Telephone (800)

Transcription

1 Telephone (800) AUTOMATED BEVERAGE SYSTEM Installation Manual IMPORTANT: TO THE INSTALLER. It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI/ASME A ; or an approved vacuum breaker or other such method as proved effective by test. 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. Part No. August 24, 2004 Revised: July 28, 2005 Revision: C THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC; PRINTED IN U.S.A

2 TABLE OF CONTENTS CHECK LIST CHECK OFF ALL ITEMS COMPLETED INSTALLATION KIT (P/N ) SELECTING LOCATION ELECTRICAL REQUIREMENTS INSTALLATION PLACING DISPENSER IN OPERATING POSITION PREPARING THE DISPENSER FOR OPERATION SET-UP & PROGRAMMING TOUCH PANEL LAYOUT & EXPLANATION INTRODUCTION PLEASE READ CAREFULLY DISPLAY EXPLANATION USING THE KEYPAD ACCEPTING CHANGES MOVING THROUGH THE MENU EXPLANATION OF CONVEYOR POSITIONS INITIAL SET-UP, PROGRAMMING INITIALIZING AND SELF TEST MANUAL MODE ALARM/WARNING MESSAGES INITIAL SET-UP ADJUSTMENTS IMPORTANT START-UP INFORMATION INSTALLING AND FILLING CUP TUBES FILLING PRODUCT TUBING SERVICE SETUP SYRUP MAPPING SETUP MENU SYRUP MAPPING EXPLANATION ADJUSTMENTS CHANGING THE SYRUP MAPPING SETTING CUP SUPPLY SET FLOW RATE AND SET VALVE RATIO ADJUSTING WATER FLOW RATE ADJUST THE SYRUP RATIO ADJUST PORTION TOP-OFF EXPLANATION ADJUSTING THE TOP-OFF ADJUST ICE PORTION SETTING REFILL TIME IDLE TIME, SETUP

3 8.12. SAVING THE SET-UP ADDITIONAL SAVING/RESTORING INFORMATION MANUAL MODE OPERATION CLEAR THE POS ORDER BUFFER AUTOMATIC MODE OPERATION SEMI-AUTOMATIC DRINK ORDER ENTRY ALARM & WARNING MESSAGES TESTING OF THE NEW FLOAT DRINK FUNCTION: CHANGING THE FLOAT DRINK DISPENSE VOLUMES:

4 CHECK LIST CHECK OFF ALL ITEMS COMPLETED This check list is intended to permit you to be sure that all aspects of the installation have been completed. Please use this check list Don t rely on memory. For experienced installers, this check list makes an easy guide and reminder of the steps to follow. Manual Page SELECTING LOCATION REMOVE CASTERS, INSTALL NSF APPROVED LEGS CONNECTING SYRUP TUBING FILL OUT FLAVOR LINE-UP FORM FOR POS PROGRAMMER CONNECT WATER CONNECT CO ROUTE/CONNECT ABS COMMUNICATION CABLE BYPASS COLD PLATE SANITIZE & FILL ICE BIN POWER-UP ABS AND PRE COOLER (IF USED) INSTALLING AND FILLING CUP TUBES FILLING PRODUCT TUBING ADJUST SYRUP MAP FLAVORS TO AGREE WITH FORM ON PAGE ADJUST WATER FLOW RATE ADJUST THE SYRUP RATIO ADJUST PORTION (18 OZ TARGET) CHECK/ADJUST TOP-OFF/FLUSH ADJUST ICE PORTION SAVING THE SET-UP

5 INSTALLATION KIT (P/N ) The following installation kit contains the components required to install the ABS. This description is designed to assist you in identifying the components and checking the inventory. Part Number Description Qty Bracket, Drain Tube Oetiker Clamp, # Oetiker Clamp, # Leg Set, 6 inch Bracket, Chase Outer Swivel Fitting 7/16-20F X 3/8 Barb Nipple,.375 Tube X 1/2 Nut U Tube, 1/2 Barb (2) X 3/8 Barb (2) Cable Extension RS232, 100 Ft Hose Clamp, Screw Type Vinyl Tubing,.875 X ft Barbed Splicer,.375 X Swivel Nut, 5/ Gasket, 5/8 18 Male Nipple,.500 Tube X 5/8 Nut Swivel Nut, 5/ Tee Fitting, 3/8 (3) Insulating Tape, 2 Inch X 50 Ft Elbow Fitting, 1/2 Barb Shutoff Valve, 3/8 Barb 1 2

6 This is an Installation Manual for the Eight-Flavor Automated Beverage System (ABS) Post-Mix Dispenser. Retain this manual as part of your equipment documentation. 1. SELECTING LOCATION DANGER: To avoid possible fatal electrical shock or serious injury to the Operator, it is highly recommended that a GFI (ground fault circuit interrupter) be installed in the electrical power circuit. Locate the Dispenser so the following requirements are satisfied: 1.1. ELECTRICAL REQUIREMENTS 1. The electrical circuits must be properly fused (slow-blow type fuses). The precooler circuit should be protected by HACR circuit breakers. Do Not use HACR circuit breakers on the circuit for the ABS unit. HACR circuit breakers may not react to voltage surges or spikes that can damage the ABS electronics. 2. The electrical outlets must be accessible for ease of connecting and disconnecting the Dispenser or Pre-Cooler power cords. See the acceptable areas shown in Figure 1. No other electrical appliances should be connected to these electrical circuits. ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. ABS Unit 120 Volt, 60 HZ. 15 Amp. (No HACR Breaker) ABS Unit 230 Volt, 50 HZ. AS3112 Pre Cooler 120 Volt, 60 HZ. 20 Amp. Dedicated Outlet Pre Cooler 230 Volt, 50 HZ. REFILL AREA REFILL AREA Areas Acceptable for Electrical Outlets 8 X With ice maker) Outlets Cannot be Located Behind This Vertical Member 8 SERVICE AREA 72 1 Clearance to wall FIGURE 1. ABS CLEARANCE REQUIREMENTS 3. Clearance above top of the ABS unit must be open above the unit and the front of the unit stand must be open to the room. These clearances must be provided to allow for proper air flow through the PRE-Cooler refrigeration system and to allow access to the ice bin for refilling. See Figure The ABS unit and the Pre-Cooler unit must be located close to a permanent drain (preferably under the unit when in operating position) to route the ABS unit drip tray drain hose and the Pre-Cooler water tank drain hose and the water tank overflow hose. 3

