Rancilio EGRO 55 Series Technical Manual Download Page 1

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EGRO 55 SERIES TECHNICAL MANUAL

EGRO 55 SERIES

TECHNICAL MANUAL

Summary of Contents for EGRO 55 Series

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Page 3: ...opyright 2008 Rancilio North America TABLE OF CONTENTS SECTION 1 INTRODUCTION SECTION 2 INSTALLATION SECTION 3 PROGRAMMING SECTION 4 ELECTRICAL SECTION 5 HYDRAULIC SECTION 6 ADJUSTMENTS AND MAINTENANC...

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Page 5: ...NTENTS SECTION 1 Page 1 1 MACHINE OVERVIEW 2 3 1 1a Model 5511 identi es parts of machine 2 1 1b Model 5513 identi es parts of the machine and the Model KS Fridge 3 1 2 SAFETY PRECAUTIONS 4 1 3 PRE IN...

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Page 7: ...y 2 8 lbs of coffee beans 2 Display screen 3 Key pad 4 Programming key 5 Hot water spout 6 Grounds drawer door access to main power water switches 7 Drip tray 8 Coffee outlet 9 Legs 10 Temperature Sen...

Page 8: ...MODEL 5513 17 16 15 18 19 20 21 22 ITEM Model 5513 includes items 1 14 as described on the previous page PLUS the following items 15 Above the counter Model KS refrigerator 16 Model KS fridge door lat...

Page 9: ...following safety features Dedicated ground Wiring suitable for wattage capacity Circuit breaker Install the machine on a water repellent surface laminate steel ceramic etc Keep the machine away from h...

Page 10: ...tem may be used however all pre installed systems are subject to inspection and approval by a certi ed Rancilio technician DRAIN REQUIREMENTS Machine requires a 1 inch inter diameter drain pipe instal...

Page 11: ...cilio or a high quality espresso equipment ltration system may be used however all pre installed systems are subject to inspection and approval by a certi ed Rancilio technician DRAIN REQUIREMENTS Mac...

Page 12: ...fridge for model 5513 3 2 3 Install bean hoppers 3 2 4 Connect water to machine 4 2 5 Connect drain hoses 5 6 2 5A Connect the machine s drain hose to house drain 5 2 5B Connect fridge for model 5513...

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Page 14: ...1 Plastic T tting 4 5 Feet 1 Service card Cleaning tablets 1 jar TOOLS NEEDED The following tools are need for installing the Egro 55 series Phillips screwdriver P1 x 3 Standard 3 16 screw driver Smal...

Page 15: ...ter top will be easier 1 Locate the four or eight with fridge feet provided 2 Slowly tilt the Egro 55 machine or KS fridge to the right and screw in two legs one front and one back to the bottom left...

Page 16: ...gro 55 series machine The incoming water supply line to the machine should be a male 3 8 NPT tting The water connection on the Egro 55 machine is 3 8 BSPT WARNING A water softener lter for incoming wa...

Page 17: ...ched to the brew valve During the cleaning cycle pressure will increase which may cause the tube to become disconnected if it not securely attached INSTALLING DRIP TRAY DRAIN HOSE 4 Locate the provide...

Page 18: ...of the fridge and locate the 5 hoses which are looped and connected to the side of fridge for shipping 3 Push the coffee outlet all the way down and remove the Stainless Steel outlet cover by gently s...

Page 19: ...the hole of the right side panel of the fridge and through the hole of the left side panel of the machine wire connectors in the machine Match the connectors Be sure to correctly match wire colors of...

Page 20: ...HE MACHINE IS READY When the machine is turned on it must go a heating and rinsing initialization During this time do not enter programming otherwise an error may occur You may enter programming after...

Page 21: ...customizing the machine to the roast of beans to be served This will need to be done using the beans that will be served TIP Pull a shot rst and see how machine is pouring prior to adjusting the grin...

Page 22: ...escribed in Section 3 3 1 1 Insert programming key turn clockwise 1 4 turn 1 2 Press the number 4 button on the key pad 1 3 Enter the PIN code 1849 but pressing the 1 8 4 and 9 buttons 2 Scroll using...

Page 23: ...TIP First set your grinder to produce the coarseness of grind you prefer Activates Left grinder to perform test to calibrate machine Adjust grinder until grounds weigh 10 grams Machine records the tim...

