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Faults

Service Manual Cafitesse 100

07.2004

Table of Contents

Faults

Support for Fault Diagnosis

3.1

Fault Diagnosis

3.2

General Malfunctions

3.2.1

Water System Malfunctions

3.2.2

Cooling System Malfunctions

3.2.3

Dosing System Malfunctions

3.2.4

Heating Plate Malfunctions (Option)

3.2.5

Key Switch/Counter Malfunctions (Option)

3.2.6

Indicated Malfunctions

3.2.7

Faults occurred in the Market and their Solutions

3.3

Summary of Contents for Cafitesse 100

Page 1: ...coffee coffee stop coffee coffee espresso stop 35260400 July 2004 2004 Douwe Egberts Coffee Systems International Utrecht The Netherlands SERVICE MANUAL Cafitesse 100 ...

Page 2: ...ternal use only Douwe Egberts Coffee Systems issues no explanation or guarantees with regard to the contents of this publication and expressly disclaims all responsibility for any implied guarantees Douwe Egberts Coffee Systems reserves the right to revise and change the contents of this manual without notice Published by Douwe Egberts Coffee Systems Utrecht the Netherlands July 2004 2004 Douwe Eg...

Page 3: ... This Service Manual includes all Service Information sheets until SI CFT 100 139 07 2004 Service Manual Cafitesse 100 ...

Page 4: ......

Page 5: ...ystem B Dosing System C Product Delivery D Cooling System F Housing G Power Supply and Control System K External Options L Payment Systems P Preventive Maintenance 6 Service Procedures 7 Service Information 8 Modification Instructions 9 Spare Parts List 10 2004 Douwe Egberts Coffee Systems International Utrecht The Netherlands ...

Page 6: ......

Page 7: ...s Service Manual Cafitesse 100 07 2004 Table of Contents Preface and Safety Instructions 1 Preface How to use the manual 1 1 General 1 1 1 Structure of the Manual 1 1 2 Definition of Options and Accessories 1 1 3 Safety Instructions 1 2 ...

Page 8: ... the Manual 1 1 1 General This service manual is intended for trained service technicians within the D E C S organisation who have attended the product training courses for this dispenser This service manual is not a study book containing technical details about this dispenser but it can be considered and used as a reference book ...

Page 9: ...the electrical input and ouput of the water system 5 Technical specifications This paragraph explains technical specifications of the water system 6 Options Available options especially for the water system 7 Accessories Accessories for the water system 1 1 2 Structure of the Manual Chapter The service manual is divided into 10 sections numbered from 1 to 10 Subsections Sections can be divided int...

Page 10: ...on When the dispenser was subject to changes consecutively numbered Service Information sheets will inform you on these changes These are then to be filed as chapter 8 in the Service Manual Changes that must be carried out for each dispenser available on the market will be announced by Modification Instructions These are then to be filed as chapter 9 in the Service Manual After the modifications h...

Page 11: ... The level of hazard is determined by the following definitions The dispenser must be placed on a table or a counter The dispenser can be used to deliver hot beverages such as coffee espresso decaffeinated coffee or tea depending on the dispenser model The dispenser can be converted to deliver cold beverages such as café cool The present dispenser can only be used for liquid beverage concentrate i...

Page 12: ...bled short circuited burnt or subject to temperatures above 100 C or water Replace it only by a battery of the same type Spent batteries must be disposed of properly WARNING The dispenser must be connected to the drinking water supply and to the electric power supply in accordance with the local regulations Check the drinking water quality WARNING The dispenser must be connected to an electric cir...

Page 13: ...al regulations and local conditions Check if the current supply matches the instructions of the rating plate WARNING The dispenser is suitable for indoor use only CAUTION The dispenser must not be used when the water supply is interrupted because the boiler will not be refilled CAUTION Do not switch off the dispenser between beverage deliveries in order to keep the optimum water temperature in the...

Page 14: ...1 8 Preface and Safety Instructions Service Manual Cafitesse 100 07 2004 ...

Page 15: ... 2 3 Space Requirements 2 2 4 External Options 2 2 5 Unpacking 2 3 Unpacking the Dispenser 2 3 1 List of all Items that are supplied with the Dispenser 2 3 2 Disposal of Packaging and Dispenser at the End of their Service Life 2 3 3 Installation Putting into Operation 2 4 Checklist Instructions for the Customer 2 5 Transfer of the Dispenser to the Customer incl HACCP Hazard and Critical Control Po...

Page 16: ...5 mm 10 83 in Weight 21 kg 46 3 lbs empty Transport in general CAUTION Transport the dispenser carefully Do not throw the dispenser or handle it incorrectly Do not transport several unfastened dispensers on top of each other Only transport the dispenser in upright position When storing the dispenser ensure that it is only stored indoors and take precautions against parasites Protect the dispenser ...

Page 17: ...n such a manner that a safe transport is guaranteed Use the original packaging if possible Fig 1 2 When used dispensers are stored intermediately for a long time ensure that the hose between the inlet valve and the boiler is empty to avoid spoiling the taste Original packaging by the manufacturer European pallets 0 80 m x 1 20 m 12 Cafitesse100 max 2 piles of 6 dispensers U S pallets 1 00 m x 1 20...

Page 18: ... required for installation Tool required for 1 Service device Programming Part number see spare parts list 2 Pressure gauge Measuring the water pressure Part number see spare parts list 3 Several e g screw drivers adjustment of voltage selector Part number see spare parts list C L R R e p C o d e C l o c k I n p u t s e r v i c e d e v i c e ...

Page 19: ...i Dispenser Connections for hoses R3 4 3 8UNF USA CAN R3 4 R3 4 Europe R3 4 R3 8 The Netherlands USA The dispenser must be installed with an adequate return flow protection that complies with local regulations 2 2 2 Water Supply CAUTION Check the drinking water quality before the installation especially when installing a tank for manual filling A drinking water filter is recommended CAUTION When u...

Page 20: ...g device Requirements An earthed connection is required The mains connection must match the dispenser output socket Each dispenser must be protected 2 2 3 Electrical Supply Dispenser National plug on power supply cable Length of the power supply cable approx 1 80 m 71 in Fig 1 Dispenser Connections Water connection Fuses Power supply cable Water outlet e g drainage kit ...

Page 21: ...Germany VDE CE with counter 230 Volt 3 0 kW B 15 F B Netherl VDE CE key switch 230 Volt 3 0 kW B 31 F B Germany VDE CE 240 Volt 2 7 kW B 41 F B GB VDE CE 100 Volt 1 4 kW A 21 F Japan VDE CE 200 Volt 3 0 kW A 19 F Japan 220 Volt 3 0 kW B 59 F B Korea VDE CE without counter 230 Volt 2 0 kW B 50 F B Scand VDE CE key switch 230 Volt 3 0 kW B 38 F B U Europe VDE CE 208 240 Volt 3 0 kW A 20 F B Caribbea...

Page 22: ...n Plan view 2 2 4 Space Requirements 645mm 25 39 in 50mm 1 97 in 455mm 17 91 in 210mm 8 27 in Minimum requirements for floor walls and ceilings in the area of the dispenser Floor Even nonskid floor Walls There are no particular requirements for walls since the dispenser is not designed for wall mounting Ceiling Dustfree clean 455mm 17 91 in 1075mm 42 32 in Flexi pack 400mm 15 74 in 120mm 4 72 in ...

Page 23: ...2 9 Installation Putting into Operation Service Manual Cafitesse 100 07 2004 2 2 5 External Options to be used by Opcos and distributers for national information e g via external filters ...

Page 24: ...wall Keys3 2 pieces Dispenser Sticker control card Cooling compartment Cup carrier Cooling compartment 1 stand alone packaging unit 2 country specific partly included in the country kit 3 key switch available with this version 2 3 Unpacking 2 3 1 Unpacking the Dispenser Remove the fastener from the cardboard box carefully Do not use sharp utensiles to avoid scratching the dispenser Remove the card...

Page 25: ...e done in accordance with national legal safety requirements and environmental requirements Composition Liner Kraft liner GSM substance 150g m 2 marbled colour Fluting paper Wave substance GSM substance 105g m 2 brown colour Inner paper Duplex GSM substance 170g m 2 brown colour Styrofoam polystyrene with pentane CFC free 2 3 3 Disposal of Packaging and Dispenser at the End of their Service Life ...

Page 26: ...phase plug and ensure that national voltages and tolerances are provided Ensure that the fuse of the group to which the dispenser is connected is in accordance with the national regulations Contact the local power supply company to ask for the voltage values and tolerances if required Measure the water pressure Measure and check the power voltage Fig 1 Legend of the rating plate Example fig 1 1 Ma...

Page 27: ... Country kit with national accessories Measure the water pressure see chap 2 4 Measure the supply voltage Unpack the dispenser see chap 2 3 Place the dispenser on a table Remove the operating panel cover 1 the front cover 2 the housing cover 3 with cooling compartment lid 4 and air duct 5 Fig 3 CAUTION When the front cover is made of glass there is the danger of being injured due to incorrect hand...