7 2. INSTALLATION CAUTION: This Dispenser and the carbonated and plain water Pre-Cooler are intended for indoor installation only. Do not install Dispenser and Pre-Cooler in an outdoor environment which would expose them to the outside elements PLACING DISPENSER IN OPERATING POSITION CAUTION: The Dispenser is very top heavy. To prevent serious injury, Installer Personnel must exercise caution when moving or setting up the Dispenser Control Box Communications Cable, Step 8 CO 2 or Air Connection Step 10 Access Panel 1. Remove front access panel from the ABS lower cabinet. 2. Place the ABS unit on blocks so that the leveling legs can be installed. The ABS unit is very top heavy and extreme caution must used in handling or moving this unit. Install the four leveling legs. 3. Place ABS unit in it s final operating location. Allow clearances as specified previously. 4. Once the ABS unit is in place, use a 2 level to level it using the leveling legs. The unit must be level side to side and front to rear. 5. Route syrup tubing from the ABS to the location where the connections to the bundle tubing will be made. NOTE: When connecting the bundle syrup tubing to the syrup tubing from the ABS unit, keep a record of what flavor is connected to what valve number. A chart is provided at the back of this manual for that purpose. This record will be important when setting up the syrup mapping. 6. Connect labeled 3/8-inch I.D. syrup tubing to bundle tubing from the syrup supply. No tubing should be in the way of the Precooler when it is installed. NOTE: If the installation uses non-cooled syrups, they must be connected to valves 7 and/or 8. This is done by connecting the syrup supply tubing at the inlet to the valve. See the instructions in Figure 2. Tag the inlet lines to the cold plate to indicate the alternate plumbing for warm syrup. 4

8 Splice warm syrup on this side of the cut to feed directly to the valve. Cut tube here for connection of warm syrup. Only cut the tube to be used. Valve #8 (Bypass plumbed at Factory) Valve #7 Access Panel Removed FIGURE 2. CONNECTING WARM SYRUP 7. Turn the ABS power switch to the OFF position, then route the ABS power cord to the appropriate electrical outlet and plug-in. 8. If the communications cable has not been previously routed from POS system to the ABS location, do that now. The cable must be routed with the male RS 232 plug to the ABS unit. Then connect the cable to the ABS unit. After plugging the cable into the socket on the Control Box, secure the plug to the socket with the two screws on the plug. 9. Route CO 2 (bulk air) tubing from the primary source at 80 psi to the left front corner of the ABS dispenser. If a Change-Over valve is available at the Back-Room-Package, connect at the outlet of the change-over valve to provide the assurance of operation if the back-up supply is used. See Figure 3. Change-Over Valve Change-Over Valve CO 2 Bulk CO 2 Backup CO 2 In Air In Shutoff Valve From Install Kit Shutoff Valve From Install Kit Splice Tee at Outlet To ABS Splice Tee at Outlet To ABS To Carbonators CO 2 SYSTEM To B-N-B Regulator AIR SYSTEM FIGURE 3. INSTALLATION WITH CHANGE-OVER VALVE 10. Connect the CO 2 (air) tubing to the ABS dispenser air inlet connector below the control box using the tubing adapter assembly (1/4 Flare 3/8 barb) provided in the installation kit. Adjust to 60 psi at the internal regulator. 11. Route the ABS conveyor drip tray drain hose and the Pre-Cooler water tank drain hose and the water tank overflow hose to a permanent drain. Placement of these drain hoses must comply with National and Local plumbing codes. 12. If it is prefered to have the drip tray drain rigidly plumbed, this can be done by purchasing and assembling the following parts. 5

9 Item No. Part No. Name Qty. 1 PVC Elbow, 1/2-I.D. 3 2 PVC Pipe, 1/2-O.D. (Aprox. 3-5 Feet Long) 1 3 PVC/ABS Cement 1 NOTE: Bracket is supplied in the installation Kit. To mount the drain tube assembly to unit frame. Use (2) No screws also supplied. DRIP TRAY DRAIN FITTING BRACKET ( ) GLUE TO DRIP TRAY WITH PVC/ABS CEMENT GLUE JOINTS ABS CABINET SIDE WALL BOTTOM OF ABS CABINET GLUE AFTER INSTALLED IN UNIT ROTATE TO DESIRED POSITION 13. Place the Pre-Cooler unit in the ABS lower cabinet. If the electrical outlets are behind the ABS, plug the power cords in before the precooler is installed. When sliding the Pre-Cooler into the ABS dispenser lower cabinet, someone should guide the Pre-Cooler water tank and overflow hoses over front support bar of the cabinet. 14. Pull (slide) the Pre-Cooler out of the ABS dispenser lower cabinet as far as it will go (stops will prevent Pre-Cooler from sliding out too far). 15. Route and connect the three labeled 1/2-inch I.D. carbonated and plain water tubing from the ABS unit to the Precooler. The tubing is individually insulated and labeled as being water and carbonated water, the connections on the Precooler are also marked as being water and carbonated water. 16. Route 1/2-inch I.D. carbonated and plain water tubing from the bundle tubing to the Pre-Cooler and connect to the labeled 1/2-inch barbed carbonated and plain water inlet connectors on the Pre-Cooler. IMPORTANT: Before connecting the carbonated and the plain water tubing to the Pre-Cooler, the Pre-Cooler must be pulled out of the ABS dispenser lower cabinet to the stops. The water tubing is the correct length and does not need to be cut to fit. The carbonated and the plain water tubing should properly coil when the Pre-Cooler is pushed back in place inside the ABS dispenser cabinet. When Pre-Cooler is in place inside the ABS dispenser lower cabinet, the carbonated and plain water tubing must not be in contact with the refrigeration compressor, the compressor discharge tube, or the agitator motor. 6

