Sanremo CAFE RACER Technical Manual Download Page 2

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04-2017

CAFE RACER

Manual for technical

1 / 56-EN

INDEX

1. Introduction .......................................................................................................... 3

1.1 General safety warnings .............................................................................. 3

2. Removing the tray ............................................................................................... 4

3. Removing the cup heating plate ........................................................................ 6

4. Removing the panels .......................................................................................... 7

4.1 Removing the profile side

............................................................................ 7

4.2 Removing the rear panel ............................................................................. 8

4.3 Removing the coffee unit guard

.................................................................. 9

4.4 Removing the lower front panel ................................................................. 10

5. Layout of main components ............................................................................. 11

5.1 Top view .................................................................................................... 11

5.2 Rear view .................................................................................................. 12

5.3 L side view

.............................................................................................. 13

5.4 R side view

............................................................................................. 14

5.5 Removing the electrical panel ................................................................... 15

5.6 Layout of the electrical panel ..................................................................... 15

6. Adjustments - Resets ........................................................................................ 16

6.1 Ad usting mixed water

............................................................................... 16

6.2 Bleeding the air from the circuit

................................................................. 16

6.3 Resetting the service boiler safety thermostat .......................................... 16

6.4 Resetting the small boiler safety thermostat ............................................. 17

6.5 Resetting the unit safety thermostat .......................................................... 17

7. Removals - Replacements ................................................................................ 18

7.1 Replacing the cup heating plate heating element ..................................... 18

7.2 Replacing the cup heating plate probe ...................................................... 18

7.3 Replacing the small boiler heating element ............................................... 19

7.4 Replacing the boiler thermostat ................................................................. 21

7.5 Replacing the unit small boiler .................................................................. 21

7.6 Replacing the coffee boiler heating element ............................................. 23

7.7 Replacing the pump .................................................................................. 24

7.8 Replacing the pump motor ........................................................................ 25

7.9 Replacing the LED plate ............................................................................ 26

7.10 Replacing the boiler filling solenoid valve

................................................ 26

7.11 Replacing the mixed water solenoid valve

.............................................. 27

7.12 Replacing the hot water solenoid valve

................................................... 28

7.13 Replacing the cooling cycle solenoid valve

............................................. 29

7.14 Replacing the purge solenoid valve

........................................................ 29

7.15 Replacing the pre-infusion solenoid valve

............................................... 31

7.16 Replacing the unit solenoid valve

............................................................ 31

7.17 Replacing the displacement counter

....................................................... 32

7.18 Replacing the pump pressure transducer

............................................... 33

7.19 Replacing the service boiler pressure transducer

................................... 33

7.20 Replacing the pre-infusion expansion board

........................................... 34

7.21 Replacing the electronic board

................................................................ 34

7.22 Replacing the electrical panel components ............................................. 35

7.23 Replacing the display board

.................................................................... 36

7.24 Replacing the unit display

....................................................................... 37

7.25 Removing the service boiler .................................................................... 39

7.26 Replacing the steam tap .......................................................................... 40

7.27 Replacing the safety thermostat .............................................................. 41

7.28 Replacing the water dispensing tap button

............................................. 41

7.29 Replacing the LED bar ............................................................................ 42

7.30 Replacing the main switch ....................................................................... 43

7.31 Removing the head and gas ets

............................................................. 44

PRELIMINARY REV 00

Summary of Contents for CAFE RACER

Page 1: ...CAFE RACER Manuale per il Tecnico Manual for Technical ...

Page 2: ... thermostat 21 7 5 Replacing the unit small boiler 21 7 6 Replacing the coffee boiler heating element 23 7 7 Replacing the pump 24 7 8 Replacing the pump motor 25 7 9 Replacing the LED plate 26 7 10 Replacing the boiler filling solenoid valve 26 7 11 Replacing the mixed water solenoid valve 27 7 12 Replacing the hot water solenoid valve 28 7 13 Replacing the cooling cycle solenoid valve 29 7 14 Re...