Page 28: ...ary tube limiter will be released Dispensers designed to be operated with 208 240 V 60 Hz USA Canada are equipped with a voltage selector located on the back panel of the dispenser Fig 6 Adjust the voltage selector 2 before connecting the dispenser to adapt the dispenser to the mains voltage Fig 6 For the adjustment loosen the fuse holder and turn the adjusting bush 3 by means of a screwdriver unt...

Page 29: ...oling compartment The yellow LED 4 extinguishes as soon as the cooling compartment has reached the correct temperature Fig 8 Place a container below the hot water delivery tap 5 at the front of the dispenser and open the tap Fig 8 Observe if the boiler is being refilled with water at the same time WARNING There is the danger of being scalded by hot water Keep hands and other parts of the body away...

Page 30: ... CAUTION When the front cover is made of glass there is the danger of being injured due to incorrect handling or breaking of the glass Degrease the housing wall thoroughly at which the card holder 12 is to be installed Fig 11 For degreasing it is recommended to use a mixture of 50 isopropanol and 50 water Mount the card holder 12 to the dispenser Fig 11 Insert the documents into the card holder CA...

Page 31: ...uctions to the customer Instruct the customer how to operate the dispenser Remark regarding the cup carrier The turn lift support 2 can be attached to the right side of the dispenser if necessary In this position the cup carrier 7 is turned to the right side during the filling of pots Fig 13 To remove the support pull the torsion spring 3 downwards and withdraw the support pin 4 from the bottom si...

Page 32: ...ions WARNING The dispenser only operates up to the following maximum tilts Tilt to the left and front each 12 i e 130 mm 5 12 in Tilt to the right and to the rear each 10 i e 110 mm 4 33 in WARNING There is the danger of being scalded by hot water Keep hands and other parts of the body away from the delivery area If the tilts exceed these values the water supply must be closed the dispenser must b...

Page 33: ...2 19 Installation Putting into Operation Service Manual Cafitesse 100 07 2004 2 5 Checklist Instructions for the Customer ...

Page 34: ...2 20 Installation Putting into Operation Service Manual Cafitesse 100 07 2004 2 6 Transfer of the Dispenser to the Customer incl HACCP Hazard and Critical Control Points ...

Page 35: ...K gal 1 06 US gal Cold water connection Dynamic pressure min 0 8 4 bar at 1 2 l min 11 6 58 02 psi for café cool option at 0 26 UK gal min 0 32 US gal min Static pressure max 7 bar 101 53 psi Water filling amount 6 5 l atmospheric boiler 1 43 UK gal 1 72 US gal Concentrate capacity Coffee and tea flexy pack with 2 litres contents each 0 44 UK gal 0 53 US gal Electrical Tolerance Voltage Heat capac...

Page 36: ... 2 kW Cooling Thermoelectric cooling Peltier element axial blower electronic control pulse mode operation power consumption approx 40 W without fan Dosing systems Pulse dosing system dosing coil electronically controlled pulse operated pump integrated with non returnable concentrate pack electronic concentrate empty indicator Delivery modes Adjustable delivery mode size of a portion and beverage s...

Page 37: ...ult Diagnosis 3 2 General Malfunctions 3 2 1 Water System Malfunctions 3 2 2 Cooling System Malfunctions 3 2 3 Dosing System Malfunctions 3 2 4 Heating Plate Malfunctions Option 3 2 5 Key Switch Counter Malfunctions Option 3 2 6 Indicated Malfunctions 3 2 7 Faults occurred in the Market and their Solutions 3 3 ...

Page 38: ...e the malfunctions displayed on the see 3 2 see 3 2 or dispenser Which displays perform step 3 3 Is the problem described in 3 3 proceed as perform step 4 described in 3 3 4 Is the current supply okay perform step 5 see 3 2 5 Is the DC supply okay perform step 6 see 3 2 6 Is the water supply okay perform step 7 see 3 2 7 Are the flexy packs inserted correctly see 3 2 see 3 2 and full ...

Page 39: ...are hot To prevent scalding keep hands and or other parts of the body away from the beverage outlet area when beverages are prepared and during the functional test DANGER Never insert the power supply plug of the dispenser into a wet or damp socket The plug itself must not be wet or damp either Also never insert or remove the plug from the socket with wet hands DANGER The dispenser and the service...

Page 40: ...unting the dispenser Check if the dispenser heating capacity exceeds that of the local supply network replace the dispenser 1 Switch the dispenser on 2 Check the connections of the switch If the connections are okay replace the switch 1 Check connection of the fuse F05 with multi meter adjust to Ohm If no connection Replace the fuse 2 Check the output for 25 V alternating voltage see chap 5K Elect...

Page 41: ...ing of outlet elbow damaged or elbow deformed 2 Supporting ring overturned 1 Outlet valve tappet blocked 1 Decalcify the boiler 2 Check the water inlet valve for 25 V alternating voltage when the float switch arm is completely lifted If 25 V Replace the float switch 3 Replace the inlet valve Also on installation Rapidly open and close the water tap several times in order to achieve easy operation ...

Page 42: ...heck the pipe pressure with water pressure measuring device Open the water tap completely If the water pressure is less than 0 8 bar 11 6 psi the dispenser does not operate 3 Decalcify the boiler 4 Dismount and clean the filter 5 Check the inlet valve for 25 V alternating voltage when the float switch arm is completely depressed If 25 V Replace the switch 6 Check the coil for 25 V alternating volt...

Page 43: ...et button Check the connection If no connection Replace the temperature limiter Reset the dry running protection 6 Sensor tube calcified or reset the thermostat to zero and check the connection Decalcify the boiler or if connecting Replace the thermostat reduce the adjustment of the thermostat if required Press Reset button 7 Check the heating element for connection and short circuits replace the ...

Page 44: ...y The flashing stops as soon as the correct temperature has been reached after approx 1 hour 2 Replace the flexy pack follow filling and thawing requirements 3 Clean Place the dispenser with a distance to the wall of at least 5 cm 2 in 4 Clean 5 Replace the fan see chap 5F 2 6 Change the location of the dispenser 7 Disconnect sensor plug ST05 from the control unit and bridge PINs 1 and 2 of BU05 M...

Page 45: ...t 1 Change the flexy pack 2 Switch on or replace the switch 3 Check the wiring If o k check conduction of the switch If not o k Repair the wiring If no conduction of the switch Replace the switch 4 Replace the fuse 5 Check the output for 25V AC If not 25V Replace the transformer 6 Set the voltage selector according to mains voltage or replace the voltage selector 7 Replace the control unit see Cha...

Page 46: ...sh Replace diode transistor Check the empty indicator and replace it if necessary 1 Bridge PINs 1 and 4 of Bu St08 Check LED If LED flashes Defective transistor or diode replace If LED does not flash Defective control unit replace Defective LED replace LED 1 Ventilation hose in the outlet elbow is blocked or bent 2 Dosing system of flexy pack defective 3 Intervals of dosing pulses out of tolerance...

Page 47: ...ctive control unit 1 Control unit s battery empty No defect The control unit is set to mode Counting cups per pot 1 Replace the control unit see chap 5K 2 2 Replace the display 1 Replace the control unit see chap 5K 2 2 Replace the key switch 1 Replace the control unit see chap 5K 2 1 Replace the battery Disconnect the power supply plug after a few deliveries and reconnect after 30 seconds If the ...

Page 48: ...ing Delivery No Cooling Yes Display Error Water valve control Red LED Flashing Yellow LED Flash ing short frequency when cooling compartment temperature 11 C 51 8 F Delivery Yes Cooling No Display Error Peltier control Fault Possible cause Remedy Replace the control unit see chap 5K 2 if not o k Check wiring if o k change the coil Change the control unit see chap 5K 2 Change the coil see chap 5K 2...

Page 49: ...ng Yellow LED Flash ing short frequency when temperature 0 C 32 F Delivery Yes Cooling Yes Display Error Peltier control Red LED Yellow LED Delivery Yes Cooling No Display Error Last dosing Red LED Yellow LED Delivery Only water Display Error Last dosing Red LED Flashing Yellow LED Delivery No Cooling Yes Display Error Bad dosing info Fault Possible cause Remedy Replace the control unit see chap 5...

Page 50: ...3 14 Faults Service Manual Cafitesse 100 07 2004 3 3 Faults occurred in the Market and their Solutions ...

Page 51: ...rvice Manual Cafitesse 100 07 2004 Table of Contents Programme Structure 4 1 Flow Charts 4 1 1 Programming Description 4 1 2 Programming for the Customer 4 2 Reading and Resetting Counters 4 2 1 Reading further Data 4 3 ...