10 2.2. PREPARING THE DISPENSER FOR OPERATION 1. Remove two wing nuts securing the Pre-Cooler water fill hole cover, then remove the cover. 2. Make sure plug in end of the water tank drain hose is secure. NOTE: Use a low-mineral-content water where a local water problem exist. 3. Fill water tank with clean water until water flows out of the water tank overflow hose. 4. Install Pre-Cooler water fill hole cover and secure with two wing nuts. 5. Very carefully, push the Pre-Cooler back inside the ABS dispenser lower cabinet. Make sure the carbonated and plain water tubes are not kinked and not contacting the refrigeration compressor, compressor discharge tube, or the agitator motor. 6. Set the Pre-Cooler power switch to the OFF position, then plug Pre-Cooler power plug into electrical outlet. Turn the power switch for the Pre-Cooler electrical control box to the ON position. A. Leak test all tubing connections. B. Install lower access cover. 7. Install CUP CONVEYOR, loose-shipped with the ABS dispenser in the drip tray area Clean and Sanitize the Ice Bin 1. Remove the center screw on the agitator disk and lift off the agitator and the agitator disk. Wash with a mild detergent solution and rinse them thoroughly to remove all traces of detergent. 2. Wash down the inside of the hopper and top cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 3. Replace the agitator. 4. Sanitize the inside of the hopper and agitator with a solution of 1/2 ounce of household bleach in 1 gallon of water (200 PPM). The sanitizing solution may be sprayed onto the bin surfaces with a spray bottle and allowed to air dry. 5. Replace the agitator disk. Sanitize as described in Step 4. Be sure the center screw is replaced and the screw is tight. 6. Remove Ice Chute cover. 7. Clean the inside of the ice chute and ice chute cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 8. Replace the ice chute. 9. Sanitize as described in Step After the sanitizing solution has dried, fill the ABS dispenser ice bin with ice cubes. Proceed to the INITIAL SET-UP & PROGRAMMING SECTION for the completion of the installation and set-up. Be sure to fill out the Flavor Line-Up form on page 8. 7

11 Tear-Out Reference Chart FLAVOR LINE-UP NOTE: This reference chart is to be used by the POS programmer to properly set the POS system to agree with the ABS set-up. The syrup map must also be adjusted to agree with this form as described on page 14. This syrup table shows the default factory settings and provides space for you to enter your actual hook-up information. Tear this sheet out and fill in the syrup connection information as you make your hook-ups. This information will be important during the setup process. U.S. Version as follows: DEFAULT SETTINGS POS PROGRAMMING DATA VALVE DISPLAY ID POS ID ACTUAL FLAVOR 1 COCA COLA 1 2 DIET COKE 2 3 MR PIBB 3 4 MM LEMN 4 5 SPRT 5 6 HI C ORNG 6 7 ROOT BEER 7 8 TEA UNSW 8 Australian Version as follows: DEFAULT SETTINGS POS PROGRAMMING DATA VALVE DISPLAY ID POS ID ACTUAL FLAVOR 1 COCA COLA 1 2 DIET COKE 2 3 FANTA ORNG 3 4 LIFT LEMN 4 5 SPRITE 5 6 ROOT BEER 6 7 TEA LEMN 7 8 TEA UNSW 8 8

12 3. SET-UP & PROGRAMMING 3.1. TOUCH PANEL LAYOUT & EXPLANATION Display Cup Size Buttons Flavor Buttons 1 5 Flavor Buttons 6 8, PW, CW FLOAT ENTER Use to select or confirm a selection. EXTRA ICE Used to dispense an extra portion of ice. Toggle button. NO ICE used to cancel ice dispensing for a single drink selection. Toggle button. CLEAR/<<BACK Used to cancel or clear current operation or to back-up to a previous menu. ALARM/SILENCE Used to turn off the audible alarm. AUTO/MANUAL Used to toggle between Manual and Automatic modes. CURSOR (Right) Used to move selection to the right. CURSOR (Left) Used to move the selection to the left. CURSOR DOWN/FLOAT OPTION Used to move the selection down in the MANUAL MODE and used as the loat drink modifier while in the AUTOMATIC MODE. CURSOR (Up) Used to move the selection up. 9

13 4. INTRODUCTION PLEASE READ CAREFULLY 4.1. DISPLAY EXPLANATION The screen displays represented in the following illustrations are samples of the screen data. Gray highlighted items indicate text that will blink or flash USING THE KEYPAD Flashing Item Pressing the buttons on the display panel will cause a tone to sound to signify that the action was or was not accepted. A single tone means the action was valid and accepted A triple tone (chirping sound) means the action was invalid and not accepted ACCEPTING CHANGES Whenever any setting is changed, the ENTER button must be pressed to accept the change. A Reminder of this is at the top of all the pages MOVING THROUGH THE MENU As the following instructions will indicate, you can move through the menu items by using the UP/DOWN arrows and then pressing ENTER to accept the selection. A reminder of the need to press ENTER to accept a selection is at the top of all pages as at the top of this page. The partial menu flow chart below shows the use of the CLEAR/BACK button to move back to a previous menu item. The following instructions indicate when it is necessary to press the CLEAR/BACK button but the number of times the button must be pressed is not indicated. 10