Page 24: ...menu 9 1 Scroll using the number 5 button to the Grinder R test 9 2 Place a cup under the right grinder chute to catch the grounds Press the ENTER button button number 1 to activate the grinder and s...

Page 25: ...Changing operating mode how to enter programming mode 4 3 1c Programming menu overview 5 6 3 2 CUSTOMER MONITORING MODE OPERATING MODE 3 3 7 3 3 PRODUCT MENU HOW TO SET DRINK PARAMETER IN PROGRAMMING...

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Page 27: ...ack push buttons however they are labeled by small gray numbers See photo diagram below for more information Power LED When machine is on this light is lit Product LED Lights There are LED s located n...

Page 28: ...BUTTON Button number 0 is always the stop button In the programming mode Button 0 ESC Also cancels changes returns you to previous menu or aborts BUTTON 2 PRODUCT 2 10 Button 2 on the standard 5511 mo...

Page 29: ...ing key into the lock on the front of the machine 2 Turn the key clockwise to the right 1 4 turn 3 Press the appropriate button of the mode you would like 0 1 2 3 4 or 5 EXPLANATIONS OF MODES Mode 0 S...

Page 30: ...P_Cof Source P_Count P_Cycles P_Valid Mode1 P_Valid Mode2 P_Name P_Reg Nr P_Bypass Grinders GL Sec 10Gr GR Sec 10Gr Grinder L test Grinder R test Ref Temp CB Capp Corr Prerinse Press Reg Grounds Valu...

Page 31: ...e 2 MLR_Type C Request S Filling Auto Steam Ref Temp AS Last Errors Error Cycles P Serv Max cycles CLR P Serv W Serv Max Flowm CLR W Serv C Cleanings M Cleanings CLR Error Monitor Valve test Heater te...

Page 32: ...ustomer Monitoring mode or Product Total menu 1 1 Insert key turn to the right 1 2 Press number 3 button on the key pad Shows the product total for each product button that is programmed Example P1 87...

Page 33: ...ressing the 1 8 4 and 9 buttons 2 Enter the PRODUCTS menu 2 1 Using the 5 button scroll to the PRODUCT menu 2 2 Enter into the menu by pressing the 1 button Products 3 Choose the appropriate product n...

Page 34: ...milk 30 steamed and frothed milk Recommended setting for fastest milk delivery Time delay in seconds after button is pressed before coffee is delivered TIP Use this setting to help create clean looki...

Page 35: ...re more than one cycle Options 1 19 Recommended settings is 1 Enables or disables second level of all buttons Enables products 10 14 0 button enabled 1 button disabled NOT USED IN USA Sends drink pric...

Page 36: ...te Coffee 22 House Coffee 23 2x House Coffee 24 Espr macchiato 25 2x Espr macchiato 26 Jug 27 2x Jug 28 Pot 29 2x Pot 30 Cof in Glass 31 2x Cof in Glass 32 House coffee 33 2x House Coffee 34 Cap in Gl...

Page 37: ...s to grind 10 grams and uses this as bases for all product settings TIP If you adjust the coarseness of the grind run grinder test twice before weigh grounds again This will clear the chute of previou...

Page 38: ...just above the frother heads beneath the SS slider cover AFV 0 Air foam valve not present AFV 1 Air foam valve present USED FOR MODEL 5513 ONLY USED FOR MODEL 5513 ONLY USED FOR MODEL 5513 ONLY Corr...

Page 39: ...mmended Setting 1 DO NOT CHANGE Speci es the power rating of the steam boiler MUST BE SET ON 3 IN USA AND CA 1 2kw boiler 10a fuse 3 3kw boiler 16a fuse 2 2 5kw boiler 13a fuse Enables or disables a p...

Page 40: ...t enough to brew the selected drink it displays a Check Beans message Turns beeper ON or OFF 0 ON 1 OFF NOT USED IN USA Enables or disables cleaning when machine s in operating mode 2 0 rinsing disabl...

Page 41: ...f drinks before alert is displayed C Request SOFTWARE VERSIONS 1 00 2 09 0 NO TS wand present 1 TS wand is present SOFTWARE VERSIONS 1 00 2 09 0 NO TS wand present 1 TS wand is present with steam pres...

