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Technical Manual

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ELECTRICAL BOX:

The electronics box, located underneath the machine, contains all the incoming and

outgoing power to the Synesso™. Since the 2 boxes represented below (top: 3 group

box, bottom 1 group) have many of the same components, they have been labeled with

numbers for matching components and the descriptions follow in the next pages.

4

7

6

2

5

12

10

11

1

3

8

13

14 top

of lid

9

ELECTRONIC SYSTEM

1 Group Electrical Box

3 Group Hydra Electrical Box

4

5

3

1

13

6

7

12

14

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27
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Summary of Contents for Espresso Machine

Page 1: ...Technical Manual Synesso Inc 309 S Cloverdale C41 Seattle WA 98108 tel 206 764 0600 fax 206 764 0601 www Synesso com info Synesso com ...

Page 2: ...Technical Manual 2 This Service Manual is intended for use by qualified service technicians only ...

Page 3: ...ble of Contents Safety and Tools Pages 4 5 Installation Pages 6 10 Hydraulic System Pages 11 21 Electrical System Pages 22 27 Troubleshooting Pages 28 35 Periodic Maintenance Pages 36 39 Programming Instructions Pages 40 62 ...

Page 4: ...lves 1 4 for steam valve seat SAFETY AND TOOLS Safety Precautions Espresso machines have numerous potential hazards and it is of paramount importance to Synesso that people servicing our machines take all necessary precautions to ensure their personal safety Please note and follow the safety stickers on the machine When working on the machine s boilers unless otherwise instructed in the directions...

Page 5: ...d 5 8 Large Medium and Small Adjustable Wrenches Crescent Wrenches Pliers Channel Lock Standard and Side Cutters Philips Head Screwdrivers 2 short 2 long and 1 Flat Head Screwdrivers 2 short 2 medium 2 long 1 and large screwdriver to use as a pry bar Pen and paper Hand cleaner Towels SAFETY AND TOOLS ...

Page 6: ...200 ppm parts per million Total Hardness in ppm Less than 85 ppm Total Hardness in grains 3 to 5 grains divide ppm by 17 1 to get grains pH 6 pH to 8 pH Chloride 0 ppm any Chlorides can be corrosive and harmful Total Alkalinity Less than 100 ppm Chlorine 0 ppm Iron 0 ppm Water to steam tank Electrical requirements 1 Group 110v 60 hz 20 amp 1 Group 220v 50 60 hz 16 amp 2 Group 220v 50 60 hz 28 amp ...

Page 7: ...is vital to the proper functioning of the machine and the quality of the espresso served Follow the instructions provided by your water treatment system for proper installation Note Improper water filtration can result in water damage inside the machine causing scale and corrosion DAMAGE CAUSED BY IMPROPER WATER TREATMENT WILL NOT BE COVERED BY THE MACHINE WARRANTY There must be adequate room unde...

Page 8: ...pressure to have the steam tank auto filling system function properly Electrical Instructions After you make sure your receptacle and circuit are rated for the proper voltage and amperage see specifications chart on page 9 for your model install a matching plug on the power cord provided with the Synesso machine North American Configuration Outside of North America Green Ground Green Ground White ...

Page 9: ...457 18 457 18 457 18 457 Width Steam Handle to Handle add 3 18 457 18 457 29 736 40 1016 Depth 23 584 23 584 23 584 23 584 Weights Dimensions Lbs Kgs Lbs Kgs Lbs Kgs Lbs Kgs Machine Weight Empty 106 48 106 48 154 70 190 86 Machine Weight Full of Water 115 52 115 52 173 77 215 98 Shipping Weight approximate 175 80 175 80 225 103 270 123 Boxed Dimensions L x W x H 20 x30 x31 20 x30 x31 41 x32 x31 49...

