Borg & Overstrom 628 Installation & Operation Manual Download Page 81

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INSTALLATION & OPERATION GUIDE

628 & 698 MODELS

Head office: 31 Bolling Road, Bradford, BD4 7HN

Contact: 01226 720 490, [email protected]

Summary of Contents for 628

Page 1: ...INSTALLATION OPERATION GUIDE 628 698 MODELS ...

Page 2: ...ation and Descaling Guides Page 20 Trouble Shooting Guides Page 24 Exploded Diagrams Page 36 Parts Listing Page 43 Machines Accessories Listing Page 46 Product Listing Page 48 Categorised Parts Ordering Guide and Returns Note Page 56 Step By Step Guides Page 59 628 698 Models Technical Manual ...

Page 3: ...Section1 Technical Manual ...

Page 4: ...ational types Classic Reservoir Model Cold Water Storage Tank Direct Chill Model No Stored Drinking Water Both types are available as Floorstanding Countertop All Reservoir models are available as either Cold and Ambient Hot and Cold Direct Chill models are currently only available as Cold and Ambient ...

Page 5: ...ssure Reducing Valve is fitted to all supplies greater than 3 5 bar pressure The Baffle Plate inside the Cold Tank maintains separation between the lower chilled water and upper ambient water The cooling system only chills water in the lower part of the Cold Tank Dispense is at gravity pressure only via push operated Taps The Cold Temperature is thermostatically controlled via the adjustment screw...

Page 6: ... to show when compressor is operating Hot Cold Machines Electrical On Off Switches At upper rear of machine Cold Switches on Cooling Operation Hot Switches on Heating Operation 10A Fuse At upper rear of machine Hot Tap Lift Safety Tag and press downwards to dispense Hot Water Cold Tap Press downwards to dispense Cold Water Green LED Top Colours to show Cooling Operation is switched on Yellow LED M...

Page 7: ...Section 2 Technical Manual ...

Page 8: ...e drained and allowed to refill before operation of the machine commences If in any doubt at this stage please add some sanitisation fluid to your initial tank of water so as to flush the machine before use Once the machine has refilled with water the machine can be connected to the mains supply and switched on The switch at the rear of the machine then needs to be turned on before operation can c...

Page 9: ...ed into the reservoir 3 The water can be turned on again briefly to half fill the reservoir with sanitising fluid The upper half of the reservoir should be cleaned utilising sanitisation wipes supplied by Azure Whilst the sanitisation fluid is having its effect please clean the external casing with Azure sanitisation wipes Once the sanitisation fluid has been left for a satisfactory period of time...

Page 10: ...d be turned on and you will hear the header tank and ice bank starting to fill Once this has stopped filling the machine can be connected to the mains supply and switched on The switch at the rear of the machine then needs to be turned on before operation can commence NB If your water cooler has a hot water facility please allow time for the hot tank to fill up before turning on To draw water into...

Page 11: ...water button until the sanitisation until the sanitisation fluid hsa been flushed through the system 4 The last stage is to fully clean the external casing with Azure sanitisation wipes When this has been completed your sanitisation is complete If you have any question regarding sanitisation please do not hesitate to ring Azure Head Office on 0845 4 50 30 90 Top cover Cover of Header Tank Ice Bank...

Page 12: ...e drained and allowed to refill before operation of the machine commences If in any doubt at this stage please add some sanitisation fluid to your initial tank of water so as to flush the machine before use Once the machine has refilled with water the machine can be connected to the mains supply and switched on The switch at the rear of the machine then needs to be turned on before operation can c...

Page 13: ...ped into the reservoir 3 The water can be turned on again briefly to half fill the reservoir with sanitising fluid The upper half of the reservoir should be cleaned utilising sanitisation wipes supplied by Azure Whilst the sanitisation fluid is having its effect please clean the external casing with Azure sanitisation wipes Once the sanitisation fluid has been left for a satisfactory period of tim...

Page 14: ...lect fitting position Normally at top of right hand side panel towards front of machine 3 Attach self adhesive pad to mounting bracket and affix to chosen site Clean area first to ensure good adhesion 4 Additionally self tapping screws can also be used to ensure a secure fitting ...

