Cornelius Ribbon Manual

Installation and service manual
Postmix tower
Ribbon

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Installation and service manual (Original)
Document no. TD0000100
Postmix tower
Unit ID no. 221000414x
Ribbon
Version
Date of issue: 06/11/2017
Revision status: Index 0
Protection notices (in accordance with DIN ISO 16016:2002-5)
The reproduction, distribution and utilisation of this document as well as the communication of
its contents is prohibited, unless expressly permitted. Violations shall result in an obligation to
pay damages. All rights reserved with regard to filing for/registering patents, utility models or
design patents.
www.cornelius-emea.com Phone:[phone] / 79 3 – 0
Fax: [phone] / 77 4 – 38
Email: [e-mail]
Cornelius Deutschland GmbH
Carl-Leverkus-Str. 15
40764 Langenfeld
Germany

Table of contents
Installation and service manual: Postmix tower
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Cornelius Deutschland GmbH
Document no. TD0000100
Version: 06/11/2017, Index 0
Installation and service manual
Postmix tower
Table of contents
1 Safety ........................................................................................................................... 4
1.1 Intended use .................................................................................................................4
1.2 Improper use .................................................................................................................4
1.3 Staff............................................................................................................................... 4
1.4 Presentation of warnings............................................................................................... 4
1.5 Safety instructions......................................................................................................... 5
1.5.1 Safety information to prevent personal injury and equipment damage ......................... 5
1.5.2 Safety information for using electrical assemblies ........................................................ 5
2 Transport and packaging ........................................................................................... 7
2.1 Storage.......................................................................................................................... 7
2.2 Disposal ........................................................................................................................ 8
3 Description .................................................................................................................. 9
3.1 Assemblies and components ........................................................................................ 9
3.2 Functions within the dispensing system...................................................................... 11
3.3 Functions of the unit.................................................................................................... 11
3.4 Touchscreen/software................................................................................................. 12
3.5 Technical data............................................................................................................. 14
3.5.1 Tower .......................................................................................................................... 14
3.5.2 E-Box .......................................................................................................................... 15
3.5.3 Connections ................................................................................................................15
4 Preparing the unit ..................................................................................................... 17
4.1 Disconnecting the unit from power.............................................................................. 18
4.2 Moving the touchscreen into the service position ....................................................... 19
5 Installation/removal .................................................................................................. 20
5.1 Installation location...................................................................................................... 21
5.2 Preparing the installation location ............................................................................... 22
5.3 Installing the E-Box ..................................................................................................... 23
5.4 Installing the unit ......................................................................................................... 25
5.5 Installing the drain set ................................................................................................. 27
5.6 Removing the unit ....................................................................................................... 29
5.7 Removing the E-Box ................................................................................................... 30
5.8 Removing the drain set ............................................................................................... 31

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6 Maintenance .............................................................................................................. 32
6.1 Maintenance table....................................................................................................... 33
6.2 Cleaning the tubes and valves .................................................................................... 34
6.3 Visually inspecting the seals ....................................................................................... 37
6.4 Lubricating the nozzle seal.......................................................................................... 38
7 Repairs....................................................................................................................... 39
7.1 Replacing the nozzle housing ..................................................................................... 40
7.2 Replacing the diffusor ................................................................................................. 41
7.3 Replacing the diffusor seal.......................................................................................... 42
7.4 Replacing the panel .................................................................................................... 43
7.5 Replacing the drain set ............................................................................................... 44
7.6 Replacing the drip tray and the grill............................................................................. 45
7.7 Replacing the touchscreen, unit controller board, and touchscreen panel ................. 46
7.8 Replacing the cover .................................................................................................... 48
7.9 Replacing the side sections ........................................................................................ 49
7.10 Replacing the valve controller board........................................................................... 50
7.11 Replacing the housing................................................................................................. 51
7.12 Replacing the valve assembly..................................................................................... 52
7.13 Replacing the valves................................................................................................... 54
7.14 Replacing the automatic circuit breakers .................................................................... 56
8 Commissioning/shutdown....................................................................................... 58
8.1 Commissioning............................................................................................................ 59
8.2 Configuration............................................................................................................... 61
8.2.1 Software installation .................................................................................................... 61
8.2.2 Checking settings in the “Current Version” menu ....................................................... 62
8.2.3 Software updates ........................................................................................................ 62
8.2.4 Calling up the “Update Schedule” menu ..................................................................... 65
8.2.5 Checking settings in the “Status” menu ...................................................................... 65
8.2.6 Calling up the “SANITIZATION” menu ........................................................................ 66
8.2.7 Checking and configuring settings in the “Brix Set Up” menu..................................... 66
8.2.8 Checking the valves.................................................................................................... 67
8.2.9 Checking settings in the “Purge” menu....................................................................... 67
8.2.10 Checking and configuring settings in the “Recipe” menu............................................ 68
8.2.11 Checking and configuring settings in the “Commissioning” menu .............................. 70
8.2.12 Checking and configuring settings in the “BIB Dashboard” menu............................... 72
8.2.13 Checking and configuring settings in the “HMI Status” menu ..................................... 72
8.2.14 Calling up the “Critica_Aws” menu.............................................................................. 73
8.2.15 Checking and configuring settings in the “Wifi” menu ................................................. 76
8.2.16 Checking and configuring settings in the “Ethernet” menu ......................................... 78