Page 52: ...e older programming for older dispensers has no effect on further programming in this case For flow calibration Selection enables or disables pot specific settings hereunder In case Pot disabled the upper push button is not active Skipped when Pot disabled pot delivery is not active cont continous dosing until push button is released portion portioned delivery of a pot volume upon pressing the pus...

Page 53: ...on 2 off Concentrate Water ratio for lower push button cnt continuous dosing until the push button is released rp delivery of repeated complete cup volumes until the push button is released por delivery of a single cup volume upon pressing the push button once Important setting for sensitivity of empty detection 1 tea 2 coffee Pause between push button activations Standard display on Standard disp...

Page 54: ...ine older programming for older dispensers has no effect on further programming in this case For flow calibration Selection enables or disables pot specific settings hereunder In case Pot disabled the upper push button is not active Skipped when Pot disabled pot delivery is not active cont continous dosing until push button is released portion portioned delivery of a pot volume upon pressing the p...

Page 55: ...own Down Up Down Temp block 1 on 2 off Concentrate Water ratio for lower push button cnt continuous dosing until the push button is released rp delivery of repeated complete cup volumes until the push button is released por delivery of a single cup volume upon pressing the push button once Important setting for sensitivity of empty detection 1 tea 2 coffee Pause between push button activations Sta...

Page 56: ...libration Skipped when Machine old as it is always espresso norm regular coffee no mixer motor activated espr espresso mixer motor activated Ratio setting for upper push button If Machine 110 120 and Prod 1 normal then setting range Min 40 Max 2000 If Machine 110 120 and Prod 1 normal cnt continuous dosing until the push button is released rp delivery of repeated complete cup volumes until the pus...

Page 57: ... push button once Skipped if Machine 110 120 as it is always espresso norm regular coffee no mixer motor activated espr espresso mixer motor activated Concentrate Water ratio for lower push button If Machine old and Prod 3 normal then setting range Min 40 Max 2000 If Machine old and Prod 3 normal cnt continuous dosing until the push button is released rp delivery of repeated complete cup volumes u...

Page 58: ...ispensers Machine older programming for older dispensers has no effect on further programming in this case For flow calibration Selection enables or disables pot specific settings hereunder In case Pot disabled the upper push button is not active Skipped when Pot disabled pot delivery is not active cont continous dosing until push button is released portion portioned delivery of a pot volume upon ...

Page 59: ...d complete frappe volumes until the push button is released por delivery of a single frappe volume upon pressing the push button once Concentrate Water ratio for lower push button cnt continuous dosing until the push button is released rp delivery of repeated complete cup volumes until the push button is released por delivery of a single cup volume upon pressing the push button once Important sett...

Page 60: ... dispenser can be programmed for espresso or normal delivery Button 3 is always set to espresso If the software is set to machine old with out facelift design buttons 2 and 3 of Cafitesse 120 dispenser can be programmed for espresso or normal delivery Button 1 is always set to espresso The settings of the counting and indicating modes do not affect dispensers without counters 4 1 2 Programming Des...

Page 61: ...r is equipped with a clock Functions of the service device Display 2 lines 16 digits each serves to display all information regarding the software Numeric buttons that are used to enter new values data CLR Clear to erase an entered value Input Input to store an entered value Rep Code Repair code button no function Up to return to previous programming step Down to move to the next programming step ...

Page 62: ...n Set minute 12 service device Enter the correct minute Input Press Input repeatedly to check or correct the data The entered data are displayed consecutively Clock Press Clock to store the data and to switch off the service device Calling up date and time Press the activating button to switch on the service device Clock Press Clock Display on Date m d 07 21 service device Time h m 03 11p Clock Pr...

Page 63: ...concentrate is not required to be in the machine during programming Switch on the dispenser and press the activating button on the service device Switch off the dispenser After a few seconds Display on SATELLITE V2 9 service device 123456789012 The dispenser is equipped with EPROM Version 2 9 The dispenser is now in the programming mode If there is no further programming the service device exits t...

Page 64: ...Input or Flow 75cc sec Min 50 Max 75 The water flow can now be changed but should be set to 75 cc sec To change the value CLR Press CLR and enter the new value via numeric keys Acitvating pot delivery 1 Input or Pot enabled 1 disabl 2 enabl For pot delivery Fig 1 Press button 1 to select Pot disabled Beverage strength for pots only when pot delivery is activated Input or Pot ratio 1 20 Min 12 Max ...

Page 65: ...nt pot in cup pots are counted in cups When pots are delivered the counter registers the number of cups per pot Count pot in pot pots are counted The counter registers the pots delivered Press button 2 to select counting mode Count pot in pot Press button 1 to select mode Count pot in cup Programming steps for Frappé Frappé volume Input or Frappe vol cc s Min 1 0 Max 50 0 The delivery volume of co...

Page 66: ...p portions Input or Pause 01sec Min 0 Max 5 The setting for the pause can now be changed see above Programming steps for café cool Water flow café cool 2 only with option café cool Input or Ice flow 20cc s Min 15 Max 30 The water flow can now be changed see above Beverage strength café cool only with option café cool Input or Ice ratio 1 14 Min 8 Max 25 The beverage strength can now be changed see...

Page 67: ...flashing long flash frequency If the water temperature in the boiler drops below 80 C 176 F during a beverage delivery the dosing will be continued until the set delivery volume is dispensed delivery mode portioned or until the push button is released delivery mode continuous The default setting is Temp block off i e the blocking of the beverage delivery at low temperature is not activated Storing...

Page 68: ...hat of the mixer motor The setting of the following programme steps are identical to those for Cafitesse 110 Face lift Temp block 1 on 2 off Save values 1 yes 2 no Product settings for Cafitesse 120 The settings of the following programme steps are identical to those for Cafitesse 110 Facelift Machine 110 120 1 110 120 2 old Flow 75cc sec Min 50 Max 75 Input or Product button 1 Prod 1 normal 1 nor...

Page 69: ...the beverage delivery at low tempera ture Display norm counter display Standard settings 1 110 120 75 cc sec 2 coffee 1 sec 0 sec 2 off 2 on Possible settings 1 110 120 2 old 50 cc sec 75 cc sec 1 tea 2 coffee 00 sec 05 sec 0 sec 4 3 sec 1 on 2 off 1 off 2 on only with Cafitesse 110 Cafitesse 110 Facelift This setting is not available for espresso delivery with Cafitesse 120 If all buttons are set...

Page 70: ...io 1 20 Volume 1500cc Pot dosing port Count pot in cup for café cool Ice flow 20cc sec Ice ratio 1 14 Ice volume 130cc for Frappé delivery of coffee concentrate Frappé vol cc s Frappé dosing Cup ratio 1 20 Cup volume 150cc Cup dosing port Defaults Possible settings Button Factory settings Possible settings CFT 110 F CFT 120 F 1 norm coffee 2 espresso 1 10 1 99 normal 1 10 1 99 espresso 40cc 2000cc...

Page 71: ...tched on and always indicates the number of delivered cups Turn the key switch 1 to position OFF Fig 1 To read the number of delivered portions for café cool option café cool activate the café cool button To read the number or delivered pots press the STOP button 2 Display Mode OFF to be set by service technician The display is off during delivery however the counter registers the number of delive...

Page 72: ...es for button 2 press button 2 Fig 1 2 Display mode Off to be set by the service technician The display is switched off during delivery however the counter registers the number of deliveries Turn the key switch 4 to OFF Fig 1 Switch off the main switch wait approx 5 6 sec and switch it on again The display is switched on for max 10 sec The display indicates the counter value for delivered espresso...

Page 73: ...4 23 Programming Service Manual Cafitesse 100 07 2004 4 3 Reading further Data Not included ...

Page 74: ...4 24 Programming Service Manual Cafitesse 100 07 2004 ...

Page 75: ...he Hot Water Outlet Tap A 2 5 Functional Descriptions A 3 Total Overview Water System A 3 1 Function Inlet Valve A 3 2 Function Boiler A 3 3 Function Water Inlet into the Boiler A 3 4 Function Heating and Temperature Regulation A 3 5 Function Water Outlet System and Outlet Valve A 3 6 Electrical Diagrams A 4 Circuit Water Inlet Valve A 4 1 Circuit Water Coil A 4 2 Circuit Heating and Temperature R...

Page 76: ...ion Mixer C 3 3 Electrical Diagrams C 4 Circuit of the Concentrate Coil C 4 1 Technical Specifications C 5 Options C 6 Frappé C 6 1 Accessories C 7 Not available Product Delivery D Adjustments D 1 Disassemblies D 2 Installation and Disassembly of the Buttons D 2 1 Disassembly of the Pot Carrier and the Main Circuit D 2 2 Functional Descriptions D 3 Total Overview of the Product Delivery D 3 1 Func...