Page 15: ... add a Leak Detector to your Borg Overström water cooler This product does not in anyway provide a guarantee or insurance against any flooding but provides the means of added prevention Please ensure that you read this manual thoroughly before proceeding and take note of the installation and operation procedures to achieve the best results Inlet and Outlet Re set switch Probes Connection plugs ...

Page 16: ...f switch will not cut the power to the device In the event of any queries please call Technical Support on 0845 4 50 30 90 Installation Operation This product can only be used in conjunction with a Borg Overström water cooler Please follow the step by step procedures for installation 1 Please fix the Leak Detector as high as possible within the machine Ensure that the red lever has sufficient spac...

Page 17: ...bing under Hot Tank towards back of machine 7 Fit Drainage Elbow fitting see picture 2 8 Position Elbow through hole in shelf picture 3 and hold in position by fitting second drainage tube from underside see picture 4 9 Position Drainage Tank in lower compartment 10 Fit Control Unit to inside wall of lower compartment with self adhesive pad as supplied 11 Connect small wiring to Float Switch assem...

Page 18: ...ip tray area Connect the 2 lengths of silicone tube together using the 90 degree elbow Connect the shorter length to stem on the rear of the drip tray area Feed the tube to the back of the machine where it can be directed into the base Connect to the lid of the container Remove the bung from the stem of the drip tray and the machine can now be put into service ...

Page 19: ...Section 3 Technical Manual ...

Page 20: ...ne to ingest the solution Leave solution for 10 minutes inside machine for sanitisation to take effect During this time thoroughly clean the machine externally For this we recommend the use of proprietary disposable sanitisation wipes Pay particular attention to the dispense faucet and the push button controls Remember to include the drip tray If a Waste Overflow System is fitted this may benefit ...

Page 21: ...ilution ratios as supplied with the product Remove the existing filter and install a filter head to suit the service cartridge if necessary Empty 100ml of sanitisation fluid into the service cartridge and connect the cartridge to the filter head The water can be turned on again briefly to half fill the reservoir forming a sanitising solution The upper half of the reservoir should be cleaned with s...

Page 22: ...over from the appliance and the lid covering the cold tank on later models Carefully remove the Float Valve and Baffle Plate from the Cold Tank 4 Slowly pour the descaling solution into the Cold Tank This will drain directly into the Hot Tank Continue to add the solution until it also just begins to fill the Cold Tank too Leave the solution to react with the limescale as directed 5 Should limescal...

Page 23: ...Technical Manual Section 4 ...

Page 24: ...Turn off elec and water and reset Check for leaks Check Tap action Dismantle Tap and replace complete or just washer as needed Replace adjust position repair as needed Check and unblock replace as needed From Cold Tap Firstly all as for Ambient Tap Cold area of tank frozen Thermostat set too low Cold area of tank frozen Faulty Thermostat Carry out checks and actions as for ambient tap Thaw out and...

Page 25: ...d switching off cool warm to touch Thermostat set too high Faulty Thermostat Compressor runs but not Switching off Hot to touch Refrigeration problem Compressor not running at all No elec power supply Thermostat faulty Compressor only hums slightly briefly Relays loose Compressor Faulty Cold Tank Baffle Plate Not Connected Decrease Cold Thermostat set point Replace Thermostat Replace Thermostat Co...

Page 26: ...n Reset Overheat Button on Hot Tank Locate break and repair Warm Temperature not hot Main reheat element not working Red LED on all the time Hot tank heavily scaled up signs of scale in top of Cold Tank loud boiling noises etc Break in supply wiring to main element Check supply voltage and current to Heater Band and replace accordingly Check supply voltage and current to Hot Thermostat and replace...

Page 27: ...e and repair accordingly Locate and repair accordingly Water pressure too high Jammed Float Valve Split Float Valve Washer Overflowing Cold Tank Hot Tank exclusively sealed Hot Tank thermistor probe faulty Pre 0708 models only Control Board Failure Pre 0708 models only Condensation from tank or Cold Water Pipe Check pressure and fit pressure reducing valve if needed Check and repair float valve Re...

Page 28: ...nnect as necessary Also check out other symptoms as described separately Replace PCB Machine shakes on Start Up Compressor Starting Level Surface Uneven Surface Missing Fittings No action needed This is quite normal Level up machine Adjustable feet from early 2009 Replace missing fittings Tripping out Electricity supply Machine in high humidity environment Electrical circuitry faults Discuss possi...