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8.2.17 Calling up the “Drink Counter” menu........................................................................... 78
8.2.18 Calling up and checking the “System Log” menu........................................................ 79
8.2.19 Checking and configuring the “Product Price” menu................................................... 79
8.2.20 Checking and configuring the “Enable/Disable Product” menu................................... 80
8.2.21 Calling up and configuring the “UI Template Scheduler” menu .................................. 80
8.2.22 Checking and configuring the “Date & Time Setting” menu ........................................ 83
8.2.23 Checking and configuring the “Language” menu ........................................................ 83
8.2.24 Calling up and configuring the “Machine Configuration” menu ................................... 84
8.2.25 Calling up the “Disable Touch for Cleaning” menu ..................................................... 84
8.2.26 Calling up the “Exit Maintenance Page” menu ............................................................ 84
8.2.27 Calling up the “Reboot Machine Setting” menu .......................................................... 85
8.2.28 Calling up the “User Management” menu ................................................................... 86
8.2.29 Adjusting the valves .................................................................................................... 88
8.3 Shutdown .................................................................................................................... 89
9 Errors and malfunctions........................................................................................... 91
9.1 Troubleshooting table.................................................................................................. 92
A Applicable documents.............................................................................................. 96
A.1 Drill template ...............................................................................................................97
A.2 Flowchart..................................................................................................................... 98
A.3 Tower cable diagram................................................................................................... 99
A.4 E-Box cable diagram................................................................................................. 100

1Safety
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1 Safety
1.1 Intended use
By using the unit as intended you will not only protect yourself, but also prevent damage oc-
curring to the unit and its components!
You can find further information about the intended use of the unit in the tower operator man-
ual, document no. TD0000000.
1.2 Improper use
Improper use of the unit, and unauthorised modifications to the unit and its components may
cause personal injury and equipment damage for which Cornelius assumes no liability. Im-
proper use of the unit is prohibited.
You can find further information about the improper use of the unit – and the meaning of im-
proper use – in the tower operator manual, document no. TD0000000.
1.3 Staff
There is a clear definition as to what group of people is permitted to carry out what type of work
on the unit. You can find further information about who is authorised to carry out what type of
work on the unit in the tower operator manual, document no. TD0000000.
1.4 Presentation of warnings
The documents supplied with the unit provide warnings regarding any dangers or hazards that
might exist. You can find more information about the design and presentation of warnings in
the tower operator manual, document no. TD0000000.

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1.5 Safety instructions
1.5.1 Safety information to prevent personal injury and
equipment damage
Any work on the unit and its components which goes beyond operation and beyond the ser-
vicing and maintenance tasks that the operator is authorised for, may only be performed by
experts (for a definition of experts, see the tower operator manual, document no.
TD0000000.). Furthermore, it is crucial that when performing work on the unit all safety infor-
mation is observed; this information is set out in the following sections. Some of the tasks may
have additional safety information which highlights the specific dangers or hazards associated
with such work.
1.5.2 Safety information for using electrical assemblies
Danger!
To prevent risks to health and safety, please always observe the following
five safety rules:
1. Disconnect from power.
2. Secure against reconnection.
3. Verify that the system is disconnected from power.
4. Ground and short-circuit the system.
5. Cover or separate adjacent live parts.
These five safety rules are to be applied before carrying out work on the
electrical system and in the above stated order. Once work is completed,
the safety rules are to be undone again in reverse order.
Warning!
Risk of burns when touching hot parts of the unit
Touching parts of the unit after it has been in continuous use over an
extended period of time will result in a risk of burns.
•Take appropriate safeguard measures, such as by wearing heat-
resistant protective gloves.
Notice!
•Make sure that the cable markers are not removed from the cables
and/or mark or label the cables such that they can be correctly
assigned during installation.

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Caution!
Cables must be fixed in place using cable ties.
When fixing cables in place using cable ties, observe the following points:
•Once work on the product is completed, return the area to the same
state that you found it in.
•Using cable ties, combines cables in a meaningful way.
•When installing cables, be mindful of any bending radiuses that the
manufacturer may have specified.
•To fix cables in place using cable ties, use the mounting bases pro-
vided.