Page 10: ...the pump pressure activate the pump infusion by turning the brew group to the BREW position 7 Locate and read the pump pressure on the brew gauge The brew gauge is found on the right hand side of the brew group 8 Set the pump pressure to 9 Bar To do this locate the pump adjusting screw on the right side of the brass pump housing Loosen the lock nut and turn screw with a screwdriver Clockwise to IN...

Page 11: ...Technical Manual 11 ...

Page 12: ...te that many municipalities change their water sources throughout the year so additional water tests may become necessary Water Standards to keep your warranty valid Total Dissolved Solids TDS 30 to 200 ppm parts per million Total Hardness in ppm Less than 85 ppm Total Hardness in grains per gallon 3 to 5 grains divide ppm by 17 1 to get gpg pH 6 pH to 8 pH above 8 is very harmful Chloride 0 ppm a...

Page 13: ...Technical Manual 13 HYDRAULIC SYSTEM HYDRAULIC SCHEMATIC DUAL INLET ...

Page 14: ...Technical Manual 14 HYDRAULIC SYSTEM HYDRAULIC SCHEMATIC SINGLE INLET ...

Page 15: ...Technical Manual 15 HYDRAULIC SCHEMATIC HYDRA HYDRAULIC SYSTEM ...

Page 16: ...standard Hydras have a separate pump and motor per group therefore all Hydras come equipped with single inlet style pumps Water Inlet control valves Serial numbers 1 340 feature the Skinner style valves shown in the upper part of the picture on the left These were replaced on serial number 341 onwards with the Parker ZB09 for ease of repair or replacement Both valve styles feature electronic coils...

Page 17: ...its own brew gauge The gauge normally moves between 3 5 bar resting pressure to 9 bar brewing pressure and up to 12 bar expansion pressure at which point the expansion valve opens and releases the excess pressure Brew Tank Check Valve Check valves prevent water from going the wrong way in the hydraulic system Water flow should only go one direction and the check valve ensures that pressuized water...

Page 18: ...res Synesso incorporates heat exchanger tubes which run from the water inlet side through the steam tank and then go to each separate coffee boiler The internal diameter of the heat exchangers are precisely designed to aid in the energy efficiency and thermal stability of the Synesso Cold Water Valve Synesso has 2 valves which provide water to the Americano tea spout the hot water valve and the co...

Page 19: ...water into the steam tank The water then fills the tank until the probe grounds out on the water and the valve is then closed Steam Tank Inlet Fill Line Dual inlet machines only This is the incoming 3 8 steel braided line which supplies the steam tank with water Vacuum breaker Allows steam pressure to build above atmospheric pressure As the element heats the water in the steam tank the pressure fr...

Page 20: ...roup as well as function without a group in the system if something has gone wrong with a group There is a 3 way brew valve which controls the flow of water to the group head Brew tank drain tube Each group head is fitted with a drain tube to easily drain the tank In order to drain a brew group remove the pressure from the brew groups by turning off the water cycling through the control panel to t...

Page 21: ...e upper part of the steam tank to the steam valve to heat and foam milk Steam tank thermal overload switch Cuts power to the element if the temperature exceeds 280 F Thermal probes 2K ohm probes have been part of the Synesso machines since serial number 229 prior to this 100 ohm probes were standard These probes are highly sensitive and send thermal data to the PID controller to control the temper...

Page 22: ...Technical Manual 22 ...

Page 23: ... and or unplugging the unit prior to working on the machine The major components of the electrical system can be broken down into the following functional categories 1 Heating components temperature probes elements thermal resets and various parts of the CPU 2 Water control water inlet valves brew valves mix and hot water valves water level probes an various parts of the CPU rocker and brew preinf...

Page 24: ...Technical Manual 24 Electrical System Wiring schematic ELECTRONIC SYSTEM ...

Page 25: ...sso Since the 2 boxes represented below top 3 group box bottom 1 group have many of the same components they have been labeled with numbers for matching components and the descriptions follow in the next pages 4 7 6 2 5 12 10 11 1 3 8 13 14 top of lid 9 ELECTRONIC SYSTEM 1 Group Electrical Box 3 Group Hydra Electrical Box 4 5 3 1 13 6 7 12 14 ...