Page 42: ...and frothed milk for the latte button on the iSteam wand This temperature is in Celsius Use this parameter to set the emulsion level or foaming level associated with the latte button on the iSteam wan...

Page 43: ...lay Options 0 99 These are in increments of 1000 cycles example 1 1000 15 15 000 Clears the P Serv counter and set it to zero Displays the volume of water used in m3 since the last CLR W Serv Speci es...

Page 44: ...0 Steam boiler re ll valve J10 7 8 11 CAP_1 Y4 0 Steam valve for Capp left J10 9 10 12 CAP_2 Y5 0 Spare Capp right J10 11 12 13 Bypass Y6 0 Bypass valve optional J10 13 14 14 Function Switches on heat...

Page 45: ...from home position Home position P1 S15 Home position P2 S17 PIST 1 M7 008 Component Status Display Motor Jack peak to peak PIST 1 M7 008 Spindle motor 1 Piston P 1 J2 1 2 24V PIST 1 M7 008 Spindle m...

Page 46: ...MP1 0 Component Status Signal Inputs Press Button Function Check the eight 24V DC inputs Status 1 signal active 0 signal not active ADDITIONAL I O Display Component Jack on Control Board LED red MP 1...

Page 47: ...o valve right LED 14 Spare LED 4 14 Red On active 3 7b LED LIST FOR R2 MAINBOARD DL 1 24 Volt green continuous DL 2 5 Volt green continuous DL 3 Run mode green ashing DL 4 Pump DL 5 Left grinder DL 6...

Page 48: ...witch S13 using monitor menu e Check and make sure one phase of the power supply is not missing 61 No signal from Flowmeter P1 a Flowmeter is clogged or not responding check using monitor menu b Expan...

Page 49: ...olution counter S16 is faulty c Increase upper piston height P1 by 2 in Con g 1 menu P1 Turns parameter 97 No signal from upper piston P1 limit switch S14 a Check the upper spindle motor M7 use the mo...

Page 50: ...cts 9 P_Cap Product De nes which frother heads delivers milk Products 9 P_Cap Time Quantity of milk delivered Products 9 P_Cof Delay Time delay after button is pressed before coffee is delivered Produ...

Page 51: ...age Speci es which language Con g 2 14 P1 Turns DO NOT CHANGE Factory setting of the position of the top brewing piston Con g 1 13 P2 Out DO NOT CHANGE Factory setting of the position of the top brewi...

Page 52: ...before PM service alert is shown Service 18 Product_total Shows the total number of products produced since last PT_Clear Mode 3 7 PT_Clear Enables or disables product counter menu clear function Con...

Page 53: ...vates the boiler heaters Service Monitor 19 Inputs Checks the 24V DC inputs Service Monitor 21 Niveau test Checks the water level sensor in the steam boiler Service Monitor 20 POS SW Test Activate the...

Page 54: ...PARAMETER MENU PAGE M_Cleanings Service 19 Max_Cycles Service 18 Max FlowM Service 18 MB_Sensor Con g 2 45 MLR Parameter Con g 1 13 MLR Type Con g 2 15 NBUP Con g 1 13 Niveau test Service Monitor 20 P...

Page 55: ...TM_S4_electricalV3 EGRO 55 SERIES TECHNICAL MANUAL SECTION 4 ELECTRICAL TABLE OF CONTENTS SECTION 4 Page 4 1 INTRODUCTION 2 4 2 HIGH VOLTAGE COMPONENTS 2 4 4 3 LOW VOLTAGE COMPONENTS 5 7 4 4 MAINBOARD...

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Page 57: ...S WARNING TURN THE MACHINE OFF AND UNPLUG IT FROM THE WALL PRIOR TO WORKING WITH ANY HIGH VOLTAGE COMPONENTS PUMP MOTOR Generation 1 55 Series machines are equiped with a magnetically controlled 230v...

Page 58: ...heating element HEATING ELEMENT STEAM BOILER The steam boiler contains a 208V 3000w internal heating element RELAYS Electrical device such that current owing through it in one circuit 24v from the ma...

Page 59: ...CAPACITORS 230v incoming HIGH LIMIT SWITCH HOT WATER BOILER The hot water boiler high limit has a switch for each leg of power This is a thermo protection for the heating element Press the two brown b...