Page 3: ...7 8 9 Pump pressure offset 48 8 10 Programming doses 48 8 11 Four doses 48 8 12 Displacement counter offset 1 2 3 48 8 13 Sensitivity 49 8 14 Maintenance cycles 49 8 15 Temperature 49 8 16 Temperature C F 49 8 17 Boiler temperature 50 8 18 Unit temperature offset 50 8 19 Inactivity time 50 8 20 Filling timeout 51 8 21 Water filter 51 8 22 Number of credits 51 8 23 Cooling cycle 51 8 24 Password 52...

Page 4: ...me care When operating on the machine chec that the water contained in the machine is cold When some operations ad ustments need to be carried out with the machine at oper ating temperature operate with extreme care and use suitable personal protective equipment Suitable personal protective equipment must be worn in any case as required by cur rent safety regulations in the country of use Current ...

Page 5: ...CAFE RACER 04 2017 Manual for technical 4 56 EN EN 2 REmovING tHE tRAy Remove the grille 1 Lift and remove the tray 2 ndo the four Allen screws 3 1 2 3 ...

Page 6: ...04 2017 CAFE RACER Manual for technical 5 56 EN EN Loosen the screw 4 and remove the tray support 5 When reassembling the tray 5 check the conditions of the oR gaskets 6 and grease them 4 5 6 ...

Page 7: ...6 EN EN 3 REmovING tHE cuP HEAt ING PLAtE nscrew screw 1 on both sides Remove the grilles 2 Lift the cup heating plate 3 Disconnect the connector 4 of the probe Disconnect the heating element connector 5 Remove the cup heating plate 3 1 2 4 5 3 ...

Page 8: ...ovING tHE PANELS Remove the side panels and the cup heat ing plate to access all the internal ma chine components 4 1 Removing t e profile side Unscrew the screws 1 Remove the profile side 2 Unscrew the screws 3 fastening the panel 4 Remove panel 4 1 4 2 3 4 ...

Page 9: ...ER 04 2017 Manual for technical 8 56 EN EN 4 2 Removing the rear panel nscrew the two side screws 1 Remove the pipe 2 connecting the two shoulders Unscrew the three screws 3 Loosen the three screws 4 1 2 3 4 4 ...

Page 10: ...ual for technical 9 56 EN EN 4 3 Removing the coffee unit guard nscrew the screws 1 on both sides Remove the rear panel 5 Widen the two guards 2 and remove them Pull out the guard 3 with the display toward the front 5 1 2 3 ...

Page 11: ...CAFE RACER 04 2017 Manual for technical 10 56 EN EN Disconnect the connectors 4 and 5 4 4 Removing the lower front panel Loosen the two Phillips screws 1 Pull out panel 2 5 4 1 2 ...

Page 12: ...cement counter 7 nit 1 pre infusion solenoid valve 8 nit 2 pre infusion solenoid valve 9 nit 3 pre infusion solenoid valve 10 RH steam tap shut off tap 11 LH steam tap shut off tap 12 Service boiler 13 Steam pressure transducer 14 Safety valve 15 Pump motor 16 Water pump 17 Drain solenoid valve 18 Unit 1 shut off tap 19 Unit 2 shut off tap 20 Unit 3 shut off tap 9 3 6 8 2 5 7 1 4 15 16 17 14 18 12...

Page 13: ... 04 2017 Manual for technical 12 56 EN EN 5 2 Rear view 1 Service boiler 2 Drain manifold 3 Cooling cycle solenoid valve boiler water regen eration 4 Steam boiler drain tap 5 Mixed water solenoid valve 1 2 3 4 5 ...

Page 14: ...hnical 13 56 EN EN 5 3 LH side view 1 Loading flange 2 Pump pressure transducer 3 Water loading solenoid valve 4 LED plate 5 Main electronic control unit 6 Pre infusion expansion board 7 Front and side LED on off switch 5 7 1 4 2 3 6 2 ...

Page 15: ...CAFE RACER 04 2017 Manual for technical 14 56 EN EN 5 4 RH side view 1 Purge drain connections 2 Purge button 3 Purge solenoid valve 4 Expansion valve 5 LED plate 6 Boiler heating elements 2 5 4 3 6 1 ...