Page 77: ... F 3 1 Function Cooling System F 3 2 Electrical Diagrams F 4 Cooling Circuit F 4 1 Technical Specifications F 5 Options F 6 Not available Accessories F 7 Not available Housing G Adjustments G 1 Not required Disassemblies G 2 Disassembly of the Front Part G 2 1 Disassembly of the Operating Panel G 2 2 Functional Descriptions G 3 Total Overview of the Housing G 3 1 Electrical Diagrams G 4 Not requir...

Page 78: ...K 3 4 Function I2 C Bus Extension Board K 3 5 Electrical Diagrams K 4 Technical Specifications K 5 Options K 6 Not available Accessories K 7 Not available External Options L Depending on the different Nationalities to be completed by the OPCOs and the Distributors Payment Systems P Adjustments P 1 Installation P 2 Installation of the Kit Coin Module Cafitesse 100 Facelift P 2 1 Functional Descript...

Page 79: ...n console 10 Boiler cover 11 Boiler 12 Outlet valve 13 Water outlet tap Tomlinson handle 14 Metal air supply channel 15 Shielding cover 16 Drip tray 17 Drip grid 18 Cup carrier 19 Delivery button 20 Operating panel 21 Operating panel board 22 Key switch option 23 Counter 24 Socket for programming with the service device 25 Operating panel cover 26 Tension rod 27 Front cover 28 Advertising panel Fi...

Page 80: ... 14 Metal air supply channel 15 Shielding cover 16 Drip tray 17 Drip grid 18 Cup carrier 19 Delivery buttons 20 Operating panel 21 Operating panel board 22 Key switch option 23 Counter 24 Socket for programming with the service device 25 Operating panel cover 3 8 7 5 6 11 12 1 13 16 17 21 23 22 24 19 27 18 15 9 26 10 4 25 29 30 32 31 33 34 26 Tension rod 27 Front cover 28 Advertising panel 29 Mixe...

Page 81: ...ad there must be a lock washer Fasten the screws tightly ground connection WARNING The manufacturer cannot be held liable or responsible when other than original spare parts are used for repair work WARNING Cable harnesses must not be repaired but must be replaced completely WARNING When the front part has been dismounted in the course of repair processes make sure that the hose 1 is mounted corre...

Page 82: ...07 2004 5 8 Functions Service Manual Cafitesse 100 ...

Page 83: ... food industry in a protective tube switches off when a fault occurs Adjustment of the Standard adjustment up to the stop of the regulator approx 95 C thermostat 203 F When installing the Must be adjusted at the location according to the altitude dispenser at 2000 m over Must not be set to max mean sea level A Water System A 1 Adjustments ...

Page 84: ...f the glass Remove the cooling compartment lid 4 Fig 1 Remove the housing cover 6 Fig 1 Remove the air duct 7 Fig 1 Remove the rear housing wall 5 Fig 1 Place the dispenser in such a manner that the rear housing wall is at the edge of the table or counter Position a sufficiently large container underneath it 10 l bucket CAUTION There is the danger of being scalded by hot water CAUTION Prevent the ...

Page 85: ...ompartment lid 4 Fig 1 Remove the housing cover 6 Fig 1 Remove the air duct 7 Fig 1 Remove the rear housing wall 5 Fig 1 Drain the water from the boiler see chap 5A 2 Put the boiler drainage hose 8 aside Fig 2 Disassembly Loosen the screws of the inlet valve 9 Fig 2 Push the inlet valve completely into the dispenser inlet spout and remove it towards the top Disconnect the cable harness contacts fr...

Page 86: ...the dispenser from the water supply Remove the flexi pack from the cooling compartment Place a sufficiently large container underneath the hot water delivery tap 1 and actuate the tap until there is no more water delivered Fig 1 CAUTION There is the danger of being scalded by hot water Keep parts of the body away from the outlet area Remove the front part 2 Fig 2 see chap 5G 2 Fig 1 Fig 2 1 2 xx x...

Page 87: ...rds Fig 3 CAUTION Make sure that the distance washer 6 does not get lost Fig 3 If the water coil shall be dismounted turn the support ring clockwise and remove it after the disassembly of the outlet elbow Assembly Assembly is done in the reverse order For the assembly of the outlet valve insert the tappet and connect the outlet elbow to the outlet spout When mounting ensure that the air hose is no...

Page 88: ...owards the side Fig 1 CAUTION When the front cover is made of glass there is the danger of being injured due to incorrect handling or breaking of the glass Remove the cooling compartment lid 4 Fig 1 Remove the housing cover 6 Fig 1 Remove the air duct 7 Fig 1 Remove the rear housing wall 5 Fig 1 Remove the fan 8 and the fan console 9 Fig 1 Drain the water from the boiler see chap 5A 2 CAUTION Ther...

Page 89: ...tion 15 Fig 2 Disconnect the cable harness of the low temperature sensor from the control terminal 20 Fig 3 Disconnect the cable harness of the float switch from the control terminal 21 Fig 3 Disconnect the main cable harness contacts from the thermostat 10 Fig 2 Compress the clamping supports of the boiler cover on one side of the housing first and slightly lift the boiler cover Repeat the proces...

Page 90: ...draw the thermostat with support 3 from the boiler cover Fig 1 Withdraw the thermostat sensor 4 from the protective tube 5 Fig 1 4 Assembly Assembly is done in the reverse order When mounting the thermostat wind the sensor wire from the sensor side approx three or four times Position the wound part of the sensor wire in the recess of the cover 6 underneath the thermostat Fig 1 Insert the thermosta...

Page 91: ... of the float switch 2 apart by using a pair of expansion nippers or universal nippers Fig 1 Remove the float switch 2 Fig 1 CAUTION Do not pull at the cable harness 3 for removing the float switch from the support Fig 1 Disconnect the float switch cable harness 6 from the control 7 Fig 2 Remove the contacts 8 of the float switch cable harness from the inlet valve 9 Fig 3 Assembly Assembly is done...

Page 92: ... apart Fig 2 Floater washer and floater wire Disassembly Dismount the boiler cover 1 Fig 1 see chap 5A 2 Unhinge the floater wire 2 at the float switch Fig 1 Compress the floater wire 2 at the bottom by means of a pair of nippers Fig 1 Pull the floater washer 3 over the floater wire 2 Fig 1 Again compress the floater wire 2 at the bottom and guide it through the opening in the boiler cover towards...

Page 93: ...onnect the cable harness of the low temperature sensor 1 from the control 2 Fig 1 Withdraw the low temperature sensor 3 from the boiler cover 4 Fig 2 Assembly Assembly is done in the reverse order When mounting the low temperature sensor ensure that the cable harness 5 is placed between the guides 6 in the boiler cover Otherwise the float switch function 7 may be affected Fig 1 Fig 2 2 1 ...

Page 94: ...thermostat 6 Fig 2 Make sure that the lock washers do not get lost Remove the overflow safety thermostat Remove the wiring towards the sensor of the overflow safety thermostat from the support at the boiler wall Assembly Assembly is done in the reverse order When mounting the wound wiring of the overflow safety switch unwind approx 3 windings from the sensor side upwards and approx 2 windings of t...

Page 95: ...ng element Fig 2 Remove the heating element the screw and the bottom part of the seal 7 10 Fig 3 4 towards the bottom Withdraw the upper part of the seal 6 towards the top Fig 2 Assembly Assembly is done in the reverse order CAUTION When replacing the heating element the dry running protection must be replaced as well The sensor wire of the dry running protection must be wound around the heating e...

Page 96: ...Eltra 7 red seal When replacing the seals the corresponding spare parts included in the kit seal for heating must be mounted in the correct order in accordance with fig 3 or 4 The seals can be distinguished by their different colours Loval white Eltra red The distance plates can be distinguished by their thicknesses The Eltra distance plate is thicker than the Loval distance plate ...

Page 97: ...ee chap 5A 2 Dismount the control see chap 5K 2 Remove the foil Disassembly Disconnect the overflow hose 1 from the overflow tray 2 Fig 1 Remove the overflow tray 2 Fig 1 Press the clamping supports of the boiler cover on one side against the housing first and unhinge the boiler towards the top Repeat the process on the other side of the housing Remove the boiler Simultaneously remove the hose of ...

Page 98: ...hten the sensor wire Guide the wire and the sealing disc through the opening in the boiler cover Wind the sensor wire around the heating element as follows Pull the sensor wire loosely up to the recess in the heating coil which is situated approx 15 cm below the heating element contacts Starting from the recess the sensor wire must be wound downwards around the heating element Fig 2 Wind the senso...

Page 99: ...asily Close the hot water delivery tap 3 counterclockwise Fig 2 Make sure that the seals of the hot water delivery tap inside and outside the housing do not get lost Assembly Mount the new hot water delivery tap in the reverse order CAUTION When a new hot water delivery tap is mounted Loctite must be applied between the thread and the brass bushing as protection against torsion Ensure that the sea...

Page 100: ...07 2004 5A 18 Functions Water System Service Manual Cafitesse 100 A 3 1 Total Overview Water System Fig 1 Total overview standard dispenser A 3 Functional Descriptions ...