14 4.5. EXPLANATION OF CONVEYOR POSITIONS Cup Extraction Position Ice Fill Position Beverage Fill Position ABS ON/OFF Switch Conveyor Positions 5. INITIAL SET-UP, PROGRAMMING FIGURE 4. CONVEYOR POSITIONS The ABS 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. You will be required to make the following settings: 1. Water flow rates and syrup to water ratio. 2. Match valve flow rate to the ABS control. 3. Test and adjust (if necessary) the ice portion sizes INITIALIZING AND SELF TEST Turn ON the ABS unit at the ABS ON/OFF switch located on the left top corner of the stand (see Figure 4). 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 and will remain for 5 seconds before the unit is placed in the manual mode. Dots will increase as test progresses If the Initialing process ends with a Failed No POS Host Cable 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, press the CLEAR button to bypass the Failed message. The system will then be placed in the MANUAL mode MANUAL MODE In the MANUAL mode, POS data is updated (provided the communication cable is connected) and ALARM messages are displayed. In MANUAL mode the highlight flashes to alert operator to place unit in AUTO mode ALARM/WARNING MESSAGES If the alarm sounds, press the SILENCE button and then follow the screen directions. Use the LEFT/RIGHT arrows scroll the alarm list and the number of unresolved warnings and alarms are displayed with direction cues to scroll. The most common messages that you will encounter during Start-Up are shown below. 11

15 Message LOW ICE - REFILL SOON NO AIR Solution Fill ice bin with ice Check CO 2 (air) supply and correct cause of no pressure 6. INITIAL SET-UP ADJUSTMENTS 6.1. IMPORTANT START-UP INFORMATION NOTE: All CO 2 (air), syrup and water products must be connected and operational before the Start-Up sequence can be started. The cup tubes must be in place and filled with cups. The bin must be full of 32 F. ice INSTALLING AND FILLING CUP TUBES Station 4 Station 5 Station 3 Station 1 42 oz. CUP TUBE MD LG (OPTIONAL) Station 2 (OPTIONAL) (STANDARD) The cup tubes must be installed onto the 5-sided column. The cup tubes can only be installed in one position. The cup tubes will be labeled with the cup size (Child, Small, etc.). When two tubes of Medium cups are used, an adapter is required to adapt the mounting of the Medium tube to the Extra Large position (see illustration). While in the MANUAL mode, press cup size button labeled CH on the keypad to bring the smallest cup tube position to the front (extract) position. Install the CH cup tube and repeat for the remaining cup Tubes. NOTE: Multiple cup tubes of the same size will fit in only one position. For example: the medium cup tube that fits onto the adapter will only fit on the adapter and not anywhere else. Once again, while in the MANUAL mode, press CH (cup size 1) on the keypad to bring the CH cup tube to the front (extract) position. Fill the cup tube with correct cup size. Pressing SM (cup size 2) to bring the SM cup tube to the front and fill it with SM cups. As each tube is rotated to the front, fill it with the proper cup size for that tube. NOTE: Australian instructions are the same, except default sizes are as follows: Station 1: Large Station 2: Large Station 3: Medium Station 4: Small Station 5: Medium 12

16 To change from the Manual mode to the Service mode, use the UP/DOWN arrows to highlight the TO SERVICE selection. Press ENTER to go to SERVICE. When entering the SERVICE mode it is necessary to enter the 4 digit code (password). The code is entered using the keypad. Password (Flavor Buttons) 1, 2, 3, 4 Refer to the front cover for location. NOTE: Entry into SERVICE mode requires caution: the ABS will not accept drink orders from the POS Host and will indicate its status to be Not OK. During this initial set-up this is not a concern. To enter the SERVICE mode press ENTER. To return to MANUAL press CLEAR/BACK twice (<<Back, <<Back). This display is a notice that all POS orders have been stopped and you must press ENTER to continue. This is also one last chance to return to the MANUAL mode if you do not wish to enter the SERVICE mode FILLING PRODUCT TUBING Select TEST and press ENTER. Select VALVES and press ENTER. While in this mode, press each syrup flavor button, SODA and WATER until all air is purged from the tubing. In this mode the valve will remain open as long as a button is pressed. All air must be purged from the tubing before proceeding. At the end of this sequence press the CLEAR (<<Back) button repeatedly to return to the desired menu SERVICE SETUP Using the UP/DOWN arrows highlight SETUP and press ENTER. WARNING Entering the SETUP mode will clear any drink orders in the drink buffer. During this initial setup this is not a concern so press ENTER to go into the SETUP mode. 13

17 Check the factory default settings to see if they meet your requirements. It may be necessary to obtain a listing of the POS set-up for the flavors. The POS flavor I.D. and the ABS syrup map must agree. 7. SYRUP MAPPING 7.1. SETUP MENU Syrup Map The table below, Figure 6, shows all the flavor names that are resident in the ABS system. The shaded area is the default flavors. U.S. Version as follows: DISPLAY I.D. POS I.D. TYPE RATIO TOP- OFF TIME DISPLAY I.D. POS I.D. TYPE RATIO TOP OFF TIME SODA 0 CW 0 00 DR PEPR CW WATR 15 PW 0 00 MELO YELO CW COCA COLA 1 CW DIET SPRT CW DIET COKE 2 CW FRUT PNCH CW MR PIBB 3 CW STRWBRRY CW MM LEMN 4 PW GRAP CW SPRT 5 CW MM ORNG CW HI-C ORNG 6 PW MM OTHER CW ROOT BEER 7 CW HI-C PINK PW TEA UNSW 8 PW HI-C OTHER PW TEA RASP PW PWRA FRUT PW TEA LEMN PW PWRA ORNG PW TEA PEAC PW PWRA LEMN PW TEA OTHR PW PWRA OTHER PW COKE FREE CW CARB OTHR CW SURG CW DIET OTHR CW CHRY COKE CW WATR OTHR PW FIGURE 5. SYRUP FLAVOR TABLE (SYRUP MAP) 14