Page 29: ...n incoming supply are fitted and are turned on Check power cord connected and live and machine is switched on Reset Waterblock and check for any leaks Check valve action Carefully dismantle valve and clean out part replace complete replace as needed Valve clicking but no water Check if hole in centre of washer is clear Valve not clicking Check whether voltage is present when operated Caution High ...

Page 30: ...ank frozen Faulty Thermostat Chiller tank Frozen faulty air pump Carry out checks and actions as for ambient tap Thaw out and check and replace Cold Water temperature set point Thaw out and check and replace Air pump and or check electricity supply to pump present From Ambient or Cold Valve Button Not being pressed enough Faulty PCB Press button firmly N B This could be caused by a surrounding col...

Page 31: ...Cold water not Cold Compressor runs and switching off cool warm to touch Thermostat set too high Faulty Thermostat Compressor runs but not Switching off Hot to touch Refrigeration problem Compressor not running at all No elec power supply Compressor only hums slightly briefly Relays loose Compressor Faulty Decrease Cold Thermostat set point Replace Thermostat Contact Azure Technical Support Check ...

Page 32: ...machine Water lying in bottom of machine or on mid shelf Overflowing Drip Tray Leak in supply inlet pipe work and or filter Leak from machine water pipework fittings Overflowing Header Tank Water pressure too high Jammed Float Valve Split Float Valve Washer Empty Drip Tray Locate and repair accordingly Locate and repair accordingly Check pressure and fit pressure reducing valve if needed Check and...

Page 33: ...power supply and reconnect as necessary Also check out other symptoms as described separately Replace PCB Machine shakes on Start Up Compressor Starting Level Surface Uneven Surface Missing Fittings No action needed This is quite normal Level up machine Adjustable feet from early 2009 Replace missing fittings Tripping out Electricity supply Machine in high humidity environment Electrical circuitry...

Page 34: ...ater pressure is low or after filter change Button Not being pressed enough Faulty PCB Hold button on to purge air out This could take several minutes where pressure is low Pre flush filters Press button firmly N B This could be caused by a surrounding cold environment making the action stiffer Replace PCB From Ambient or Cold Water Valve and hammering noise Fluctuating mains water pressure situat...

Page 35: ...Section5 Technical Manual ...

Page 36: ...B Borg Overstrom Classic 628 Cold Ambient Countertop Exploded Component View Production no 628 10 Jan 2009 628 698 Models 36 ...

Page 37: ...B Borg Overstrom Classic 628H Hot Cold Countertop Exploded Component View Production no 628 10H Jan 2009 628 698 Models 37 ...

Page 38: ...B Borg Overstrom Classic 698 Cold Ambient Floorstanding Exploded Component View Production no 698 10 Jan 2009 628 698 Models 38 ...

Page 39: ...B Borg Overstrom Classic 698H Hot Cold Floorstanding Exploded Component View Production no 698H 10 Jan 2009 628 698 Models 39 ...

Page 40: ...628 698 Models 40 Borg Overstrom 628 698 Cold Ambient Ambient Electrical Diagram ...

Page 41: ...628 698 Models 41 Borg Overstrom 628 698 Hot Cold Production series No 10 ...

Page 42: ...Technical Manual Section6 ...

Page 43: ...121255 628 Left Side Panel 1 1 1 0 0 0 M3 M3 M3 121526 628 Right Side Panel 1 1 1 0 0 0 M4 M4 M4 122825 Back Panel 1 1 0 1 1 0 122835 Back Panel IEC 1 1 1 1 1 1 M5 M5 M5 M5 M5 M5 122945 Rear Cover Strip 0 0 0 1 1 1 M6 M6 M6 122245 Rear Cover Strip 1 1 1 0 0 0 M14 M6 M14 174318 698 Condenser 0 0 0 1 1 1 M9 M9 M9 174319 628 Condenser 1 1 1 0 0 0 M9 M9 M9 174316 Dryer 1 1 1 1 1 1 M10 M10 M10 M10 M10 ...