Page 60: ...the hot water boiler and the brew group BREW CHAMBER HEAT SLEEVE 24v Keeps the brew chamber at constant temperature to promote temperature stability during espresso extraction STEAM BOILER PRESSURE S...

Page 61: ...er piston motors that power the upper and lower pistons for tamping during the brewing process TS OR iSTEAM WAND PROBE 5v Temperature sensing probe for steaming milk Adjust the nal or shut off tempera...

Page 62: ...LOW VOLTAGE COMPONENTS CONTINUED SOLENOIDS MODEL 5513 In addition to the ve solenoids located in the Model 5511 there are three solenoids exclusive to the Model 5513 STEAM SOLENOID FOR LEFT FROTHER HE...

Page 63: ...S4_electricalV3 EGRO 55 SERIES TECHNICAL MANUAL Section 4 Page 8 Copyright 2008 Rancilio North America EGRO 55 SERIES TECHNICAL MANUAL 4 4 MAINBOARD DIAGRAM Diagram for the R2 Mainboard on the Egro 55...

Page 64: ...puccino valve left DL 13 Cappuccino valve right DL 14 Bypass Y6 DL 15 Steam valve for TS steam ASV DL 16 not in use DL 17 iFaom iSteam capp DL 18 iMilk iSteam latte DL 19 25 not in use DL 26 Res 2 DL...

Page 65: ...io North America E55_TM_S5_HyraulicV3 EGRO 55 SERIES TECHNICAL MANUAL SECTION 5 HYDRAULIC TABLE OF CONTENTS SECTION 5 Page 5 1 INTRODUCTION 2 5 2 HOT WATER COFFEE BOILER 2 3 5 3 STEAM BOILER 3 5 5 4 B...

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Page 67: ...FFEE BOILER HOT WATER SOLENOID FITTING Sends hot water to the mixing chamber when the hot water solenoid opens TEMPERATURE SENSOR Reads the temperature of the water in the boiler Sends temperature rea...

Page 68: ...ter to only pass in one direction incoming to the boiler WATER PRESSURE GAUGE Located on the bottom of the boiler Indicates the water pressure from the pump through the boiler Recommended resting pres...

Page 69: ...djustable from the top STEAM SOLENOID HOT WATER Supplies steam to the mixing chamber for use with hot water TS STEAM WAND SOLENOID Three way solenoid located between the grinder chutes Waste connects...

Page 70: ...o Mainboard Blue wire grounded on top of boiler connects to Mainboard INJECTION CHAMBER Union where steam meets water from coffee boiler and continues on to hot water tap Used for prepartion of tea wa...

Page 71: ...L MANUAL 5 4 BREW GROUP ASSEMBLY Following is a diagram of the brew group assembly All brewing and extraction takes place in the brew group assembly For a complete guide to repairing and rebuilding th...

Page 72: ...coffee outlet C Allen bolts or cotter pins that hold the brew group together D Piston motor Drives the gear box E Piston gear box Drives the piston auger shaft F Sweeper arm Clears the coffee puck fr...

Page 73: ...ECTION 6 ADJUSTMENTS AND MAINTENANCE TABLE OF CONTENTS SECTION 5 Page Adjustments 6 1 CALIBRATING MACHINE TO BEANS DIALING IN 10 GRAMS 2 3 6 2 ADJUSTING GRIND 3 Maintenance 6 3 REPLACING BREW GROUP 6...

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Page 75: ...menu and press enter button 1 1 2 1 1 2 Grinders Config1 3 Config1 Service Products Config2 X X X Product Total X Grinders GL Sec 10Gr GR Sec 10Gr Grinder L test Grinder R test TIP First set your grin...

Page 76: ...enths of a second can greatly affect the resulting weight 8 6 Press ENTER button 1 to save the changes 8 7 Scroll forward button 5 to the Grinder l test again And repeat the test as described in 8 1 t...

Page 77: ...Turn the collar on the top of the grinder to adjust the grind Finer grind Turn collar clockwise Courser grind Turn collar counter clockwise 5 Make sure that the adjustment plate is securely held in pl...

