFF switch located on the left top corner of the stand. During the
power-up sequence the Self Test and Initializing messages will be displayed as each test is being made. When
the tests are complete the final message will be displayed.
Figure 3.
If the Initialing process ends with a “No COM System Ports Found” see message, it means that the communication
cable between the POS system and ABS system is not connected. If it is not convenient to connect the cable at this
time but you wish to proceed with the Set Up, Choose CLOSE WINDOW from screen to bypass the Failed
message.

ABS 2.0 Service Manual
Publication Number: 621058590SER - 8 - © 2019, Cornelius Inc.
MANUAL MODE OPERATION
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.
Figure 4.
In the manual mode select the Brand then Press and hold button to dispense Beverage as required.
as same as Press ICEbutton to dispense ice. There is no need of cup selection in manual mode.
NOTE: When Manual mode please remove the carousel for dispense drinks, See Carousel Assembly
Removal on page 14.

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 9 - Publication Number: 621058590SER
AUTOMATIC MODE OPERATION
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. the word AUTOMATIC will flash.
Figure 5.
CLEAR THE POS ORDER BUFFER
Table 5.
Step Action Figure
1Select Order Queue as shown Figure 6.
Figure 6.
2
A. Delete Undesired Orders or Delete All
B. If several orders stack up and are no longer
needed, it may be easier to delete all and
manually enter in what is missing
Figure 7.

ABS 2.0 Service Manual
Publication Number: 621058590SER - 10 - © 2019, Cornelius Inc.
SEMI-AUTOMATIC DRINK ORDER ENTRY
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.
NOTE: Steps 1, 2, 3, 4 below can be made in any order. If any selection in any step is incorrect it may be
reentered. “Order Entry” will be displayed on the second line of the display.
NOTE: Pressing the Clear button at any time will cancel the operation.
While in the Automatic mode:
1. Press a Cup button to select the size of drink desired. The display will indicate the selection made.
2. Press a BRAND button to select the brand desired. The display will indicate the selection made.
3. Press the No Ice or Extra Ice, or FLOAT button if either ice feature is desired, or a float drink is requested. Not
pressing these buttons will cause the normal ice portion to dispense. The display will indicate the selection
made. The No Ice, Extra Ice and light Ice buttons are toggle buttons, so, if an error is made simply press the
button again to cancel.
4. After the proper selections are made, press the Enter button to dispense the drink.
Once entered, the ABS system will determine how many drinks are ahead in the POS queue before the Semi--
Automatic drink order will be started.
Figure 8.

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 11 - Publication Number: 621058590SER
TOSERVICE
Introduction to ABS 2.0 Programming
Default Settings/Restoring Settings
The ABS 2.0 system is factory set to satisfy the majority of all installations. Do not make any adjustments until you are
sure the factory settings will not satisfy the store requirements. Touch Panel Layout & Explanation
Cup Size
Water PW/CW
Used to Dispense
ENTER- Used to select or
confirm a selection.
BRANDS
Menu
Automatic Mode
Manual mode
Order Queue
SCREEN 1 SCREEN 2
See Figure 10
Ice Amount
Figure 9.

ABS 2.0 Service Manual
Publication Number: 621058590SER - 12 - © 2019, Cornelius Inc.
DISPLAY EXPLANATION
The screen displays represented in the following illustrations are samples of the screen data.
Figure 10.
1. Software Version.
2. Page/Menu.
3. Order Queue.
4. Cup Refill.
5. Automatic/ Manual (Dark is Selected).
-Currently in Automatic Mode
6. Alarm, cleaning due or past due.
7. Order - Current example.
-L (Large), Regular (Ice type)
-Order (ABS 2.0 = Semi Auto or Order Number)
8. Finished Drinks 1-6, left to right, Coke is Position one.
9. Flush - CW has flushed the Nozzle.

ABS 2.0 Service Manual
© 2019, Cornelius Inc. - 13 - Publication Number: 621058590SER
ENTERING the TECHNICIAN SCREEN
Table 6.
Step Action Figure
1. 1. Select the Menu as shown in Figure 11.
Figure 11.
2. 3. Select the Technician Icon as shown
Figure 12.
Figure 12.
4. 5. Enter 9876, then green arrow as shown
Figure 13.
Close the
Keypad
Clear the
entry
Figure 13.
6. 7. See the Technician Screen as shown Figure
14.
Figure 14.

ABS 2.0 Service Manual
Publication Number: 621058590SER - 14 - © 2019, Cornelius Inc.
CAROUSEL ASSEMBLY / SPLASH PANEL REMOVAL
CAROUSEL ASSEMBLY REMOVAL
Table 7.
Step Action Figure
1Select manual button from start screen as shown
Figure 15.
Figure 15.
2Remove cover by loosening the 3 thumb screws and
lifting it upwards.
Figure 16.
3Remove the carousel by lifting it upwards.
NOTE:Avoid carrying carousel by cup holder.
Figure 17.
4Remove the grille by lifting it upwards.
NOTE:Note cup locater spring position.
Figure 18.