McDonald's CORNELIUS AUTOMATED BEVERAGE SYSTEM User manual

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 [phone]
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

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved. 1
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 OF ALERTS
!
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.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young
children or infirm persons without supervision. Young children should be supervised to ensure that they do not
play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
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.
!

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
2
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should 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:
!
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. A freezing ambient environment will cause residual sanitizing solution or
water remaining inside the unit to freeze resulting in damage to internal components.
CO2(CARBON DIOXIDE) WARNING
!
DANGER:
CO2displaces oxygen. Strict attention MUST be observed in the prevention of CO2gas leaks in the
entire CO2and soft drink system. If a CO2gas leak is suspected, particularly in a small area,
IMMEDIATELY ventilate the contaminated area before attempting to repair the leak. Personnel exposed
to high concentrations of CO2gas experience tremors which are followed rapidly by loss of
consciousness and DEATH.
!
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 all federal, state
and local codes.
Failure to comply could result in serious injury, death or damage to the equipment.
Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed
and maintained according to Federal, State and Local laws.
!
WARNING:
This unit is not designed for a wash down environment and must NOT be placed in an area where a
water jet could be used.

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved. 3
Failure to comply could result in serious injury, death or damage to the equipment.
!
WARNING:
Water and CO2to the system must be turned off and the system depressurized prior to performing this
service.
Failure to comply could result in serious injury, death or damage to the
equipment.
!
WARNING:
This unit must be grounded to avoid possible electrical shock to the operator. The unit power cord is
equipped with a three pronged plug. If a three pronged (grounded) outlet is not available use an
appropriate method to ground the unit.
Failure to comply could result in serious injury, death or damage to the equipment.

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
4
INTRODUCTION
The Automated Beverage System (A.B.S.) is
an automated cold beverage dispenser for
drive-thru applications. The ABS was
designed for drive-thru area installation or
other restricted area that is not accessible to
unauthorized personal. When a beverage is
ordered from the P.O.S. register, the A.B.S.
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 conveyor to the pick-up
station and the drink description is displayed
on the panel.
Operation of the ABS is restricted to employ-
ees and service personal that have been
trained and certified in the proper operation,
service and maintenance of the equipment.
The ABS has three modes of operation:
• Automatic Mode
In automatic mode, the customer places an
order at the drive-thru and the A.B.S. auto-
matically 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.auto-
matically produces the drink as ordered.
• Semiautomatic Mode
In automatic mode, operator presses desired
cup size button, desired flavor button and
ENTER and drink is dispensed. If extra ice or
no ice is required, EXTRA ICE or NO ICE
button is pressed after flavor button has been
pressed, before ENTER. Drink is dispensed.
• Manual Mode
Remove the conveyor. Enter the manual mode
by pressing the Manual/Auto button. (Don’t
pull cups from A.B.S. Turret as damage may
occur to cup tubes.) Locate a sleeve of cups
and remove a cup. Hold the cup under ice
chute, press EXTRA ICE. Ice is dispensed.
Hold cup under nozzle, press and hold desired
flavor button. Drink is dispensed. Reinstall
conveyor and return A.B.S. unit to normal
operation.
SAFETY
Always disconnect CO2or air pressure to unit
before cleaning or servicing grabber arm or
ice chute. Disconnect switch for ice gate is
located on control box behind cup lid holder
panel.
Insure that unit is in manual mode before
removing or replacing conveyor assembly to
avoid pinching fingers in the drain area.
Dispenser is very top heavy. To prevent seri-
ous injury, exercise caution when moving or
setting dispenser in place.
CO2used in the system is under 60 PSI min.
pressure. (ABS has a regulator to control up to
200PSI incoming). Caution should be used
when servicing the unit. Undetected CO2
leaks may cause harm or death due to aphyxi-
ation. Installation and service personal must
carefully inspect all CO2tubing, fittings and
components for any damage or leaks. Also
check and clean all fittings before reusing.
Make sure tank is properly secured to avoid
tipping.
Noise level can exceed 65 dBA in short time
intervals for single unit activities. Warning
devices are 88dBA at 24” from unit. Measure-
ment for noise shall be made 39” from any
machine surface.
Unit is equipped with independent manual
leveling legs. Total incline not to exceed 5
degrees in any direction.
Functions without damage from 32°-105°F
with 100% rh, incoming water & syrup of
32°-105°F. No visible condensation on out-
side or dripping inside dispenser when oper-
ated at 75°F, 45% rh or 90°F, 65% rh.

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
5
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
PRINTED ON RECYCLED PAPER
10% Post-Consumer Content
40% Pre-Consumer Content
1 .................... ................ 620052935 .....Ventilation Grill
2 .................... ................ 620516680 .....Access Hole Cover
3 .................... ................ 560000291 .....Air Filter
4 .................... ................ 560000289 .....Front Panel (Built before Serial No. 56A0019AB102)
...................... ................ 560002774 .....Front Panel (Serial No. 56A0019AB102 and after)
Assembled Unit Diagram
A.B.S. Unit Access
12
3
4
TURRET
FLAVOR DISPLAY
CUP GRABBER
CONTROL PANEL
ON/OFF SWITCH
OPTIONAL PRECHILLER