Page 44: ...rain Pipe 0 1 0 0 0 0 H8 154525 Hot Vent Pipe Fitting 0 1 0 0 1 0 Hot Vent Pipe cover 0 1 0 0 1 0 151543 Hot Vent Filter 0 1 0 0 1 0 628 Drain Bung 0 0 1 0 1 1 H12 154411 698 Hot Tank DC Drain outlet 0 0 1 0 1 1 R7 H13 151544 698 Hot Tank DC Drain Bung 0 0 1 0 1 1 R8 H14 R8 183242 698 Hot Tank DC Drain Nut 0 0 1 0 1 1 R9 H12 R9 Hot Tank Only 0 1 0 0 1 0 172311 Heater Element 0 1 0 0 1 0 H6 H5 1732...

Page 45: ... 0 0 0 1 1 1 M3 x 4 RHD M Screw 0 2 0 0 2 0 182251 M3 x 4 RHD M Screw 0 4 0 0 4 0 H4 H4 182461 M4 x7 M Screw 0 2 0 0 2 0 H7 H7 M4 x 7 RHD M Screw 0 2 0 0 2 0 181125 4 0 x 16 S S PHD S T Screw 0 0 6 0 0 6 181122 4 0 x 8 PHD S T Screw 0 0 1 0 0 1 C13 C13 181342 4 0 x 20 PHD S T Screw 4 4 4 0 0 0 M15 M15 M15 181692 4 0 x 16 B A PHD S T Screw 4 4 4 0 0 0 M13 M13 M13 128961 698 Polystyrene Carton Base ...

Page 46: ... and Ambient Silver CW628 Countertop Cold and Ambient Graphite CW628H Countertop Cold and Hot Silver CW628H Countertop Cold and Hot Graphite DC698 Direct Chill Floorstanding Cold and Ambient Silver DC628 Direct Chill Countertop Cold and Ambient Silver ACCESSORIES CW051 Overflow System CWLD1 Leak Detector W2081 Standard Cup Dispenser CW2081 B O Cup Dispensor CWLVS Level sensor CWWB Wall Brackets CW...

Page 47: ...Section7 Technical Manual ...

Page 48: ...nel 698 Graphite no Drip 120925 Front Panel 698 Graphite with drip 120926 Door panel Graphite 120927 Infill Front Panel Dark Graphite 120929 Infill Door Panel Dark Graphite 120931 Filter Blanking Panel Graphite 121255 Side Panel 628 Left 121256 Side Panel 628 Right 121855 Side Panel 818 Left 121856 Side Panel 818 Right 121859 Side Handle 121955 Side Panel 698 Left 121956 Side Panel 698 Right 12224...

Page 49: ...el Graphite 126825 DC Tap Cover 127841 Compressor Shelf 127842 Reservoir Shelf 128201 B O Carton 628 128202 B O Carton 728 128203 Poly Bag 628 728 128261 Polystyrene Carton Base 628 128803 Polystyrene Carton Top 628 698 128901 B O Carton 698 128902 B O Carton 798 128903 Poly Bag 698 128961 Polystyrene Carton Base 698 128981 B O Carton 818 COLD WATER PARTS 131422 1 4 Inlet Connector Back Nut 131423...

Page 50: ...ype Push Fit 132457 Reservoir Float Valve Lid type 133411 Tank Lid 133412 Clip on Tank Lid 133413 Faucet 133414 DC Header Tank 133415 DC Cold Tank Inner Lid 133416 DC Cold Tank Lid 133417 DC Header Tank Bracket 133418 DC Header Tank Lid 133419 Reservoir Baffle Plate 133421 133422 133512 Faucet 134510 DC Tank Pipe Assembly 134561 Straight Tube 134562 Straight Tube 134563 Straight Tube 134564 Straig...

Page 51: ...82 Hot Tap Safety Tag 144071 Tap Back Nut 144072 Back Nut Spanner HOT WATER PARTS 151542 Hot Tank Bung 151543 Hot Vent Filter 151544 698 Hot Tank DC Drain Bung 154411 698 Hot Tank DC Drain outlet 154412 Hot Vent Pipe cover 154520 Hot Vent Pipe Set 154521 Hot Vent Pipe 154522 Hot Vent Pipe 154523 Hot Water Pipe DC Tank Pipe 154524 Hot Tank Feed Pipe 154525 Hot Vent Pipe Fitting 154526 Straight Type...