Page 26: ... power switch Turns the machine off and on If the machine is plugged into an electrical source the light will be lit red in the On position 8 Conduit Tube Tube containing power and signal lines to elements switches and valves 9 Power board Controls heating elements valves and level fill system 10 Ribbon cable Transfers signals from display board to power board Volumetrics and shot timers use addit...

Page 27: ...Technical Manual 27 ELECTRONIC SYSTEM ...

Page 28: ...rce is a Heat Shrink Gun Blue Loctite Seals quickly and holds firm but can be broken without the use of heat Red sealant is used on pipe threads all brass that is not connected to a copper tube and 6 32 threads Blue sealant is used on nuts screws and brass flow jets Food Grade Grease is used on all tube fittings flared stainless steel and brass any moving parts steam valves steam wand steam actuat...

Page 29: ...rewing process and into the steam tank If this is an unacceptable situation there are a few things you can do to minimize or eliminate the pressure drop There is an auto fill probe delay setting in the programming that is set at the factory to 5 seconds This means that the auto fill probe waits to fill until it senses a continuous signal to fill for 5 seconds and it does not stop filling until is ...

Page 30: ...ter If your machine is made before 240 and this issue becomes unacceptable contact your dealer service pro vider or the Synesso factory to purchase a retrofit tube Brew Tem perature Readout for Brew Water Temperature Varies by a Few Degrees The control must detect a temperature one increment 0 5 F on original machines or 0 1 F on current machines above the set point before it sends a signal to tur...

Page 31: ...gauge when pressure drops allow the heating elements to heat the cold water being introduced into the steam tank Check to make sure all Set points especially steam tank settings are accurate and functioning Check that the element breaker on the electrical box is in the ON posi tion Steam Tank is not filling Debris caught in the water control valve or worn out valve Water level probe auto fill need...

Page 32: ...es sure On machines built prior to 01 01 2011 Test zone 5 functionality Turn down the set point for zone 4 a few degrees below zone 5 Turn up zone 5 by a few degrees and confirm that the temperature rises to the new set point If the temperature has risen then zone 5 is functioning properly Test zone 4 functionality See Test zone 5 above for instructions If either zone is not working properly then ...

Page 33: ... box is ON then the relay has failed An Individual Zone Reads HI or Above 250 F and the Cor responding Tank is Cooling Test the connections to the probe Test probe for failure with ohm meter and compare reading to neighbor ing probe Tanks will Not Heat to Full Temperature Clean dust and debris from electronics box Take a soft brush clean paint brush to loosen debris and use a small vacuum hose to ...

Page 34: ...rior to 01 01 2011 Proper transformer voltages to ground Blue 110v Red 110v Grey 12 15v Black 12 15v The green wire is connected to ground and should have no voltage po tential Heating Elements Testing Heating Ele ments DISCONNECT MACHINE FROM POWER SUPPLY BEFORE TESTING Test with an ohm meter across the element posts Voltage Wattage Ohms 110v 700 15 to 19 110v 1000 11 to 13 220v 700 64 to 72 220v...

Page 35: ...s replace the por tafilter gasket General Nonde script Dirty brown water under the machine indicates the drain box is clogged or overloaded Remove the right side panel and clear any ob structions in the drain box Be sure the drain hose has an even steady slope toward the floor drain Kinks dips or flat runs will slow or stop the flow of waste water from the machine drain A small amount of water may...

Page 36: ...Technical Manual 36 PERIODIC MAINTENANCE ...

Page 37: ...he system of any detergent residue Cleaning 1 Clean the surface of the machine using a soft damp cloth Avoid using abrasive cleaners or cleansing pads Take extra care on the mirror finish stainless steel surfaces 2 Make sure the steam wands and tips are free of milk built up It is always best to clean the steam wand and tip after each use Approved espresso industry cleaners can be used to help dis...