Page 101: ...nction Inlet Valve The essential parts of the inlet valve are fig 1 the diaphragm with cleaning wire 1 the tappet 2 the coil the valve housing 3 with sieve flow rate controller and outlet spout When the valve is closed the tappet closes the bore in the middle of the diaphragm 2 1 3 ...

Page 102: ...Water can flow through it from the upper part As the pressure compensation hole is much smaller than the opening in the middle of the diaphragm the pressure cannot be compensated any more The pressure on the upper side of the diaphragm decreases in contrast to the water pressure on the lower side This causes the diaphragm to move upwards and open the outlet spout Water is running from the water su...

Page 103: ...ressure falls below 0 8 bar 11 6 psi a sufficient flow rate cannot be guaranteed In this case the water level in the boiler cannot be controlled any more especially when the beverage delivery takes too long or with frequent beverage deliveries Consequences Deviations in the dosing quantity Possible blocking of the delivery see error codes Filter sieve A removable filter sieve 1 in the valve inlet ...

Page 104: ...outs for the water coil 4 and the hot water delivery tap 5 are situated in the upper boiler part Fig 1 This guarantees the delivery of hot water as cold water is added in the boiler base which then is heated up and afterwards moves upwards Additionally the outlet spouts positioned in the upper boiler part guarantee that the water level in the boiler does not fall below these Dry running of the hea...

Page 105: ...r downwards Fig 1 When the water level in the boiler is low the floater washer pulls the float switch lever downwards The float switch connects the water inlet circuit output of 24 VAC The inlet valve opens 3 Fig 1 Water from the supply lines runs through the inlet spout and the non return valve 4 from below into the boiler Fig 1 With increasing water level floater washer moves upwards and the flo...

Page 106: ...cuit is interrupted by opening the contacts Thus overheating due to lack of water in the boiler is prevented The dry running protection is equipped with a manually actuated reset button 4 in the boiler cover Fig 1 The safety thermostat overflow 5 is placed on the outside Its sensor 6 is mounted in the boiler cover above the overflow tube The thermostat contacts open and interrupt the heating proce...

Page 107: ... volume depends on the beverage strength ratio and the volume Both values are adjusted on the control board see programming The hot water delivery tap 6 is connected directly to a second outlet spout at the boiler Fig 1 Outlet valve The water flow rate depends on the water pressure and the outlet cross section The water inlet system enables a constant water level in the boiler and therefore a cons...

Page 108: ...ter delivery tap The hot water delivery tap is connected to an individual outlet spout in the boiler by means of a hose The hot water delivery tap can be opened by pressing the lever upwards or downwards Hot water is delivered continuously as long as the lever of the hot water delivery tap is pressed downwards or upwards Fig 1 ...

Page 109: ...fitesse 100 A 4 Electrical Diagrams A 4 1 Circuit Water Inlet Valve The water inlet valve and the float microswitch are connected in series in the secondary circuit of the transformer T 02 Fig 1 F05 main switch mains T02 float switch 25 V water inlet valve ...

Page 110: ...e applied at A Standard no delivery When no delivery button is actuated and there is no voltage registered at A by the microprocessor for an interval of 5 sec the positive voltage is switched off and the empty LED starts flashing Standard delivery When no delivery button is actuated there must be no voltage applied at A If there is however a voltage applied at A in the case of an error there will ...

Page 111: ...lement Electric current runs via the main switch the closed contacts of the dry running protection the heating element and the closed contacts of the thermostat and the safety thermostat overflow Fig 1 A 4 3 Circuit Heating and Temperature Regulation dry running protection S05 heating E01 thermostat S06 overflow safety thermostat S12 mains main switch ...

Page 112: ... valve tank top Temperature 90 C 194 F Pressure 0 60 mbar 0 0 87 psi Voltage 24 V AC 50 Hz directly switching Boiler Pressure atmospheric pressure Capacity 6 5 l Tank tank top version Capacity Water tank 4 l Thermostat Temperature 95 C 3 C 203 F 37 4 F Outlet valve integrated in the boiler Flow rate 4 5 l min Voltage 24 V DC Overflow safety thermostat Triggering temperature 90 C 8 K 194 F Triggeri...

Page 113: ...ol Delivery of cold beverages Kit café cool In different countries external dosing unit Overflow safety thermostat Installation of the Cafitesse 100 Kit for the application of 85 C 185 F at 2000 m over Cafitesse 100 at altitudes mean sea level over 2000 m A 6 Options Overview water system options ...

Page 114: ...07 2004 5A 32 Functions Water System Service Manual Cafitesse 100 Fig 1 A 6 1 Café cool ...

Page 115: ... 2 4 or a more actual version which contains special functions for the delivery of cold beverages café cool The inlet valve of the cold water system is controlled by an additional interface board Water supply Connection to the water supply Maximum static water pipe pressure 10 bar 145 psi Minimum dynamic water pipe pressure 0 9 bar 13 1 psi Water system Water supply connections supply the separate...

Page 116: ...lenoid valve as shown in fig 3 Fasten the silicone hose 7 with hose connector 3 and union nut 2 to the outlet of the cold water valve Fig 3 Install the cold water valve at the left dispenser wall with the outlet side mounted towards the top Use clamps 4 for this purpose Fig 3 Push the hose towards the front between boiler and side wall CAUTION The hose must not be bent or squeezed Replace the outl...

Page 117: ...5 connect the outlet hose 1 and the hose 4 by means of the fastening clip 3 Fig 5 Remove the control see corresponding chapter Drill a bore into the rear wall which has a diameter of 28 mm as shown in fig 6 For this purpose it is recommended to use a punching tool e g a Rekord puncher 160 ø28 31 Fig 6 ...

Page 118: ... an older EPROM version replace the EPROM on the control Required EPROM version SAT1 V2 4 or more up to date Unplug the power supply see chap 5K 2 Remove the cup carrier Remove the coil of the inlet valve Remove the dummy cap at the right front side of the pot carrier Insert the wirings of the cold water valve 4 cable harness S30 NO and S30 C 5 into the drip tray at the right front side Fig 10 Con...

Page 119: ...lug 14 is mounted to the cable harness of the operating panel 18 connect the contact bush and the receptacle to the two free terminals of the operating panel cable harness 18 as follows Fig 10 PIN 1 SAT BU20 XII PIN 2 SAT BU20 XIII Connect the plug 14 to the 2 pole contact bush 15 of the adapter cable harness Fig 10 Connect the bush BU03 17 of the adapter cable harness 16 to the plug ST03 of the i...

Page 120: ...device Fig 12 Delivery of café cool CAUTION Check the drinking water quality before starting the delivery of café cool Observe the national regulations Before delivering café cool even if the dispenser has not been used for a longer time period e g during the night or the weekends rinse the dispenser once for 1 minute in order to drain residual water from the lines For the rinsing process place a ...

Page 121: ...water delivery tap Overflow protection Securing the water supply Manual filling of the water tank when no water supply line is provided Delivery of hot water at side wall of the dispenser WARNING In this case there is no drip tray underneath the hot water delivery tap Overflowing of the boiler caused by a blocked float or defective float switch is avoided Kit tank top Europe Kit tank top USA Kit O...

Page 122: ...rinking water quality is bad the dispenser can be retrofitted with a tank to fill in the water manually WARNING Only use drinking water for filling the tank Fill in fresh drinking water daily Fig 1 option tank top Water system tank top Water system The function of the water system is identical to that of the standard system see fig 1 ...

Page 123: ...ater supply Loosen the screw 2 and remove the operating panel cover 1 Fig 2 Remove the front cover and the advertising panel 3 towards the side Fig 2 CAUTION When the front cover is made of glass there is the danger of being injured due to incorrect handling or breaking of the glass Remove the cooling compartment lid 4 Fig 2 Remove the housing cover 6 Fig 2 Remove the air duct 7 Fig 1 Remove the r...

Page 124: ...tion S06 2 9 of the main cable harness from the thermos tat Fig 3 Connect the plug adapter kit tank top to the free thermostat contact Connect the plug connections S06 2 of the main cable harness and E01 B of the water tank switch cable harness kit tank top to the plug adapter Connect the plug connection S05 A of the water tank switch cable harness kit tank top to the free dry running protection c...

Page 125: ...ank top Replace the heating plate switch at the right front side of the pot carrier see corresponding chapter by the dummy cap included in kit tank top Mount the rear wall included in kit tank top Insert the water outlet hose into the round opening 3 at the bottom of the rear wall Fig 4 Guide the plug connections S05 A 6 of the main cable harness former dry running protection S03 2 and S03 3 7 of ...

Page 126: ...it tank top as an outlet hose to the outlet opening 3 of the tank and to the angular piece 4 included in kit tank top Fig 5 Fasten the angular piece to the valve Switch on the dispenser with the main switch CAUTION Make sure that the heating switch 3 at the rear wall of the dispenser is switched off otherwise the dry running protection would be activated Fill the tank with water drinking water qua...