Page 16: ...or 4 Single phase static relays to control steam boiler heating 5 Condenser 6 WIFI interface board optional 7 Power unit cooling fan 8 Switching power unit stabilised transformer 9 Fuse F2 3 15 A LED fuse 10 Fuse F1 1 A Control unit fuse 5 5 Removing the electrical panel Remove the lower front panel as described in the rel evant paragraph nscrew the two nobs 1 located under the front of the machin...

Page 17: ...tton 1 located in the right front lower part to energise the coils and bleed any air from the circuit eep the button pressed until only water comes out of the drain not water mixed with air 6 3 Resetting the service boiler safety thermo stat Remove the R side panel as described in the rel ative paragraph Press the safety thermostat 1 to reset it If the thermostat trips again when the machine is re...

Page 18: ...ed after re setting the safety thermostat check the adjustment of the small boiler temperature thermostat or its proper functioning 6 5 Resetting the unit safety thermostat Remove the unit guards as described in the rele vant paragraph Press the safety thermostat 1 to reset it If the thermostat trips again when the machine is restarted after re setting the safety thermostat check the adjustment of...

Page 19: ...2 Clean the surface of glue residues Screw the ground nut bac in and gradually place the heating element 2 on the surface so that there are no air bubbles between the surface and the heating element 7 2 Replacing the cup heating plate probe Remove the cup heating plate as described in the relevant paragraph nscrew the nut 1 and remove the stopping plate 2 nscrew the nut 3 and remove the probe 4 Wh...

Page 20: ... the rele vant paragraph Remove the lower front panel as described in the relevant paragraph Ensure the machine is off and the water supply tap is closed Drain the coffee circuit by opening the tap 1 of the boiler unit Disconnect the two Faston connectors 2 from heating element 3 Disconnect the water drain tube 4 press the ring nut and pull the tube Unscrew the nut 5 of the water supply tube 1 2 3...

Page 21: ... for technical 20 56 EN EN Unscrew the screws 6 fastening the boiler cover Use a plastic hammer to tap the cover 7 to facili tate its removal Remove the cover 7 nscrew the nuts 8 and replace the heating ele ment 9 7 7 6 6 6 8 9 ...

Page 22: ...cing the boiler thermostat Remove the boiler cover 1 as described in para graph Replacing the boiler heating element nscrew the nut 2 and remove the thermostat 3 When reassembling spread conductive paste on the contact surfaces between the thermostat 3 and the cover 1 7 5 unit boiler replacement Remove the cup heating plate and the front panel as described in the relevant paragraphs Drain the coff...

Page 23: ...or technical 22 56 EN EN Disconnect the boiler electrical connections 2 3 Disconnect the probe connector 4 Unscrew the two water connection tubes 5 Loosen the nuts 6 lift it and detach it from the support brac et 7 3 4 5 5 7 2 6 ...

Page 24: ...ream main switch to OFF Remove the RH side panel and the cup heating plate as described in the relevant paragraphs Open the tap 1 to drain the water from the boiler 2 Disconnect all wires connecting the heating ele ment 3 to the machine wiring unscrewing the relevant nuts 4 Remove the Seeger ring 5 and guard 6 Remove the heating element 3 Refit everything operating in reverse order from removal ch...

Page 25: ...described in the relevant paragraph Disconnect the pump from tubes by unscrewing nuts 1 and 2 Loosen the strap 3 Remove the complete pump 4 When reassembling pay attention to properly fit the pump pin onto the cran shaft When reassembling pay attention to properl fit t e pump pin onto t e cran shaft 1 3 4 2 ...

Page 26: ...ecting the inta e and delivery pipes nscrew the two screws 1 and move the LED plate 2 with the relevant brac et 3 Loosen the screws 4 fastening the pump to the plate 5 Disconnect the two pump connectors 6 and 7 Lift the pump motor 8 detaching it from the plate 5 and remove it Reassemble everything in reverse order of remov al paying attention to connect connector 7 to the 3 way connector below it ...