2 Transport and packaging
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2 Transport and packaging
Choose a suitable packaging when returning the unit itself or one of its components to
Cornelius Deutschland GmbH, e.g. for repairs. In particular, make sure that the unit and any
components are protected from shock/impact, moisture, dirt and electrostatic discharge
(ESD). This will prevent transport damage to the unit and to the components, for which the
manufacturer shall assume no liability.
2.1 Storage
Avoid excessive temperature fluctuations as condensate may form, which in turn may cause
damage to the unit or to the components.
The permissible storage temperature is -10 °C to +50 °C.
The acclimatisation period is 6 hours.
Caution!
Component damage due to freezing liquids
Ambient temperatures that are below freezing will lead to the freezing of
any water or cleaning agent residue remaining inside the unit. This will lead
to damage to internal components.
•Before shipment, storage or relocation of the unit, the unit is to be
cleaned and the cleaning solution is to be fully drained from the unit.
Caution!
Damage due to improper storage
Dirt or moisture entering a unit, as well as certain weather conditions (e.g.
condensate forming at the unit, sunlight) will cause damage to the unit and
its components.
•Protect the unit and its components by storing the unit in a clean and
dry place, and by ensuring stable ambient conditions.
•If possible, store the unit in its original packaging. Unpacked units
must be covered with a dustproof cover. No condensate must form
under the cover.

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2.2 Disposal
Disposal of the units must be carried out in compliance with the applicable local and/or national
and international regulations. Units must not be disposed of with household waste.
If the unit contains fuels or lubricants in liquid, paste-like or gaseous form, such as oil, grease,
cooling agents etc., such fuels or lubricants are to be collected using appropriate measures
and disposed of in compliance with the applicable local and/or national and international reg-
ulations. Such fuels or lubricants must always be prevented from seeping into the ground, the
sewage system and any bodies of water, and must always be prevented from entering the at-
mosphere.
Caution!
Risk of electrostatic charge!
Improper handling or storage may result in electrostatic charges.
•If possible, store units and/or any electronic components in their
original packaging.
•Keep units and/or electronic components away from charged
objects, fields and insulators.
•Avoid electrostatic charges when removing packaging and/or han-
dling electronic assemblies and components by working at an ESD-
protected workstation or work area.
•When working at the unit or its components, wear a grounding (anti-
static) wrist strap at the very least and wear antistatic gloves if nec-
essary.
Caution!
Component damage due to material ageing
Material can age due to long storage periods, thereby affecting the mate-
rial’s properties (e.g. plastics and seals may become brittle). The proper-
ties of lubricants may change due to long storage periods.
•Check the assemblies and components for damage before each
use/before installing them. Do not install assemblies or components
that show visible signs of ageing.

3 Description
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3 Description
3.1 Assemblies and components
With the exception of the E-Box, the housing holds all other assemblies. The touchscreen can
be removed for servicing purposes and can be attached to the housing in such a way that it
remains functional during service operations while simultaneously allowing access to the in-
ternal assemblies.
The unit comprises the following assemblies:
1
2
3
4
6
5
8
7
9
11
10
Figure 1
1 Touchscreen
2 Housing
3 E-Box (with AC power line)
4 Plug cable no. 141647504 EU
5Ferrit
6 Plug cable no. 220046667
7 Tubes
8Drainset
9 Drip tray
10 Panel
11 Dispensing nozzle with nozzle inlay and
diffusor

3 Description
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The dispensing nozzle assembly comprises the following components:
1. Nozzle housing
2. Diffusor
3. Diffusor seal
4. Diffusor O-ring
The drain set assembly comprises the following components:
1. Drain fitting
2. O-ring
3. Flat seal
4. Fastening nut
5. Tube
6. Tubing clamp
7. Insulation
If you lift and remove the touchscreen you will gain access to
the valve assembly (Figure 4/1) that is kept in place inside the
valve assembly mount (Figure 4/2).
2
34
1
Figure 2
2
1
3
4
5
6
7
Figure 3
1
2
Figure 4

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3.2 Functions within the dispensing system
3.3 Functions of the unit
Each individual beverage type is dispensed by opening the valve assigned to the respective
beverage component.
Valve control takes place via the unit’s control electronics and depends on the inputs made via
the touchscreen.
The beverage components flowing from the valves are supplied to the diffusor, where they are
mixed. From there, they are poured into the cup via the dispensing nozzle.
Notice!
The description of how the unit works within the dispensing system is
included in the relevant operator manual for this unit; see the document
“Tower operator manual”, document no. TD0000000.
Notice!
For valve assignment, see chapter A.4, page 100.