18 Australian Version as follows: DISPLAY I.D. POS I.D. TYPE RATIO TOP- OFF TIME DISPLAY I.D. POS I.D. TYPE RATIO TOP OFF TIME SODA 0 CW 0 00 CARB OTHER CW WATR 15 PW 0 00 DIET OTHER CW COCA COLA 1 CW UNUSED CW DIET COKE 2 CW UNUSED CW FANTA ORANGE LIFT LEM- ONADE 3 CW UNUSED CW CW UNUSED CW SPRT 5 CW UNUSED CW ROOT BEER 6 CW UNUSED CW TEA LEMN 7 PW UNUSED CW TEA UNSW 8 PW UNUSED CW TEA RASP PW UNUSED CW TEA LEMN PW UNUSED CW TEA PEAC PW UNUSED CW TEA OTHR PW UNUSED CW FRUT PNCH CW UNUSED CW STRWBRRY CW UNUSED CW GRAPE CW UNUSED CW SYRUP MAPPING EXPLANATION FIGURE 6. SYRUP FLAVOR TABLE (SYRUP MAP) The Store POS system will be programmed with each drink flavor. The Syrup Map makes the POS system agree with the flavor information in the ABS system Mapping First Step The illustration in Figure 7 does not represent an actual situation. It is for explanation only. In this illustration, Diet Coke has been installed at valve #2. We must now tell the ABS system that Diet Coke is installed on valve #2. The SYRUP MAP: EDIT must be set at 2 (See A). Then the LABEL must be set to display DIET COKE (See B). When this has been done, the ABS system will then display Diet Coke as the flavor dispensed on valve #2. Now go to Mapping Second Step 15

19 ABS System Display Diet Coke Field Connection COLD PLATE # Mapping Second Step FIGURE 7. SYRUP MAP EXPLANATION 1 The display below does not represent an actual situation. This is for purposes of learning only. After the ABS system is set as shown in paragraph , then we must tell the POS system where Diet Coke is located on the ABS system. In this illustration, Diet Coke is located at POS ID #2. Therefore the POS system must be set at to have Diet Coke at 2 in the drink flavor list. (See C). Now the ABS system is set so that when the POS system sends a signal to pour ID#2 Diet Coke, the ABS system will open valve #2 and pour Diet Coke and it will display Diet Coke on the drink display. If the ABS system default settings do not agree with the POS system, then the POS system must be changed. Sample POS System Drink ID List ABS System Display C FIGURE 8. SYRUP MAP EXPLANATION 2 NOTE: Remember, these are just examples and do not necessarily represent the actual POS or ABS settings you will encounter Drink List Create a drink list showing the exact position of each drink in the ABS system and present this to the POS programmer. 16

20 POS ID Flavor / Aust. Version 1 Coca Cola 2 Diet Coke 3 Mr Pibb / Fanta Orange 4 MM Lemon / Lift Lemonade 5 Sprite 6 Hi C Orange / Root Beer 7 Root Beer / Tea Lemn 8 Tea Unsweetened FIGURE 9. DRINK LIST 8. ADJUSTMENTS 8.1. CHANGING THE SYRUP MAPPING The syrup mapping determines what flavor, from which POS I.D., will pour from any of the 8 syrup flavors and PW and CW. The factory default settings are shown in Figure 9. During the installation of the ABS unit a record was to be made of which syrup was connected to which valve number. This record should be used in the following steps to ensure that the syrup mapping is correct. If all the default settings are correct and the syrup was connected to agree with the table in Figure 9, then the following steps can be skipped. The SYRUP MAP selection is available from the SERVICE:SETUP menu. Use the UP/DOWN arrows to highlight 1. SYRUP MAP. Press ENTER Use the UP/DOWN arrows or the RIGHT/LEFT arrows to select the valve position to be changed. The selected item will be flashing, shown here with the shaded bar. Press Enter. Once the edit mode is entered, the display changes to highlight each data item that can be edited. Use the UP/Down arrows to scroll through the available options for that data item. The display must agree with the syrup flavor connected to the valve position number shown in the SYRUP MAP: EDIT. The POS ID# cannot be changed. Press ENTER to accept the changes or CLEAR << to reject the changes. Continue the steps above for each valve/label/id setting that must be changed SETTING CUP SUPPLY The default settings for Cup Supply should not require any changes. If changes are required, see the service manual for complete directions 17