Page 27: ...escribed in the relative paragraph Unscrew the two screws 1 Disconnect the connector 2 from the unction box and replace the complete plate 3 1 Replacing t e boiler filling solenoid valve Remove the L side panel as described in the rel evant paragraph Disconnect the two Faston connectors 1 from the coil 2 3 1 2 ...

Page 28: ...ay attention to properly con nect the Faston connectors to the coil When reassembling the core pay atten tion to properly reassemble the gasket core and spring 7 11 Replacing the mixed water solenoid valve Remove the L side panel the L side profile and the rear panel as described in the relevant para graphs Unscrew the two bushings 1 Unscrew screw 2 1 2 2 3 4 5 4 1 ...

Page 29: ...eplace the coil or replace the entire solenoid valve 5 When reassembling pay attention to properly con nect the Faston connectors to the coil 7 12 Replacing the hot water solenoid valve Remove the cup heating plate as described in the relevant paragraph Disconnect the Faston connectors 1 nscrew the two nuts 2 and remove the solenoid valve 3 Replace the coil or solenoid valve and reassemble in inve...

Page 30: ... the coil 3 ndo the four screws 4 and remove the core 5 When reassembling pay attention to properly con nect the Faston connectors to the coil When reassembling the core pay atten tion to properly reassemble the gasket core and spring 7 14 Replacing the purge solenoid valve Remove the R side panel as described in the rel ative paragraph nscrew the two screws 1 and move the LED plate 2 with the rel...

Page 31: ...CAFE RACER 04 2017 Manual for technical 30 56 EN EN Cut the strap 4 Disconnect the tube 5 Loosen the nut 6 fastening the flange 7 to the brac et Disconnect the Faston connectors 8 4 5 7 6 8 ...

Page 32: ...described in the relevant paragraph Disconnect the Faston connectors 1 nscrew the three nuts fittings 2 and remove the solenoid valve 3 When reassembling pay attention to properly con nect the Faston connectors to the coil nscrew the three nuts fittings 2 and remove the solenoid valve 3 When reassembling pay attention to properly con nect the Faston connectors to the coil 7 16 Replacing the unit s...

Page 33: ...onnectors to the coil When reassembling the core pay atten tion to properly reassemble the gasket core and spring 7 17 Replacing the displacement counter Remove the cup heating plate as described in the relevant paragraph ndo the screw 1 and remove the head 2 nscrew the nuts 3 and disconnect the tubes 4 Loosen the two nuts 5 located under the support square then pull out the displacement counter 6...

Page 34: ...straps 1 fastening the transducer cable to the machine wiring nscrew the transducer 2 nscrew screw 3 and disconnect contacts 4 from transducer 2 7 19 Replacing the service boiler pressure trans ducer Remove the cup heating plate as described in the relevant paragraph nscrew the transducer 1 nscrew screw 2 and disconnect contacts 3 from transducer 1 1 2 3 1 2 2 4 3 ...

Page 35: ...rew the fastening screw of the expansion board Disconnect the connectors 2 Pull out the board 3 and disconnect the rear con nector 4 mark the position of connectors so that they are inserted in the relevant seat when the board is reassembled 7 21 Replacing the electronic board Remove the L side panel as described in the rel evant paragraph nscrew the two screws 1 and move the LED plate 2 with the ...

Page 36: ...components to perform this check the electrical con nection must be inserted therefore the electrical panel components 4 are pow ered up operate with utmost care In order to chec proper operation of the electrical panel components pull the panel out and connect the relevant extension supplied upon request Remove the lower front panel as described in the relevant paragraph Pull out the electrical p...

Page 37: ... heating plate as described in the relevant paragraph Loosen the four nuts 1 two on each side If the plate 5 is removed assemble the connec tors as shown in the figure paying attention to po sition the guide 6 for both connectors as posi tioned in the figure Disconnect the connector 2 5 1 2 At Bt 6 1 ...