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3.4 Touchscreen/software
1. “BRANDS”
2. “FLAVOUR” (flavour shot)
3. “SODA” (carbonated water)
4. “POUR”
5. Cup sizes
1. PIN input
1. “VMC Settings” (virtual machine control settings)
2. “HMI Status” (user interface status)
3. “Software & UI Update”
(software & user interface update)
4. “Critica_Aws”
5. “Wi-Fi”
6. “Ethernet”
7. “Drink Counter”
8. “System Log”
1
34
2
5
Figure 5
Figure 6
2
1
3
4
5
6
7
8
Figure 7

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1. “Product Price”
2. “Enable/Disable Product”
3. “UI Template Scheduler”
4. “Date & Time Setting”
5. “Language”
6. “Machine Configuration”
7. “Disable Touch for Cleaning”
8. “Exit Maintenance Page”
9. “Reboot Machine Setting”
10. “User Management”
2
1
3
4
5
6
7
8
9
10
Figure 8

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3.5 Technical data
3.5.1 Tower
Description Parameter Value Unit
Dimensions
Height 643/25.3 mm/in.
Width 404/15.9 mm/in.
Depth 311/12.1 mm/in.
Ambient temperature
Storage -10 to +50 °C
Operating environ-
ment +10 to +32 °C
System output
Syrup 8
Flavour shot 4
Power supply 230/50 V/Hz
Max. output < 70 W
Supply requirements
Max. pressure 100 (water),
70 (syrup) PSI
Min. pressure 40 (water),
40 (syrup) PSI
Protection class I / IP 21
Flow rate 2-3 per second (2-3 fl oz
= approx. 59-89 ml)
Touchscreen 256.54/10.1
mm/in.
Android operating
system with flexible
branding/flexible ani-
mation
Key switch I/0
Wi-Fi 80 b/g/n
Min. side clearances
required
top 100/3.9 mm/in.
sides 100/3.9 mm/in.
Rear 100/3.9 mm/in.

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3.5.2 E-Box
3.5.3 Connections
Description Parameter Value Unit
Part no.
141647727 EU
Height 290/11.4 mm/in.
Width 200/7.8 mm/in.
Depth 115/4.5 mm/in.
Part no.
620063745 US
Height 340/13.4 mm/in.
Width 290/11.4 mm/in.
Depth 115/4.5 mm/in.
Power supply
115/230 V
50/60 Hz
Max. output
60 W
4A
Protection class I/IP21
Connection Type/pin assignment
Carbonated water inlet 3/8 inch inside diameter, 1/2 inch outside
diameter
Carbonated water return 3/8 inch inside diameter, 1/2 inch outside
diameter
Still water inlet 1/4 inch inside diameter, 3/8 inch outside
diameter
Syrup inlets 1/4 inch inside diameter, 3/8 inch outside
diameter
Flavour shot inlets 1/4 inch inside diameter, 3/8 inch outside
diameter
Drain set 1 inch inside diameter
Cable 220046667 Tower mains/power supply via E-Box
Cable 141647504 EU E-Box mains/power supply

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Cable 220046667 Promate computer cable (for touchscreen)
and ADA keyboard (optional)
Cable 220046670 DC 24 V output (still water control) for still
water only in the undercounter cooler
Connection Type/pin assignment

4 Preparing the unit
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4 Preparing the unit
This chapter describes the tasks that may be required before carrying out any actual mainte-
nance or repair work.
Danger!
Risk of personal injury and equipment damage due to non-compli-
ance with safety information
Failure to observe the safety information will result in a risk of bringing
about operating conditions at the unit which may cause personal injury or
equipment damage.
•Please always strictly observe all safety measures and information/
instructions; see chapter 1, page 4.
Danger!
You may only continue working on the unit if the unit carries no voltage.
If the unit still carries a voltage after you have disconnected it from power,
this indicates a defect. Resolve this defect before continuing the checks/in-
spections or any work.

4 Preparing the unit
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4.1 Disconnecting the unit from power
1. Turn the key switch (Figure 9/1) to position “0”.
2. Disconnect the plug (cable no. 141647504 EU)
(Figure 10/2) of the E-Box (Figure 10/1) from the mains
supply, see chapter A.3, page 99.
3. Disconnect the plug (cable no. 220046667) (Figure 10/3)
from the E-Box (Figure 10/1), see chapter A.3, page 99.
4. Wait 1 minute before continuing your work on the unit.
Prerequisites Reference
The panel has been removed. see chapter 7.4, page 43.
Required tools/materials ID/
Reference Qty/ amount Comment
Tower cable diagram 220046668 1
E-Box cable diagram 220046683 1
1
Figure 9
1
2
3
Figure 10