21 8.3. SET FLOW RATE AND SET VALVE RATIO Remove the conveyor assembly to allow easy access to the area under the valve for the ratio cup and graduated beaker. Use the UP/DOWN arrow keys to scroll to the 4 RATIO VALVE selection and press ENTER. When in the RATIO VALVE mode, pressing (and releasing) any flavor button (including WATER and SODA) will cause the valve to dispense for 4.0 seconds. This allows you to set the flow rates for water and carbonated water and then also to set the syrup to water ratios for all the flavors ADJUSTING WATER FLOW RATE FIGURE 10. TOP VIEW, VALVE Setting the Water Flow Rate: Begin by holding the water compartment of a ratio cup below the valve and press the WATER button. The valve will pour for 4.0 seconds. U.S. Version as follows: The liquid poured during the 4.0 seconds should be: Water: Carbonated Water: 12 ounces 1/2 ounce 13 ounces 1/2 ounce Australian Version as follows: The liquid poured during the 4.0 seconds should be: Water: Carbonated Water: 335 ml (11.33 oz.) 383 ml (12.95 oz.) If the volume poured during the 4.0 seconds is more or less than desired the flow regulator must be adjusted. This must be repeated for the SODA. See Figure 10 for location of the flow adjustment screws on the valve. 18

22 Carbonated beverages are commonly set at a flow rate of 4.0 ounces/second and plain water beverages are set at a flow rate of 3.5 ounces/second. U.S. Version Finished Drink Flow Rate Ounces Water Poured In 4 Seconds Oz Oz. FIGURE 11. OUNCES WATER POURED IN 4-SECOND SET POUR TIME Australian Version: Finished Drink Flow Rate Ounces Water Poured In 4 Seconds ml (11.33 oz.) ml (12.95 oz.) FIGURE 12. OUNCES WATER POURED IN 4-SECOND SET POUR TIME 8.5. ADJUST THE SYRUP RATIO After the water flow rates are set, the syrup ratio must be adjusted. The water flow rates were set based on a ratio of 4.75:1 (4.25:1 = Australia). The actual ratios will be set at 4.75:1 and 5.25:1, therefore, the finished drink flow rate will vary slightly from the desired flow rate of 4.0 oz/sec. NOTE: Always adjust the ratio for the syrup with the highest viscosity first. Some syrups may be too viscous and you might be unable to achieve the desired ratio. In these cases, the PW or CW flow rate will have to be lowered to permit setting the proper ratio. NOTE: Once the PW and CW flow rates are set they should not be be changed. Any change to the PW or CW will require that all syrup to water ratios be readjusted. NOTE: Be sure to use the correct ratio cup for the ratio being adjusted. U.S.A. Follow the procedure below: 1. Hold the ratio cup water compartment below the valve and press the water button if adjusting a non-carbonated drink or the carbonated water button if adjusting a carbonated water drink. 2. Hold the appropriate ratio cup syrup compartment below the valve and press the syrup flavor button. 3. Acceptable ratio is shown in the illustration below as the Correct Reading within the same bandwidth. ACCEPTABLE RATIOS Syrup Too Low Syrup Too High Correct Reading SYRUP WATER FIGURE 13. RATIO CUP, ACCEPTABLE RATIO 19

23 Australia Follow the procedure below: 1. Using the table below, determine the volume of syrup that should dispense in the 4 second pour. Example: The ratio for the flavor is 5.25, and it is a carbonated (CW) drink, the unit should dispense 75.7 ml of syrup in the 4 second dispense. If the ratio for the flavor is 5.25, and it is plain water (PW) drink, the unit should dispense 66.3 ml of syrup in the 4 second dispense. Ratio CW/PW ml Syrup 5.25/1 5.25/1 CW PW /1 4.75/1 CW PW /1 4.25/1 CW PW /1 PW Hold the volume measuring device below the valve, and press the syrup flavor button. 3. Adjust the flow regulator as required. See Figure 10 for location of the adjustment screws on the valve. At the end of this adjustment press the CLEAR (<<Back) button twice to return to the main menu ADJUST PORTION The ABS control normally assumes the valve flow rate is 4.0 oz./sec for the 4.75 (4.25 = Australia) ratio beverage flavors. The ABS control also assumes the valve has been set to the ratio listed in the syrup set-up table. Any variation from these norms will affect the portion. To complete the adjustment of the ABS control for valve flow rates and ratios use the UP/DOWN arrows to highlight the ADJUST PORTION mode and press ENTER. Use the UP/DOWN arrow keys to highlight option #1, NORMAL PORTION, and press ENTER. Using the RIGHT or LEFT arrows, select the flavor to be adjusted and when highlighted, press ENTER. Note: The PW & CW must be adjusted first Adjusting the Carbonated Water In this example the menu shows that you are adjusting the portion for CW, you will test dispense 18 oz. (532.3 ml) and the current time setting is 0. 20

24 The following is a test pour only and has no connection to the cup size. Press any cup button to start the 18 ounce (532.3 ml) test pour. Compare the test pour to the desired 18 ounces (532.3.ml). If the test pour is less than 18 ounces (532.3 ml) increase the TIME = 0 value. If the test pour is greater than 18 ounces, decrease the TIME = 0 value. The number in brackets is only for reference and is not an actual time or volume quantity. The TIME = 0 value can be increased by pressing the UP arrow and decreased by pressing the DOWN arrow. Retest the portion and make any additional adjustments necessary to set the pour to the test value of 18 ounces (532.3 ml). Press ENTER to accept the settings Adjusting the Plain Water In this example the menu shows that you are adjusting the portion for PW, you will test dispense 18 oz. (532.3 ml) and the current time setting is 0. The following is a test pour only and has no connection to the cup size. Press any cup button to start the 18 ounce (532.3 ml) test pour. Compare the test pour to the desired 18 ounces (532.3 ml). If the test pour is less than 18 ounces (532.3 ml) increase the TIME = 0 value. If the test pour is greater than 18 ounces (532.3 ml), decrease the TIME = 0 value. The number in brackets is only for reference and is not an actual time or volume quantity. The TIME = 0 value can be increased by pressing the UP arrow and decreased by pressing the DOWN arrow. Retest the portion and make any additional adjustments necessary to set the pour to the test value of 18 ounces (532.3 ml). Press ENTER to accept the settings Adjusting the Flavors The Top-Off delay and the flush function can now be adjusted for each flavor at this time Adjusting the FLOAT PORTIONS FLOAT EXPLANATION: The ABS is capable of pouring a partial filled, no ice drink, which is intended to have ice cream added to become a float drink. the ABS will pour any flavor, and size combination float drink, when the float option is selected during the ordering process. When in the AUTOMATIC mode, the DOWN arrow key serves as the FLOAT option button. When the unit is in the MANUAL, TEST, and SERVICE modes, the DOWN arrow key assumes its normal function. Using LEFT/RIGHT, UP/DOWN arrow keys, select the cup size that requires float liquid level adjustment, and press ENTER. Use the UP/DOWN arrow keys to adjust the number closer to 99 (decrease the liquid level) or 0 (increase the liquid level). Press ENTER to accept the setting change, prior to pressing BACK/CLEAR to move out to the previous menu. 21