Page 38: ...ve the frame 5 nscrew the two screws 6 and remove the dis play board 7 from brac et 8 7 24 Replacing the unit display Remove the coffee unit guards as described in the relevant paragraph Disconnect the two connectors 1 and 2 and re move the sponge 3 Unscrew the three front screws 1 3 6 4 7 1 2 1 5 8 6 3 1 ...

Page 39: ...internal frame 3 nscrew the two screws 4 and remove the dis play 5 After replacing the display set the dip switch 6 according to the fact that unit 1 2 or 3 is in stalled see the figure to ad ust the dip switch 1 ON ECE 2 3 4 1 ON ECE 2 3 4 1 ON ECE 2 3 4 1st unit 2nd unit 3rd unit 2 3 5 4 6 ...

Page 40: ...t 5 and disconnect the right steam tap connection tube 6 nscrew and remove the temperature probe 7 Disconnect the maximum level probe connector 8 Disconnect the minimum level probe connector 9 nscrew the nut 10 and disconnect the air bleed tube 11 nscrew the nut 12 and remove the transducer tube 13 nscrew the nut 14 and disconnect the left steam tap connection tube 15 nscrew the nuts 16 and discon...

Page 41: ... safety valve drain tube 20 Pull out the boiler upwards 7 26 Replacing the steam tap Remove the cup heating plate as described in the relevant paragraph Close the tap 1 pertaining to the steam tap to be replaced nscrew the nut 2 and disconnect the tube 3 Unscrew the nut 4 fastening the tap to the ma chine body 18 20 19 1 4 2 3 ...

Page 42: ...aph Unscrew the two screws 1 disconnect the ther mostat 2 from the support square and disconnect the Faston connectors Cut the strap 3 and 4 and pull out the bulb 5 When reassembling pay attention to properly con nect the Faston connectors and properly position the straps 7 28 Replacing the water dispensing tap button Undo the two screws 1 and remove the ring nut 2 5 1 2 3 4 5 2 1 ...

Page 43: ...e wires 4 When reassembling properly reconnect the wires 4 7 29 Replacing the LED bar Remove the left panel with shoulder and the low er front panel as described in the relevant para graphs Unscrew the three screws 1 Disconnect the connector 2 Pull out the LED bar 3 from the side 3 4 1 2 3 ...

Page 44: ...the main switch saying maintenance in progress so that no one turns on the power during this operation Remove the cup heating plate as described in the relevant paragraph Cut the strap 1 Disconnect all the connectors 2 Unscrew the ring nut 3 Remove the switch 4 Reassemble everything in reverse order referring to the attached wiring diagram for electrical con nections 1 2 2 3 4 ...

Page 45: ...nd relevant gas et 2 Insert the new gas et 2 on the head 1 The bevel corners A of the gas et must be facing upward Remove the filter from the filter holder 3 and as semble the head with gas et on the filter holder 3 Wet the head with water and assemble the filter holder 3 on the machine pressing thoroughly Loc the filter holder 3 1 2 A 1 3 ...

Page 46: ...e various programming sequences therefore scroll through the sequences and confirm the set data until reaching the desired sequence to be modified The programming sequences are Language Name Service tel Number of units Chrono function Inta e coffee Watt Steam pressure transducer Pump pressure offset Programming doses Four doses Displacement counter offset 1 Displacement counter offset 2 Displaceme...

Page 47: ...ne name is shown in this section Press the button to go to the next section 8 3 Service tel In this section you can set the phone number of the service centre the modifiable number blin s to set the number press button to confirm the number and move to the next number by press ing button Press the button to confirm the phone num ber set and go to the next section 8 4 Number of units This section i...

Page 48: ...s to DISA BLED otherwise set it to ENABLED Press button to enable or disable the func tion Press the button to confirm the selection and go to the next section 8 7 Watt This function is used to set the machine power be tween a minimum of 3500 watt and a Full maximum of 8750 watt the default setting is 6500 watt Press button or to change watt Press the button to confirm the selection and go to the ...