Page 127: ...NING The tank may only be filled with drinking water The drinking water has to be changed daily WARNING The water tank may not be exposed to sun rays CAUTION The water tank as well as the pump unit have to be cleaned daily The boiler is filled from the tank via a hose connection on the rear side of the dispenser When filling the boiler for the first time the heating must be switched off by means o...

Page 128: ...ompartment lid 3 Fig 2 Remove the old back panel 4 Fig 2 Remove the housing cover 5 Fig 2 Remove the air duct 6 Fig 2 Pull the rear side of the dispenser to the edge of the table or counter Fig 3 ATTENTION Danger of tipping Put a container of sufficient size 10 ltr bucket underneath Fig 2 ATTENTION Danger of being scalded by hot water ATTENTION Observe that the circuit board does not come into con...

Page 129: ...at 2 was turned to zero counter clockwise up to the stop heating off Fig 5 ATTENTION If the thermostat is not turned to zero the dispenser starts heating and actuates the capillary tube limiter Loosen and remove the screws 3 of the inlet valve 4 Fig 6 7 Push the inlet valve out of its seat and pull it off Disconnect all contacts of the cable harness 5 from the inlet valve Fig 7 Remove the clip fro...

Page 130: ...nd connect the hose coupling 1 inside the dispenser to the inlet tube 2 of the boiler Fig 8 Secure the inlet tube 2 and the hose coupling 1 by means of the clip Insert 1 2 ribs of the corrugated hose 3 into the opening of the housing Fig 9 Connect the cable harness of the pump unit 4 to the rectifier Fig 10 ATTENTION Observe the marks Fig 10 Connect the cable harness of the inlet valve to the rect...

Page 131: ...harness and pull the plug connection S05 A to the rear of the dispenser Disconnect the plug connection S06 2 4 of the main cable harness from the thermos tat Fig 13 Connect the plug adapter D 0258 to the free thermostat contact Connect the plug connections S06 2 of the main cable harness and E01 B of the cable harness switch G 4973 to the plug adapter Connect the plug connection S05 A of the cable...

Page 132: ...ction to PIN 1 of the switch 4 Fig 14 Connect the plug connections S03 2 to PIN 2 and S03 3 2 to PIN 3 of the switch 3 Fig 14 Mount the heating switch to the rear wall Reconnect the power plug CAUTION Make sure that the heating switch 2 at the rear wall of the dispenser is switched off otherwise the dry running protection would be activated Fig 14 Switch on the power switch 5 and wait until the bo...

Page 133: ...16 ATTENTION The pump unit may only slightly but not totally rest on the bottom of the water tank Fill the tank with water drinking water quality Close the tank Switch on the heating switch 2 and carry out a functional test Fig 17 If the water in the tank is used up the reed switch has to switch off the pump unit in order to prevent damages Fig 17 2 Fig 16 1 ...

Page 134: ...let valve The time switch can be variably adjusted using a jumper on the circuit board Fig 1 40 sec 25 sec 1min 30 sec The time switch is used to measure the period of time during which the inlet valve is in its opened state As soon as the pre set period of time is exceeded the time switch will trip and the inlet valve will be closed Whenever the time switch has tripped this will be signalled to t...

Page 135: ...al connection ST03 4 Fig 3 The position of the jumper 7 determines when the water inlet in the boiler stops Fig 3 See also the positioning diagram on the previous page For Cafitesse 100 dispensers with an already built in I2 C bus circuit board Cafitesse 120 or with café cool option the circuit board is installed the same way When the boiler is being filled for the first time it is possible that t...

Page 136: ...07 2004 5A 54 Functions Water System Service Manual Cafitesse 100 ...

Page 137: ...07 2004 5B 1 Functions Brewing System Service Manual Cafitesse 100 B Brewing System Not available ...

Page 138: ...07 2004 5B 2 Functions Brewing System Service Manual Cafitesse 100 ...

Page 139: ...07 2004 5C 1 Functions Dosing System Service Manual Cafitesse 100 C Dosing System C 1 Adjustments Not required ...

Page 140: ...07 2004 5C 2 Functions Dosing System Service Manual Cafitesse 100 C 2 Disassemblies C 2 1 Disassembly of the B2 Coil and the Diode Carrier Fig 1 STOP xxxxx xx xx x 1 6 5 4 7 9 8 2 3 10 12 11 ...

Page 141: ...ings are positioned correctly For a better mounting place the o ring on the cooling compartment When remounting the screened coil insert the 3 screws 12 Fig 1 After the assembly ensure that the screened coil is positioned evenly on the cooling compartment Disassembly of the empty detection Remove the insulation ring 10 Fig 1 Remove the 3 screws 12 Fig 1 CAUTION When remounting ensure that the scre...

Page 142: ...he tap WARNING There is the danger of being scalded by hot water Disassembly of the mixer unit Remove the shielding cover Press the bottom edge of the mixer support 1 upwards and tilt the mixer unit 2 towards the front Fig 1 Withdraw the sieve housing 4 Fig 2 Remove the mixing funnel towards the top 1 Fig 2 Turn the mixing container 5 to the right and withdraw it towards the front Fig 2 WARNING Th...

Page 143: ...e flange of the mixer motor Fig 4 Withdraw the o ring 8 Place it on the new motor if required Fig 4 Replace the mixer motor 9 Fig 4 When replacing the mixer motor it is recommended to replace the sealing 10 as well For this purpose the adjusting nut 11 must be removed Fig 4 CAUTION When inserting the sealing 10 observe that the sealing is inserted as shown in fig 4 the adjusting nut 11 is fastened...

Page 144: ...itesse 100 C 3 Functional Descriptions C 3 1 Total Overview of the Dosing System Fig 1 bag with concentrate box tappet ring trough empty control coil bellows concentrate coil triggered water flow residual water 0 3 sec delay pulses water coil 0 3 sec inlet ...

Page 145: ...from the microprocessor on the control circuit board The dosing pump delivers for coffee 0 105 ccm contrate volume per pulse to the dosing coil Delivery is done as follows The tappet consisting of tappet ring 4 ring carrier 3 and inlet valve 5 is pulled downwards The bellow 6 filled with concentrate is pressed together and delivers the concentrate onto the trough via the outlet valve 8 Directly af...

Page 146: ...is equipped with a nozzle in the outlet elbow which limits the flow to 4 5 l min 75 cc sec When it has been programmed with the Service Device this value determines the time for which the valve will be open and the pulse frequency Number of pulses The concentrate water ratio can be changed see chap 4 The delivery volume per pulse is 0 105 cc The breaks between the pulses depend on the flow speed a...

Page 147: ...sers COFFEE DECAF TEA COFFEE DECAF C 3 3 Function Mixer Cafitesse 120 dispensers are equipped with a mixer unit for the delivery of espresso When a button for the delivery of espresso is actuated hot water and concentrate are dosed and are put into the mixing container 2 via the mixing funnel 1 Fig 1 When the dosing process has been started the mixer unit starts to operate with a set delay time Th...

Page 148: ...tion the pulse duration is 6 7 msec When the pulse duration is not between 6 5 msec and 10 msec the error message Error last dosing is indicated This can only be read out by means of the Service Device The microprocessor switches the transistors off after a maximum pulse duration of 10 msec even when the peak current value has not been reached Dosing is still posible when the circuit is not interr...

Page 149: ...al polypropylene natural Mixing container Material polypropylene natural Flange Material polypropylene natural Adjusting nut Material polypropylene natural Impeller Material polypropylene natural Adapter Material polyoxymethylene natural These parts must not be cleaned in a dishwasher C 6 Options C 5 Technical Specifications WHAT FOR REQUIRED FOR Frappé Delivery of coffee concentrate without hot w...

Page 150: ...ROM containing the software version 2 7 included in the kit Frappé Fig 1 Make sure that one of the two jumpers 3 on the I2 C bus board 2 included in kit Frappé is closed and the other one is opened Fig 1 It is of no regard to the function which one of the jumpers is opened and which one is closed The installation of the kit Frappé into a dispenser type Cafitesse 110 enables the delivery of coffee ...

Page 151: ...ce device and open the programming mode The display of the service device indicates FRAPPE V2 7 Check all programming settings This is required when changing over to software version 2 7 If required adjust new programming settings for the delivery of beverage concentrate Setting the concentrate volume Minimum 1 0 cc Maximum 50 0 cc in steps of 0 1 cc Setting the delivery mode for concentrate 1 cnt...

Page 152: ...07 2004 5C 14 Functions Dosing System Service Manual Cafitesse 100 C 7 Accessories Not available ...