Page 52: ...t NTC Main Wiring Loom 172156 Cold Main Wiring Loom 172157 Earth Loom 172158 DC Main Wiring Loom 172159 Fuse Wiring Loom 172161 IEC Wiring Loom 172162 IEC Socket 172175 Blue LED Light 798 172176 Blue LED Light 818 172232 B O Relays 172311 Heater Element 172312 Heater Element 110V 173246 Solenoid Valve CW Cold 173247 Solenoid Valve CW DC Hot Ambient 173248 Solenoid Valve Old DC Cold 173249 Solenoid...

Page 53: ... 175361 UV Circulating Pump 175362 UV Pump Power Pack 171205 PCBoard Conversion 173262 Thermistor Probe 173263 96C Hot Tank Overheat Cut Out FIXINGS 181121 3 0 x 8 S S RHD S T Screw 181122 4 0 x 8 S S RHD S T Screw 181123 4 0x10 S S RHD S T Screw 181124 4 0 x 12 S S RHD S T Screw 181125 4 0 x 16 S S RHD S T Screw 181231 4 0 X12 BZP RHD S T Screw 181341 3 0 x 8 YP PHD S T Screw 181342 4 0 x 20 YP P...

Page 54: ...neous fittings 191141 DC B O Label 191142 Cold B O Label 191143 Hot B O Label 191151 Elite 798 Cold Ambient Label 191152 Elite 798 Cold Hot Label 191161 B O 818 Label 191191 Please remove carbon pack Label 191192 Please make sure hot water tank Label 192131 B O Cup Dispenser 192132 Cup Dispenser Plain 192241 Cup Dispenser Odd Parts 192242 Sports Bottles Borg Overstrom 192243 Sports Bottles Ice Coo...

Page 55: ...e Direct Chill Floorstanding Cold and Sparkling 104510 Elite Direct Chill Countertop Cold and Ambient Silver 104615 Elite Direct Chill Countertop Cold and Hot Silver 103210 S Line Countertop Cold and Ambient Silver 103215 S Line Countertop Cold and Hot 103310 S Line Countertop Cold and Sparkling Direct Chill 103910 S Line Base Cabinet Silver 112910 Breakstation for 798 109910 Floorstanding cold an...

Page 56: ...FOURTEEN DAYS OF THE SUPPLY OF THE REPLACEMENT ITEM Customer Contact Address Tel No Date Description of Parts Returned Item Code Part No Replacement Items Invoice No FOR PARTS MACHINES Faulty Parts Removed From Machine Type Serial No Machine Purchase Date Inv No Description of Faults Defects Please note that descriptions such as faulty part are not acceptable Claim In Out Guarantee delete as appro...

Page 57: ...transit packaging of your return Please use the tear off slip overleaf and enter the Azure service number on the top and bottom of the form where indicated and attach securely to your packaging Please enclose a copy of your invoices Make sure the item s are adequately protected to prevent any damage Azure cannot be held responsible for any damage to goods returned without adequate protective packa...

Page 58: ...Technical Manual Section8 ...

Page 59: ...Replacement Procedure Page 60 62 Procedure for Upgrading Hot Water Temperature Control System Page 63 69 Water Tubing Replacement Step by Step Guide Page 70 71 Procedure For Checking the Compressor Cooling Operation Page 72 73 Solenoid Valve Replacement Page 74 ...

Page 60: ... blocked requiring more caution On the Floorstanding machine the drain is on the back of the machine and on the Countertop it is underneath 3 Remove the two screws at the back of the top Panel and lift off 4 Carefully remove Tap Cover Panel as shown by first squeezing inwards and then out and disconnect PCB 5 Remove the two screws at the top of the front panel and in the case of a Floorstanding ma...

Page 61: ... and carefully ease the Tank out of the machine as far as the electrical connections allow c External Thermostat Tank Can also be retrofitted to earlier Models for upgraded Procedure see separate Technical Guide b Thermister Probe Tank NB External sensor mountings may vary a Internal Element Tank Discontinued Can be retrofitted all with newer types Bottom Bolt Top Bolt 10 Carefully disconnect the ...