Page 49: ...e button to go to the next section 8 12 Displacement counter offset 1 2 3 If there are discrepancies between the set ml and the dispensed ml the setting can be ad usted by pressing the button or button Press the button to confirm the selection and go to the next section 8 11 Four doses This functions is used to enable the button multifunc tion leave it selected to ES Press button once to dispense ...

Page 50: ...onfirm the selection and go to the next section 8 14 maintenance cycles In this section you can set after how many dispens ing cycles the machine requires maintenance Press the button or to set the cycles When the set number of cycles has been reached the service phone number appears on the display Press the button to confirm the selection and go to the next section 8 15 temperature Chec that ENAB...

Page 51: ... 8 19 Inactivity time If the machine is installed in an outdoor ios the temperature is low and the machine is inactive for a few minutes the unit temperature may drop 0 5 C or 1 C ou can set an inactivity time beyond which the machine automatically increases the unit tempera ture to a value set in the next screen REST TEMP OFS Press the button or to set the values Press the button to go to the nex...

Page 52: ...achine stops this function can be enabled or disabled Press the button or to enable or dis able this functions or set the max no of coffees to be dispensed when DISABLED is selected press button to go to the next section if the quantity of coffees after which the ma chine is stopped is set the value is set with button or Press the button to confirm the value and go to the next section 8 23 cooling...

Page 53: ...nician menu If you have selected ES press the button to confirm the selection and go to the next section where the blin ing number is the modifiable one se the buttons of the first two units on the left to set the password Button a to enter number 1 Button b to enter number 2 Button c to enter number 3 Button d to enter number 4 Button e to enter number 5 Button f to enter number 6 Once the new pa...

Page 54: ...solenoid valve Ev9 10 11 Pre infusion solenoid valve FW1 2 3 Displacement counter m1 Motor with 300 litre pump oWv1 Loading flange chec valve PB1 Max level probe PB2 Minimum level probe PB3 Coffee unit temperature probe PB4 6 8 Coffee boiler temperature probe PB9 Steam boiler temperature probe R1 Steam boiler heating element R2 Unit heating element R8 9 10 Coffee boiler heating element Sv1 12Bar e...

Page 55: ... 6L1 1F 1N 24Vdc 7N1 7L1 2L2 2L3 8N1 9N1 10N1 11N1 13N1 14N1 9 F 8 F 7 F 6 F 8L1 3L2 3L3 9L1 4L2 4L3 11L1 6L2 6L3 12L1 7L2 7L3 13L1 8L2 8L3 14L1 9L2 9L3 BAR PARAMETERS DISPLAY 5 5 EVPR1 EVPR2 EVPR3 4F CN6 EXPANSION 6 RELAYS B1 Preinfusion Control 30 31 32 CN30 5Vdc OUT TS2 PUMP PRESSURE TRANSDUCER 0 16 bar 5Vdc OUT TS1 STEAM PRESSURE TRANSDUCER 0 4 bar 5Vdc OUT POWER SUPPLY SWITCHING SW1 N F 100 2...

Page 56: ... 9L1 4L2 4L3 11L1 6L2 6L3 12L1 7L2 7L3 13L1 8L2 8L3 14L1 9L2 9L3 BAR PARAMETERS DISPLAY 5 5 EVPR1 EVPR2 EVPR3 4F CN6 EXPANSION 6 RELAYS B1 Preinfusion Control 30 31 32 CN30 5Vdc OUT TS2 PUMP PRESSURE TRANSDUCER 0 16 bar 5Vdc OUT TS1 STEAM PRESSURE TRANSDUCER 0 4 bar 5Vdc OUT POWER SUPPLY SWITCHING SW1 N F 100 240V AC G7J 4A B 24V command NA 25A at 220 Vc a 150W 3 15A CN46 SLAVE TRIAC Board CN47 SL...

Page 57: ...CAFE RACER 04 2017 Manual for technical 56 56 EN EN ...

Page 58: ......

Page 59: ...SANREMO s r l Via Bortolan 52 31050 Vascon di Carbonera TV ITALIA tel 39 0422 448900 fax 39 0422 448935 p iva c f 03239750262 www sanremomachines com info sanremomachines com Cod 82012001 04 2017 ...

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