25 8.7. TOP-OFF EXPLANATION Drink flavors that tend to pour with excessive foam have been adjusted so 70% of the drink pours and then after a delay (shown in Display) the remainder of the drink pours ADJUSTING THE TOP-OFF If the Top-Off setting needs to be changed, use the RIGHT/LEFT arrows to select the Top-Off value and then change it to the desired time delay value using the UP/DOWN arrows. The value shown in the display is seconds of time delay between the first part of the drink and the second part of the drink. At the end of this adjustment press ENTER to accept these changes. Press the CLEAR (<<Back) button twice to return to the main menu ADJUST ICE PORTION Install the conveyor assembly before beginning the next procedure. Use the UP/DOWN arrows to highlight 6 ADJUST ICE. Press ENTER. If the conveyor assembly is not present the ABS control will not allow entry into the ADJUST ICE mode. Follow the instructions on the screen. Adjustment of the ice portion compensates for the different ice shapes and the varying amount of ice that will be in the ice chute. The factory default setting is set for Cornelius Ice Machine cube ice. Adjustments may not be necessary but must be tested for correct cup fill levels. The menu for the ADJUST ICE will appear. Use the UP/DOWN arrows to highlight CUP PORTION menu item. This will allow you to adjust the amount of ice dispensed into the cup. Using the UP/DOWN arrow buttons select the cup size to be adjusted and press the ENTER button to select. With the NORM value selected, use the Up or DOWN arrows to increase or decrease the value to increase or decrease the amount of ice dispensed. The ABS control will calculate the number of ice cycles necessary to dispense ice in both the normal and extra ice amounts. To test the new ice portion factor setting, pour a test drink by pressing the NO ICE button. A test drink with extra ice will be dispensed by pressing the EXTRA ICE button. Measure the level of liquid from the top of the cup. The liquid level should be 3/8 to 1/2 from the top of the cup. When the level is correct, press ENTER to save the changes and then repeat the process for all cup sizes. 22

26 8.10. SETTING REFILL TIME If the ice chute does not refill completely after each test dispense, adjust the ice REFILL timer. Use the RIGHT or LEFT arrows to select REFILL time value. Use the UP/DOWN arrows to change the time value in 0.5 second increments. It is possible that the time can be set too long and the agitator will continue to operate after the ice chute is full. This does no harm but it can delay the start of the next drink pour cycle and thereby slow down the cycle times IDLE TIME, SETUP Idle time refers to the length of time the ABS unit must be idle before the automatic agitate cycle will occur. Also part of this setting is the length of time that the agitate will continue. The idle time between agitate cycles is always displayed in minutes and the length of agitate time is displayed in seconds. The menu for the ADJUST ICE will appear. Use the UP/DOWN arrows to highlight IDLE TIMERS menu item. This will allow you to adjust the agitate time length and the interval between agitate cycles SAVING THE SET-UP The Set-Up is now completed. Repeatedly press the CLEAR button until the SERVICE:SETUP menu is displayed. Use the UP/Down arrow keys to highlight the SAVE/RESTORE item on the menu. Press ENTER Use the UP/Down arrow keys to select SAVE: YES NO, then use the RIGHT/LEFT arrows to select the YES item on the menu. Press ENTER. The display at the left will appear and you must then press ENTER to save the setup or CLEAR to not save the setup ADDITIONAL SAVING/RESTORING INFORMATION When the SAVE/RESTORE DATA menu is displayed, if NO is chosen, the following will be displayed: If NO is chosen and ENTER is pressed then the following will be displayed and you will be given the choice of restoring the old data. Press ENTER to return to the Old Data. Old Data is not necessarily the factory defaults but the last setting that was saved. Press CLEAR to choose not to save the old data. 23

27 When you are at the SAVE/RESTORE DATA menu and you choose to select the RESTORE DEFAULT menu item then the following will be displayed: If RESTORE DEFAULT is chosen and ENTER is pressed then the following will be displayed and you will be given the choice of restoring the factory default settings. Press ENTER to return to the Factory Default settings. Press CLEAR to choose not to save the Factory Default settings. 9. MANUAL MODE OPERATION The Set-Up is now complete. Press the CLEAR button twice to return to the MANUAL mode. 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 unit is in the MANUAL mode. While in the MANUAL mode, POS drink orders continue to be received and placed in the order buffer. It is highly recommended that the MANUAL mode be used when refilling the cup tubes or removing foreign objects from the conveyor/drip tray to prevent sudden movement of the turret or conveyor when an order is received CLEAR THE POS ORDER BUFFER To clear the POS buffer, the ABS unit must be in the MANUAL mode. Use the UP and DOWN arrows to highlight the xxx ORDERS. When highlighted, press the CLEAR button. A confirmation question will appear. Press ENTER to clear the entire order buffer or CLEAR to cancel action. 10. AUTOMATIC MODE OPERATION Pressing the AUTO button placed the ABS system into Automatic. The AUTO button also can be used to place the ABS unit into the MANUAL mode. If the ABS unit is in AUTO and this button is pressed, the ABS unit will be placed in MANUAL. If the ABS unit is in MANUAL and the button is pressed, the ABS unit will be placed in AUTO. If alarm conditions are present (but previously acknowledged) the ABS status will indicate Warning. While the Warning status is present. the word AUTOMATIC will flash. 24