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
6
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
1 27921 ...... 560000320Conveyor Cover
2 .............. 27922...................560000325 ..............Conveyor Assembly
3 .............. .............................560000315 ..............Cup Rest
4 .............. .............................560000306 ..............Drip Tray Assembly
Conveyor/Cup Rest Assembly Diagram
1 ................ 27921...........560000320 ...... Conveyor Cover
2 ................ 27922...........569000295 ...... Conveyor Assembly
3 ................ ..................... 560000315 ...... Cup Rest
4 ................ ..................... 560000306 ...... Drip Tray Assembly
5 ................ 20669...........560002714 ...... Water Deflector
Conveyor Assembly
1
2
3
4
POSITION “A” SENSOR
CUP POSTIONING BRACKET
CUP HOLDER
THUMB SCREWS
5

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
7
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
Ice Chute Assembly Components Diagram
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
1
2
3
6
5
4
7

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
8
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
Cup Tube Components Diagram
1 ..............27916 ..........560000207 .......5” Cup Tube Cover (30/32 - 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 .......30/32 Oz. Kit Cup Tube 32 Oz. ABS
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)
Cup Tube Assembly
1
2
3
2
2
1

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
9
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
Ice Bin Components Diagram
1 ............... ............................15346 ...................... Agitator Assembly
2 ............... ............................52887 ...................... Lid
3 ............... ............................53227 ...................... Disk
4 ............... ............................15087 ...................... Agitator Retainer
1 .............. 15346................................ Agitator Assembly
2 .............. 52887................................ Lid
3 .............. 53227................................ Disk
4 .............. 15087................................ Agitator Retainer
Agitator Assembly
1
3
2
4

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius
and McDonald’s Corporation. All Rights Reserved.
Illustrated Parts List
10
Automated Beverage System —
Ref CCUSA MFG.
Number Number Number Description
Nozzle Assembly Components Diagram
.................. 161509 ................ Complete Assembly
1................27940 560001545 .......... Nozzle
2................27939 560001544 .......... Diffuser
3................ 110677000 .......... O-Ring
6................ 325216000 ..........Nozzle Brush (Not Shown)
Nozzle Assembly
1
3
4
5
1
22A
2B
DIFFUSER BODY
DIFFUSER RING

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved. 11
COKE *
SPECIAL
EXTRA ICE
ABCD
Cup Extraction Position
Ice Fill Position
Beverage Fill Position
BCD
A
Conveyor Positions
*Drink Position Display
*Drink Position Display - Showing Drink Locations in Conveyor
AN * IS DISPLAYED WHEN A
DRINK IS DISPENSED FROM THE
A.B.S. PANEL INSTEAD OF THE
POS SYSTEM.
A # IS DISPLAYED
FOR ANY DRINK DISPENSED
WITH EXTRA ICE.
COKE
SPECIAL
EXTRA ICE
#
SPECIALSPECIAL SPECIAL
SPECIAL
EXTRA ICE EXTRA ICE
EXTRA ICE
EXTRA ICE
Fully Automatic Operation
Operational Modes
The A.B.S. has three modes of operation:
• Automatic (Normal Operation)
• Semi-Automatic (while in Auto)
•Manual
Location Diagram

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
12
Order Entered On P.O.S.
Operation of the ABS is restricted to employ-
ees and service personal that have been
trained and certified in the proper operation,
service and maintenance of the equipment.
With the unit in automatic mode, the cus-
tomer 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 auto-
matically 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.
Automatic Operation

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved. 13
Cup Turret Rotates
The cup turret rotates to move the proper size
cut to the extract position.
Cup Grabber Rises & Closes
The cup grabber is lifted by a pneumatic cyl-
inder 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.
Automatic Operation

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
14
Conveyor Operates
Sensors check for a cup in position “A.” If the
sensor is clear, the conveyor rotates clock-
wise 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 cylin-
der for the time needed to dispense the
selected ice portion. Correct operation is
insured by the ice gate full travel sensor.
The agitator continues to operate for the set
refill time to refill the ice chute.
Automatic Operation

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved. 15
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.
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 por-
tion will be dispensed. After a delay, the bal-
ance of the drink will be dispensed.
Automatic Operation

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
16
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.
Semiautomatic Operation (Unit in Automatic)

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved. 17
Press Cup Size
Operation of the ABS is restricted to employ-
ees and service personal that have been
trained and certified in the proper operation,
service and maintenance of the equipment.
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.
Semiautomatic Operation (Unit in Automatic)

Automated Beverage System
© 2004-2018 The Coca-Cola Company, Cornelius and
McDonald’s Corporation. All Rights Reserved.
18
When Correct, Press Enter
Sequence of pressing the cup size, flavor, and
special ice buttons is not important. At any
time, pressing any button changes the selec-
tion of the drink to be dispensed. When the
correct order is displayed, press ENTER and
the drink is dispensed.
Any drink entered in this manner displays 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
The word “FLOAT” will appear
when the float option is applied
to the drink order.
This button op
erates as the
DOWN arrow key
in the manual
mode, and as the
“FLOAT” key
while the unit is
in automatic.
The word “FLOAT” appears
when the float option is
applied to the drink order.
This button oper-
ates as the
DOWN arrow
key in the manual
mode, and as the
“FLOAT” key
while the unit is
in automatic.
Manual Operation