Page 153: ...ming via Service Device see chap 4 Product Cafitesse 110 coffee tea Cafitesse 120 coffee Delivery modes portioned continuous repeated Programming via Service Device see chap 4 Counter counter values Programming via Service Device see chap 4 Buttons button determination Programming via Service Device see chap 4 Cup carrier Can be adjusted in height and can be inserted on the left and on the right D...

Page 154: ... Remarks regarding the operating panel With those push buttons that shall not actuate a delivery insert the dummy button Fig 1 Programme the dispenser correspondingly Disassembly Position the dismounting tool 2 for push buttons laterally behind the push button covers and remove the push button covers towards the front Fig 2 It is necessary to remove the push button covers for programming the dispe...

Page 155: ...3 Preparation Switch off the dispenser and disconnect it from the mains supply Disconnect the dispenser from the water supply Diassembly Remove the drip grid 1 and the drip tray 2 Fig 1 2 Remove 2 screws 3 at the pot carrier 4 Fig 3 When a drainage kit is applied it must be removed D 2 2 Disassembly of the Pot Carrier and the Main Switch ...

Page 156: ...lace the main switch if required Fig 5 When remounting observe that the main switch is mounted in correct position ON OFF Fig 4 the cables are not exchanged S02 1 at PIN 1 S02 2 at PIN 2 S02 3 at PIN 3 the cable harnesses are placed on the right and on the left side plates 7 of the housing and are not bent Fig 4 the pot carrier is inserted straightly and the screws are fastened tightly When the di...

Page 157: ...OP ON OFF 7 2 3 7 2 3 xxxxx xxxxx xxxxx STOP xxxxx xxxxx POWER OFF ON ON OFF D 3 1 Total Overview Product Delivery Fig 1 D 3 Functional Descriptions Cafitesse 110 1 4 5 6 1 4 5 6 Cafitesse 120 Legend for fig 1 1 Push button 2 Turn lift support 3 Main switch 4 Cup carrier 5 Drip grid 6 Drip tray 7 Outlet trough ...

Page 158: ...us delivery cup and pot The beverage is delivered as long as the corresponding push button is pressed 3 Portioned constantly repeated delivery cup only A portioned beverage quantity is repeatedly delivered as long as the corresponding button is pressed The beverage delivery buttons can be programmed by the service technician When the stop button 1 has been actuated the beverage delivery except for...

Page 159: ...will be positioned on the cup carrier The height of the cup carrier 1 can be adjusted Fig 1 When a larger container e g a pot is used the cup carrier 1 can be turned aside The drip grid and the drip tray can be removed Fig 2 D 3 3 Function Cup Carrier Drip Grid and Pot Carrier Fig 1 xxxxx xxxxx xxxxx STOP ON OFF Fig 2 1 1 ...

Page 160: ...diene styrene polymer Push buttons Material acrylonitrile butadiene styrene polymer Main switch specific for the different countries voltage see dipenser types mains voltage see chap 2 These parts must not be cleaned in a dishwasher D 7 Accessories Overview accessories product delivery WHAT FOR REQUIRED FOR Drainage kit Drainage of the liquid water Kit drainage for the drip tray from the drip tray...

Page 161: ...sary open the float cover on the pot carrier outlet 9 Fig 2 Position the hose 2 underneath the dispenser Connect the hose to the pot carrier outlet and fasten it by means of cable binder 5 Fig 2 Move the coil spring 6 over the outlet hose 7 Fig 1 Connect the outlet hose 7 to the T union 3 Fig 1 CAUTION The coil spring 6 must be positioned in such a way that bending of the hose is prevented Fig 1 T...

Page 162: ...07 2004 5D 10 Functions Product Delivery Service Manual Cafitesse 100 ...

Page 163: ... Remove the operating panel cover 1 with screw 2 Fig 1 Withdraw the glass cover and the advertising plate laterally CAUTION When the front cover is made of glass there is the danger of being injured due to unauthorized handling or breakage of the glass Remove the cooling compartment lid 3 Fig 1 Remove the housing cover 4 Fig 1 Disassembly Remove the fan 5 Fig 1 Assembly Assembly is done in reverse...

Page 164: ... Remove the B2 coil remove the cellular sealing 4 Fig 1 loosen the screws 5 and withdraw the B2 coil Fig 1 Remove the bottom part 6 and the upper part 7 of the cooling compartment insulation and cut it up if required Fig 1 CAUTION The Peltier element must not be damaged Observe that the cooling compartment is not placed on top of the Peltier element Do not dismount the Peltier element Insert the n...

Page 165: ... 7 of the upper screw 1 do not get lost Fig 2 Clean the Peltier element support at the cooling compartment and the support at the heat sink by means of pure benzine The surface must not be scratched or damaged If the surface however has been damaged polish it slightly Clean the Peltier element surface by means of pure benzine and dry it Only use silicone grease part no K 0085 for the following ste...

Page 166: ...lowing order Fig 5 1 Lock washer 4 3 mm 5 2 Ground lug with the lug towards the top 6 3 Insulating bush 3 Place a suitable 1 mm gauge underneath one end 7 of the pressure plate Fig 4 Fasten the screw at this end 7 of the pressure plate just until the gauge is still held Fasten the screw at the other end of the pressure plate 100 Ncm by using a torque wrench part no B 0399 and the hexagonal insert ...

Page 167: ...tem Service Manual Cafitesse 100 F 3 Functional Descriptions F 3 1 Total Overview Cooling System Fig 1 2 3 4 7 6 5 1 Legend for fig 1 1 Fan 2 Flexi pack 3 Cooling compartment 4 Temperature sensor 5 Control 6 Peltier element 7 Heat sink ...

Page 168: ...t that is transferred is proportional to the electric current and to the amount of cooling cells contained in the Peltier element F 3 2 Function Cooling System Cells are electrically connected in series in the Peltier element Viewed thermally these cells are connected in parallel The typical electric current in a stable cooled state of the system is approx 3 5 A The Peltier element 1 acts as a hea...

Page 169: ... Peltier element 3 The incoming heat is taken up by the container wall and led to the Peltier element Fig 2 Fig 2 Peltier element 3 The Peltier element is made from ceramic plates The cooling elements are situated between these plates Very important for a proper functioning of the system is a very good heat conduction from the Peltier element 3 to both sides This is effected by plane contact surfa...

Page 170: ... to transfer it to the surrounding air when the fan is running without causing an accumulation of heat Fig 1 The typical temperature of the heat sink is approx 10 C above the ambient temperature Contamination by dust and grease e g especially in kitchens can reduce the heat transferring properties which in turn reduces the effectivity of the cooling system In an extreme case the temperature of the...

Page 171: ...age to the Peltier element Heat is conducted from the cooling compartment through the heat sink and the fan to the surrounding air The fan is connected to the mains supply and operates permanently The sensor disconnects the cooling circuit when the temperature decreases to approx 1 7 C The temperature regulation ensures that the concentrate is kept at a specific temperature of 2 C to 6 C The cooli...

Page 172: ...correct function of the PTC sensor is important for the correct function of the cooling system In the case of improper cooling the sensor must be checked Alternatively one of the following procedures can be applied a Comparative measurement old new at the same temperature b Resistance measurement and comparison with the value from the diagram Due to self heating the measuring current must not exce...

Page 173: ... 5 A The microprocessor activates flashing of the empty indicator LED or when for more than 10 sec I 1 A or 4 A The microprocessor activates flashing of the empty indicator LED This error can be caused by lacking heat conduction of the heat sink it is either very dirty or the fan is not operating When the heat sink temperature increases the electric current through the Peltier element decreases No...

Page 174: ...46 Ohm correspondingly T 4 7 C The microprocessor activates flashing of the temperature indicator LED when temperature high R 905 Ohm correspondingly 12 7 C temperature low R 830 Ohm correspondingly 2 4 C The temperatures mentioned above are sensor temperatures The product temperature is almost by 3 C lower than the sensor temperature The temperature of the cooling compartment base is almost the s...

Page 175: ...C Low temperature 2 4 C Fan Capacity 220 240 V 50 Hz VDE national 115 V 60 Hz UL CSA 208 240 V 60 Hz UL CSA Peltier element Manufacturer indications F 5 Technical Specifications F 7 Accessories F 6 Options Not available WHAT FOR REQUIRED FOR Damping the fan noises The air filter avoids contamination by dust and grease at the heat sink of the Peltier element This results in a steady high cooling ef...

Page 176: ...07 2004 5F 14 Functions Cooling System Service Manual Cafitesse 100 ...

Page 177: ...is the danger of being injured due to unauthorized handling or breakage of the glass Remove the cooling compartment lid 8 Fig 1 Remove the housing cover 9 Fig 1 Remove the air chute 10 Fig 1 Remove the rear wall 3 Fig 1 Loosen the cables 4 5 6 7 at the control Fig 1 Remove the fan 11 Fig 1 Remove the fan console 12 Fig 1 Remove the metal air supply channel 13 Fig 1 Remove the shielding cover 14 Fi...