28 10.1. 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 drink desired. The display will indicate the selection made. 2. Press a Flavor button to select the flavor 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 FLOAT 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. NOTE: Failing to enter a flavor selection will result in an empty cup being produced with or without ice. 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. 25

29 10.2. ALARM & WARNING MESSAGES To view warnings, press the MANUAL button. LEFT and RIGHT arrows scroll the alarm list and the number of unresolved warnings and alarms are displayed with direction cues to scroll. To hide all alarm messages press the CLEAR<< button. Listed below are all of the Alarm and Warning messages that may appear on the display screen. Message Explanation Correction [X] CUP OUT AT STATION (Y) CLEAR SYRUP SOLD OUT The cup tube for cup size [X] is empty at station [Y]. The clear syrup (Sprite) is sold out (empty B-I-B) Sensor must be installed and connected to the ABS system for this warning to occur. Refill the empty cup tube with the correct cup size and then press ENTER to continue dispensing. Connect a new syrup supply and the ABS unit will continue. If the ENTER button is pressed before the syrup supply is replenished, automatic operation will resume but only the cup and ice will be dispensed for this flavor. LOW ICE REFILL SOON Ice level in the ice bin is low. Refill the ice bin with 32 F ice. Press ENTER. CLEAR CUP JAM NO CUP EXTRACTED TURRET STALLED CONVEYOR STALLED Cup(s) is jammed in the conveyor at the cup extraction position and the conveyor and turret are unable to operate. The gripper did not or could not extract a cup from the cup tube. Cup(s) is jammed in the conveyor at the cup extraction position and the conveyor and turret are unable to operate. Conveyor failed to index from position to position in correct amount of time. Remove all cups from the conveyor cup holders at the Extract Position before pressing the ENTER button. Another cup will be extracted and dispensing will continue. Check cup supply at the extract station and make sure the cups are not stuck. Make sure the gripper pads are not damaged Remove all cups from the conveyor cup holders at the Extract Position before pressing the ENTER button. Another cup will be extracted and dispensing will continue. Clear obstruction before pressing ENTER. Conveyor must be installed correctly. Check index sensor operation. CO 2 or AIR PSI OUT CO 2 supply is low or empty Change CO 2 cylinder or have bulk tank refilled. Air compressor not operating Check cause or non-operation and repair. 26

30 ABS FLOAT SOFTWARE NOTE: The software in this ABS contains the new FLOAT option. This option 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. The store may, or may not wish to have float drinks available at this time. However, following is the set up procedure, along with drink ordering steps. It is important that the drink ordering procedure, and keypad function changes, be included in the store personnel training. It is also important to note that this FLOAT option is only available from the ABS touch pad. 11. TESTING OF THE NEW FLOAT DRINK FUNCTION: NOTE: The down button now functions as the FLOAT modifier when the unit is in AUTOMATIC mode, and functions as the DOWN arrow key when the unit is in the MANUAL mode. 1. Order a float drink: Place the unit in AUTOMATIC MODE Select the CUP SIZE Select the FLAVOR Press the DOWN ARROW/FLOAT KEY Press ENTER 2. Check that the unit dispenses the correct size cup, the correct flavor product, NO ice, and fills the cup to approximately 70% full level. 3. Check that the flavor display is reading the correct product name, the Special box should contain an asterisk indicating that the drink was ordered from the front panel, and the remaining box should have a the letter F in it, to indicate the drink is a float drink. The word FLOAT will appear when the float option is applied to the drink order. This button operates as the DOWN arrow key in the manual mode, and as the FLOAT key while the unit is in automatic. 27

31 4. Repeat #3 for both PW and CW drinks, for all available cup sizes. 5. Demonstrate the new function to the store managers and workers. 12. CHANGING THE FLOAT DRINK DISPENSE VOLUMES: **The default dispense volumes for float drinks is 70% of the size drink ordered. The store personnel may desire higher or lower levels for the various sizes of cups, dependant upon the volume of ice cream they intend on placing in the float drink. To change the liquid dispense levels, perform the following: 1. Put the unit in MANUAL mode, press the down arrow key to go into SERVICE mode, enter the password (flavor buttons 1, 2, 3, 4), and select the SET UP mode. 2. Arrow down to, and select the ADJUST PORTIONS menu. 3. Select the FLOAT PORTIONS option. 4. Inside of this menu option, you will find all available cup sizes. Use arrow keys to select the size that required a dispense volume change, and press ENTER. 5. You will see for any size that is selected, that the setting is 20. This is the default setting, and results in the ABS dispensing a float drink that is 70% the volume of a drink with no ice, for that particular size cup. This number is adjustable from 99, to 0. **A setting of 99 will result in the LEAST amount of product dispensed. **A setting of 0 will result in the LARGEST amount of product dispensed. NOTE: REMEMBER TO PRESS ENTER AFTER MAKING EACH CHANGE, AND BEFORE PRESSING BACK/CLEAR TO GET OUT OF THE SCREEN, TO ALLOW THE ABS TO ACCEPT THE CHANGES MADE. 6. After making the desired changes, return to the AUTOMATIC MODE, and re check the float fill levels. 28