Page 38: ...offee grounds Do NOT over tighten the screws Gently turn them until they are snug but not past that point Monthly 1 Check your water filtration system and make sure the cartridges and filters are changed as needed In areas of high mineral content hard water high particulate count or in very busy locations the filtration systems will need to be checked more often Quarterly 1 Change portafilter gask...

Page 39: ...ings Hot water switch Diffuser screens Pump relay Inspect and replace if necessary Pump and motor Expansion valve EV rebuild Hot water tap aerator Braided steel hoses Steam tube ball valves A checkmark in a box indicates that this item was inspected but not re placed If a number is present in the box that indicates the quantity of this part that was replaced Electrical inspection Ensure electrical...

Page 40: ...tes the operable brew group s and the associated temperature s Line 3 indicates the operations of brew groups 3 and 4 if applicable Line 4 indicates the steam tank temperature to the left and error codes if any to the right On Line 2 of this Temperature Overview display screen brew group 1 represented as BG1 is reading LOW This indicates that BG1 is below the temperature probe s set range of measu...

Page 41: ...r a boost pump To change the Stage 1 time press the button associated with line 3 The current time will begin to flash To alter the time on the indicator press the or buttons until the desired time is reached Note setting the Stage 1 timer to 00 will automatically set the Stage 2 timer if present to 00 Once the desired time is reached press the line 3 button to save the Stage 1 time The number wil...

Page 42: ...ssociated with line 4 Volumetric If the machine has volumetric capabilities the indicator lights on the button pad of the brew group selected will all light up Place the portafilter used for back flushing into the selected brew group and press any button on the lit pad The machine will now back flush 10 seconds on followed by 10 seconds off for 5 cycles While cycling the button pad lights will go ...

Page 43: ...le set range for the steam tank is between 170F and 270F 76 6C and 132 2C Line 3 and 4 are indicating that loops 1 and 2 of the elements are activated To change the temperature set point press the button next to line 2 The current set temperature 250 0F will begin to flash To adjust the temperature settings press the or buttons until the desired temperature is reached Press the button next to line...

Page 44: ...tton associated with line 2 Use the buttons to select the desired time followed by the line 2 button once again to confirm the selection The hot water tap will now dispense hot water for the allotted amount of time By selecting the line 3 Program Time you may set the desired time by placing the cup size you wish to fill under the hot water tap press the hot water button on the top of the machine l...

Page 45: ... number Ex v1 04 Lines 3 and 4 on the display will indicate the serial number given to this machine This screen will show when starting up the machine Please have this number available if you contact technical support to aid in more rapidly identifying your machine PROGRAMMING PROGRAMMING ...

Page 46: ... Bypass valve open time out valve has been held open for 5 minutes ST Steam system Codes LW Low water probe is dry meaning it is not in contact with water an audible alarm will also sound FP Fill probe is dry water is not touching it for 1 min an audible alarm will also sound FV Fill valve open time out valve has been held open for 5 minutes OT Over temperature over 270F VM Volumetric system UF Un...

Page 47: ...ter in the brew group s to fully drain in approximately 5 minutes When the brew group s are finished draining set the Brew Valve indicator back to the NORMAL setting If the draining process takes longer than 5 minutes the machines safety programming will automatically turn the brew Valve indicator to the NORMAL setting while exiting back to the Display Default Overview screen An error message will...

Page 48: ...play screen is showing a 5 second delay indicating that the fill probe will wait this long before turning on or off the steam tank fill valve To change the delay time press the button associated with line 2 Use the buttons to select the desired time and then confirm the selection To cycle to the next display screen press the button next to line 1 PROGRAMMING ...