Page 62: ...e spade terminals onto the external sensors as follows Top Sensor Single large white wire and pair of large white small white wire Bottom Sensor Pair of large red small red wire and pair of large white wires 14 Carefully reconnect the silicone rubber pipes connecting as fully as possible Connect new thermistor probe cover cap to side of Tank as applicable Bottom sensor Top sensor Bottom bolt Top b...

Page 63: ...628 698 Models 63 Procedure for Upgrading Hot Water Temperature Control System Tools required PH1 Philips Screwdriver Part required B O Hot Upgrade Kit ...

Page 64: ... Remove Top Lid of the cooler and then carefully remove the Tap Cover from the front panel by squeezing and then lifting off away from front Fig 2 Disconnect both large and small plugs Fig 3 Remove the existing circuit board ...

Page 65: ...nser and very carefully ease condenser away as shown below in Fig 6 Fig 6 Access now possible to Hot Tank If also replacing Hot Water Tank follow Hot Water Tank Replacement Procedure sections 7 15 at this stage This may then mean some of the follwing stages of this procedure are already covered there ...

Page 66: ...628 698 Models 66 Fig 7 Remove the Thermistor Probe with black wire complete with the clear silicone rubber holder Fig 8 Bung hole with cap as supplied Fig 9 Remove the existing Overload Thermostat ...

Page 67: ...ithout button to bottom Ensure that the white Heat Transfer Paste is already applied to the back of the thermostats before fitting Fig 11 Reconnect the original Overload Thermostat wiring to the top overload Thermostat Fig 12 Take new wiring loom and feed the end with plastic plug up from the back ...

Page 68: ...s 68 Fig 13 Feed out of hole in front panel ready to plug onto new circuit board Fig 14 Attach the two connectors on the other end to each of the terminals on the bottom Tank Thermostat Fig 15 Refit condenser panel ...

Page 69: ...and side of tank and down and out of rear of machine Fig18 Connect the plastic plug onto the new circuit board already fitted to the Tap Cover Refit the Tap Cover by locating the top and right side lugs first followed by squeezing the cover to locate the left side lug Refit the Top Cover to the cooler and check the electrical operation All LEDs should light IF TESTING PRIOR TO INSTALLATION ONLY TE...

Page 70: ...of existing white tubing from bulkhead fitting inside and at the back of the lower compartment 4 Draw out the existing tubing from the top and discard 5 Rotate the push fit elbow one half turn 6 Take the replacement tubing as supplied and straighten one end Insert the straightened end into the same tank shelf cut out as the existing tube was withdrawn from taking care to pass through to the right ...

Page 71: ...kwise around the top tank as shown and connect to the push fit elbow joint AS with any push fit joints ensure the tubing is fully inserted into joint and gently pull back on the tubing to lock into position 10 Refit the top lid and secure with the two screws The task is now complete In the event that you have any questions or queries then please call Technical Support on 0845 450 30 90 Water Tubin...

Page 72: ...Remove the compressor relay cover and carefully remove the relays If the power has been even recently connected to the compressor the solid stat relay will be energised and will need discharging 5 Check the Compressor resistance readings Approx readings could be R C 12ohms S C 34ohms R S 46 Ohms sum of both N B There should always be some variation between compressors What should be identified is ...

Page 73: ...perature could indicate a blockage A high current draw would confirm this Contact Azure Technical Support 3 Continue to follow the pipe work from the end of the condenser to the dryer A frozen iced dryer will indicate a blockage Contact Azure Technical Support Again a high current draw would confirm this 4 The dryer exits into the capillary tube Check this for restrictions and NB This has a very s...

Page 74: ...g Solenoid Valve C down to Mounting Plate 5 Remove Screw E securing Mounting Plate D 6 Using a suitable flat bladed screwdriver depress collet ring on push fit connection on inlet side of solenoid valve at F and disconnect pipe work 7 Remove Solenoid Valve by drawing forwards and away from machine frame 8 Refit Solenoid Valve by reversal of the above procedure Ensure correct connection of water in...

Page 75: ...Notes ...

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Page 81: ...INSTALLATION OPERATION GUIDE 628 698 MODELS Head office 31 Bolling Road Bradford BD4 7HN Contact 01226 720 490 info refreshmentsystems co uk ...

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