Page 78: ...Chamber Heating 3 5 6 4 DRAINING THE STEAM BOILER STEPS TO DRAINING THE STEAM BOILER 1 Cool down the machine using the Cool Down function in the programming menu Service Monitor Cool Down 2 Remove th...

Page 79: ...he upper grinder housing GRINDERS WITH AN INTERNAL ADJUSTMENT 4b Remove the grinder adjustment by removing the two screws which hold it to the upper grinder housing 5 Unscrew the upper burr plate by r...

Page 81: ...E PART S KIT 2 INCLUDES Ref Num Part Describ P N QTY Included 1 Upper piston O ring 039061 1 2 Upper piston scrapper O ring 039064 1 3 Lower piston O ring 029441 1 5 O ring for coffee brew valve assem...

Page 82: ...rounds puck sweeper arm BREW GROUP ASSEMBLY OR BGA the complete brewing module of the Egro 55 series espresso machines PISTON ASSEMBLY UPA OR LPA The upper and lower piston assemblies are identical ex...

Page 83: ...er piston head 17 Piston stabilizing ring 18 Piston head scrapper ring and O ring 19 Stainless steal piston plate 20 Shower screen 12 13 14 15 16 17 13 18 19 20 UPPER PISTON HEAD This is an exploded v...

Page 84: ...es from the motherboard The connections are J2 J3 and J16 on the motherboard 2 3 Discount the Te on water deliver hoses from the upper and lower pistons 2 4 Loosen the 2 nuts located behind the BGA 2...

Page 85: ...GRAMMING MENU DIAGRAM To access the programming menu Insert key and turn to right Enter Pin code 1849 using numbers on keypad Scroll through programming until you reach the SERVICE menu Enter SERVICE...

Page 86: ...VE HOSES FROM PISTONS A2 1 Remove hoses from both the upper and lower pistons A2 1 A 1 REMOVE BGA FROM MACHINE AND REMOVE GROUNDS PUCK CHUTES A1 1 Remove the BGA from the machine Follow steps 1 1 to 1...

Page 87: ...and the orange O ring from the piston head A3 4 A3 1 A3 2 A3 3 A 3 REMOVE UPPER PISTON O RINGS A3 1 Place the BGA on the workbench and remove the Upper Piston Assembly UPA by loosening the two cotter...

Page 88: ...less steel upper piston plate onto upper piston TOOL Phillip s head screwdriver CAUTION Do not over tighten or cross thread PLEASE NOTE For PM Type 2 please replace the brew shower screens with new sc...

Page 89: ...Allen wrench into the gear box of the UPA and manually moving the piston A5 3 Set UPA aside for now A5 2 A 6 REMOVE LOWER PISTON O RINGS A6 1 Place the BGA on the counter upside down and remove the Lo...

Page 90: ...Loctite PN 36781 A7 2 Replace lower piston O ring PN 029441 small orange seal A7 3 Reassemble shower screen onto lower piston TOOL Screwdriver PLEASE NOTE For PM Type 2 please replace the shower scree...

Page 91: ...when the BGA is facing towards you and the cotter pins are inserted from the front of the BGA If the cotter pins which hold the UPA in place do not easily insert into the frame manually move the pisto...

Page 92: ...nds slides to the sides of the BGA TIP The shorter bent puck slide goes on the right side of the BGA when the BGA is facing towards you Funnel towards you A10 1 A 11 REASSEMBLE BGA INTO MACHINE A11 1...

Page 93: ...e the brew shower screens instead of cleaning them Shower Screen Part Number 060116 PERFORM ALL THE STEPS NECESSARY FOR PM TYPE 1 PLUS FOLLOWING STEPS 12 REPLACE COFFEE BOILER EXPANSION VALVE 12 1 Rep...

Page 94: ...1 Replace the seal on the steam wand tip PN 040501 PLEASE NOTE Be careful not to slice the seal when reassembling the tip to the wand the threads of the steam tip are very sharp 15 TURN MACHINE ON 15...

Page 95: ...rings Lubricated and replaced lower piston O ring Cleaned shower screens on upper and lower pistons GRINDERS Inspected grinders Cleaned hoppers OUTLETS AND STEAM WAND Ran automatic coffee cleaning pr...

Page 97: ...n about 32oz of water or Squeeze lemon juice into about 32oz of water Do NOT use dish soap or any harsh cleaners which contain abrasive chemicals These items can leave a nasty residue on the BGA compo...