Page 178: ...m the water supply Disassembly Remove the operating panel cover 1 with screw 2 Fig 1 Withdraw the front cover and the advertising panel towards the side CAUTION When the front cover is made of glass there is the danger of being injured due to unauthorized handling or breaking of the glass Hold the operating panel 3 at the cross shaped front 4 and pull it towards the front and then remove it toward...

Page 179: ...g 1 G 3 1 Total Overview Housing Legend for fig 1 1 Rear wall 2 Housing 3 Cooling compartment lid 4 Operating panel cover 5 Operating panel 6 Shielding cover G 3 Functional Descriptions xx xx x xx xx x STOP xx xx x 1 2 3 4 5 6 G 3 2 Function Housing Not described ...

Page 180: ...ical Specifications G 6 Options WHAT FOR Housing with opening Installation of payment systems G 4 Electrical Diagrams G 7 Accessories WHAT FOR Advertising panel front Branding specific for the customer Advertising panel rear if required see spare parts list Kit cover with heating plate Keeping the coffee hot Kit key switch Blocking the delivery reading the counters Kit housing cover with lock for ...

Page 181: ...ove the operating panel cover 1 Fig 1 Withdraw the glass cover and the advertising panel 3 towards the side Fig 1 CAUTION When the front cover is made of glass there is the danger of being injured due to unauthorized handling or breaking of the glass Remove the cooling compartment lid 4 Fig 1 Remove the housing cover 5 Fig 1 Remove the air chute 6 Fig 1 Remove the turn lift support with the cup ca...

Page 182: ... to PIN 1 S03 2 to PIN 2 and S03 3 to PIN 3 of the switches Fig 3 Mount the housing cover with heating plate 17 connect the plug ST14 15 of the cable harness Flexi to BU14 16 of the heating plate cable harness Fig 4 Mount the cooling compartment lid 18 If required apply the cooling compartment lid with imprints which is included in the kit Fig 3 Remount the dispenser completely and check its funct...

Page 183: ...Hold the operating panel at the cross shaped part A pull it towards the front and remove it towards the top Fig 1 Remove the pc board 3 with 4 screws Fig 1 Remove the stop button from the operating panel with no imprints and mount it to the operating panel with imprints Engage the lock 4 into the pc board base and press the locking ring 5 downwards until the stop Fig 1 Move the safety device for t...

Page 184: ...07 2004 5G 8 Functions Housing Service Manual Cafitesse 100 ...

Page 185: ...07 2004 5K 1 Functions Power Supply and Control Service Manual Cafitesse 100 K 1 Adjustments Voltage selector 208 V 220 V 240 V dispensers for the USA K Power Supply and Control ...

Page 186: ... the advertising panel 3 towards the side Fig 1 CAUTION When the front cover is made of glass there is the danger of being injured due to incorrect handling or breaking of the glass Remove the cooling compartment lid 4 Fig 1 Remove the rear wall 5 Fig 1 Remove the housing cover 6 Fig 1 Remove the air chute 7 Fig 1 Disassembly Withdraw the overflow hose 8 from the overflow tray 9 Fig 2 Lift the ove...

Page 187: ...the power supply with console from the dispenser Assembly Assembly is done in the reverse order Fig 3 1 Disassembly of the power supply cable Disassembly Disassemble the power supply Loosen the nuts the screws and the cable clamp 5 and remove the ground connection line 6 Fig 3 Remove the power supply line from the terminal clamps 7 Fig 3 Loosen the screw 8 of the tension relief Fig 3 Remove the po...

Page 188: ...orrect handling or breaking of the glass Remove the cooling compartment lid 4 Fig 1 Remove the rear wall 5 Fig 1 Remove the housing cover 6 Fig 1 Remove the air chute 7 Fig 1 Disassembly CAUTION In order to prevent damaging of the pc boards and their components due to electrostatic charge first touch a metal table or a metal cupboard before touching the pc boards Fig 2 xxx xx xxx xx ST OP xx xx x ...

Page 189: ...tatic charge first touch a metal table or a metal cupboard before touching the pc boards Assembly Assembly is done in the reverse order Fig 6 1 Fig 4 2 3 Fig 5 4 Assembly Assembly is done in the reversed order When mounting the control it must be observed that the insulating foil 1 is suspended between the control 2 and the boiler 3 Fig 4 When applying the I2 C interface board espresso café cool p...

Page 190: ...UTION When the front cover ios made of glass there is the danger of beinmg injured due to incorrect handling or breaking of the glass Disassembly Hold the operating panel at the cross shaped part 3 pull it towards the front and remove it towards the top Fig 1 CAUTION In order to prevent damaging of the pc boards and their components due to electrostatic charge first touch a metal table or a metal ...

Page 191: ... to prevent damaging of the pc boards and their components due to electrostatic charge first touch a metal table or a metal cupboard before touching the pc boards Disassemble the operating panel board Remove the plug connection 1 of the LEDs at the operating panel board Fig 2 Remove the plug connections 2 of the LEDs at the operating panel Fig 2 Fig 2 1 2 ...

Page 192: ...07 2004 5K 8 Functions Power Supply and Control Service Manual Cafitesse 100 K 3 Fonal Descriptions K 3 1 Total Overview Cable Harnesses Overview main cable harness xx xx x xx xx x STOP xxxxx option ...

Page 193: ...07 2004 5K 9 Functions Power Supply and Control Service Manual Cafitesse 100 ...

Page 194: ...iew control cable harnesses Legend 1 Cable harness temperature sensor 2 Cable harness B2 coil photodiodes 3 Cable harness Display 4 Cable harness operating panel 5 Cable harness empty low temperature 6 Cable harness I2 C interface 7 Cable harness mixer motor 8 Control 5 6 8 1 2 3 7 4 ...

Page 195: ...sse 100 Legend 9 Cable harness low temperature sensor 12 Cable harness inlet valve float switch 10 Cable harness Peltier element 13 Cable harness water coil 11 Cable harness voltage supply 14 Peltier element interface Different wiring for Cafitesse 120 8 9 10 11 12 13 14 ...

Page 196: ...control 4 Terminal clamps 5 Angular piece Power supply USA Canada 115 V Power supply Europe GB Switzerland Australia Power supply Japan 100 V 200 V Power supply USA 208 240 V 6 Power supply cable 7 Tension relief 8 Fuse F04 9 Fuse F05 10 Ground connection 11 Main cable harness 12 Interference filter 13 Voltage selector 14 Ferrit sleeve 1 4 10 5 6 7 14 9 8 11 3 2 12 1 4 10 5 6 7 9 8 11 3 2 12 1 4 1...

Page 197: ...ig 1 Transformator T02 2 Fig 1 Power supply cable 6 Fig 1 Fuse F04 8 Fig 1 Fuse F05 9 Fig 1 Fig 3 Fig 2 1 2 1 2 The power supply is equipped with low voltage transformators The transformator T 01 supplies the control with secondary voltage With dispensers suitable for 208 240 V operation delivered in the USA and Canada the primary supply of the T 02 is connected to a voltage selector The boiler he...

Page 198: ...llow 5 12 V dc voltage ST 04 6 connection for low temperature sensor ST 05 7 connection for cooling compartment temperature sensor ST 01 8 connection for operating panel ST 02 9 connection for counter ST 10 10 connection for I2 C bus extension BU 08 11 connection for photo transistor transmitter and flexi coil BU 09 12 connection for outlet valve ST 03 13 connection for inlet valve and for float s...

Page 199: ...nection for control cable harness counter ST 20 3 connection for control cable harness operating panel Selector button 4 when these are actuated the control receives a signal for beverage delivery Stop button 5 Each beverage delivery is stopped BU 4 6 connection for low temperature and empty indication BU 1 7 connection for Service Device to programme the dispenser Key switch 8 for reading and res...

Page 200: ...xtension board 1 Fig 1 ST 01 2 connection for control ST 02 3 connection for cold water valve café cool connection for coin interface payment system with Cafitesse 120 BU 06 4 connection for cold water valve café cool connection for mixer espresso BU 05 5 connection for hot water coil café cool connection for control espresso BU 04 6 connection for Peltier element espresso ST 03 7 connection for o...

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Page 209: ... V Transformators T01 Peltier Secondary voltage 13 V T02 control Secondary voltage 25 V Fuses power supplies USA Canada 115 V Fuse F04 at T01 0 75 AT Fuse F05 at T02 1 0 AT USA Canada 208 240 V Fuse F04 at T01 0 4 AT Fuse F05 at T02 0 75 AT in the voltage selector Europe 220 240 V Fuse F04 at T01 0 315 AT Fuse F05 at T02 0 5 AT Japan 200 V Fuse F04 at T01 0 31 AT Fuse F05 at T02 0 5 AT K 5 Technic...

Page 210: ...07 2004 5K 18 Functions Power Supply and Control Service Manual Cafitesse 100 ...

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Douwe Egberts Cafitesse 100, Service Manual

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