Page 98: ...late 11 Grounds puck sweeper arm Brew Group Assembly or BGA the complete brewing module of the Egro 55 series espresso machines Piston Assembly UPA or LPA The upper and lower piston assemblies are ide...

Page 99: ...ose 16 Upper piston head 17 Piston stabilizing ring 18 Piston head scrapper ring and O ring 19 Stainless steal piston plate 20 Shower screen 12 13 14 15 16 17 13 18 19 20 Upper Piston Head This is an...

Page 100: ...lug the machine 1 2 Remove the left and right side panels of machine 1 3 Disconnect the piston motor and brew chamber heating element power cables from the motherboard PLEASE NOTE These are the connec...

Page 101: ...6 7 BREW GROUP REBUILD GUIDE Section 6 Page 28 EGRO 55 SERIES TECHNICAL MANUAL 3 REMOVE HOSES FROM PISTONS 3 1 Remove hoses from both the upper and lower pistons 3 1...

Page 102: ...piston guide arms 4 6 Remove piston shaft from piston head TOOL 3mm Allen wrench 4 4 4 DISASSEMBLE AND CLEAN THE UPPER PISTON ASSEMBLY UPA 4 1 Place the BGA your work area and remove the Upper Piston...

Page 103: ...r assembly clean with a damp towel 4 DISASSEMBLE AND CLEAN THE UPA Continued 4 7 4 9 4 10 Clean all lube from auger shaft using a piece of plastic wrap or a towel CAUTION do not use paper towels as pi...

Page 104: ...om the piston head TIP Tighten Allen screws half way and lay on the edge of the table or at surface and tighten the rest of the way 5 7 5 6 5 5 5 REASSEMBLE THE UPPER PISTON ASSEMBLY UPA 5 1 Lubricate...

Page 105: ...g it down the auger shaft using a 3mm Allen wrench inserted into the gear box of the UPA bottom of the mounting plate TOOL 3mm Allen wrench PLEASE NOTE Be sure the quick connect faces to the outside o...

Page 106: ...a slight rocking motion to remove LPA from housing 6 2 If necessary remove coffee build up from LPA using a toothbrush or a screwdriver CAUTION Do this gently as not to damage parts 6 3 Remove the lo...

Page 107: ...screwing screws using a Phillip s head screwdriver TOOL Phillip s head screwdriver 6 11 Remove piston spring plate by unscrewing two 4mm Allen Screws TOOL 4mm Allen Wrench 6 8 Remove wiring harnesses...

Page 108: ...an using towel and toothbrush if necessary 6 13 Clean all lube from auger shaft using a piece of plastic wrap or a towel CAUTION do not use paper towels as pieces of them may get into threads of auger...

Page 109: ...l 7 3 Reassemble brew screen onto lower piston TOOL Screwdriver 7 4 Reattach piston shaft to piston head using Allen screws TOOL 3mm Allen wrench CAUTION Do not overtighten or cross thread 7 5 Reattac...

Page 110: ...OWN PLEASE NOTE You must replace the zip tie which holds the wires in place if you cut them during disassembly 7 9 Lubricate lower piston auger shaft and auger shaft hole in piston LUBE Krytox RFE PFP...

Page 111: ...k apart the brew group housing frame please follow Steps 9 1 9 4 to reassemble the frame If you did not take it apart please be sure to clean it thoroughly before reassembling UPA and LPA into the fra...

Page 112: ...ousing PLEASE NOTE motor goes to the left when the BGA is facing towards you and the cotter pins are inserted from the front of the BGA If the cotter pins which hold the UPA in place do not easily ins...

Page 113: ...puck slide goes on the right side of the BGA when the BGA is facing towards you Funnel towards you 11 REATTACH HOSES TO UPPER AND LOWER PISTONS 11 1 Reattach the hoses to the upper and lower pistons...

Page 114: ...REBUILD GUIDE Section 6 Page 41 EGRO 55 SERIES TECHNICAL MANUAL CONGRATULATIONS CONGRATULATIONS YOU HAVE REFURBISHED YOU HAVE REFURBISHED AN EGRO 55 SERIES BREW GROUP ASSEMBLY AN EGRO 55 SERIES BREW...

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