Page 49: ...ith a thermal probe inserted 1 8th of an inch from the surface and in the middle of the puck packing and tamping the grounds in the basket as usual The thermal probe is then wired to a FLUKE thermometer to relay the actual temperature of the water flowing through the puck while pouring a 2 ounce shot This process is repeated a minimum of 3 times per brew group in order to get the most accurate rea...

Page 50: ... at the steam tank temperature probe as the electronics maintain your Set Temperature Line 4 indicates the temperature adjustment made at the Synesso factory in order to create the exact temperature desired in the steam tank This offset should not be altered without first consulting Synesso To cycle to the next display screen press the button next to line 1 PROGRAMMING ...

Page 51: ...ndicates the programmable date settings Line 4 stores the programmed date in the format indicated on line 3 Press the line 2 button followed by the buttons to make appropriate adjustments to the 24 hr clock so that any alarms programmed will work correctly To adjust line 4 press the corresponding button followed by the buttons to select the appropriate date Press the line 1 button to cycle to the ...

Page 52: ...mode will start Line 4 indicates the settable time at which your power save mode will end Enabling the power save mode will drop the temperature in the brew group s to 180F 82 2C and the steam tank to 220F 104 4C for the time span set This will help conserve energy while preventing maintenance issues that occur due to depressurizing and re pressurizing when machines are turned off and on This will...

Page 53: ...en held open for 5 minutes 01 through 04 groups 1 4 OT Over temp over 220F 104 4C UT Under temp under 180F 82 2C for 1 min while group is trying to heat PR Pump relay on timeout relay has been held open for 5 minutes BP Bypass valve open timeout valve has been held open for 5 minutes ST Steam system LW Low water probe is dry an audible alarm will also sound FP Fill probe is dry for 1 min an audibl...

Page 54: ...utton will cycle back to the Temperature Display screen on menu level 2 Pressing the line 3 button will cycle back to menu level 1 s Display Default Overview screen In order to enter menu level 3 press and hold both the line 4 button and the button at the same time for approximately 4 seconds Access to level 3 is only available from this screen PROGRAMMING ...

Page 55: ...ING PROGRAMMING Menu Level 3 Volumetrics The functioning of Volumetrics is only applicable on machines with volumetric hardware If the machine does have volumetric hardware this indicator should always be left in the ON posi tion ...

Page 56: ...al 56 PROGRAMMING Menu Level 3 Brew Groups The Brew Groups Present will be set to correspond directly to the physical definition of your machine and should not be altered without first contacting Synesso PROGRAMMING ...

Page 57: ...by pressing the line 3 button This option will undo ALL changes that have been made to the machine This includes the Synesso programmed offsets serial number and machine configuration information It is highly recommended that you make note of all Synesso programmed settings before doing a Full Reset of the machine ...

Page 58: ...8 PROGRAMMING Menu Level 3 Bypass The Bypass Hardware on the pump can be activated and deactivated from this screen If your machine has the bypass capability this program will be set to ON as indicated above PROGRAMMING ...

Page 59: ...en gives the option of selecting between SINGLE pump use or MULTIPLE pump use In the case of a Hydra the pump configuration will be set to MULTIPLE Otherwise it will be set to SINGLE These selections will be set at the Synesso factory and should not need to be altered PROGRAMMING ...

Page 60: ...algorithms using separate finely tuned parameters to achieve a desired set point Synesso strongly recommends against altering these parameters Line 2 indicates the level at which the P Gain Proportional Gain is set Line 3 indicates the level at which the I Gain Integral Gain is set Line 4 indicates the level at which the D Gain Derivative Gain is set PROGRAMMING PROGRAMMING ...

Page 61: ...tification given to the machine according to the month year and order of completion This method of identification may be used to help diagnose any issues or determine any specific needs that may arise during the life of this machine For this reason the machine serial number should not be altered PROGRAMMING ...

Page 62: ...vel 3 Return Line 1 indicates that you are on the Return screen Line 2 indicates the option to return to menu level 1 s operation mode Line 3 indicates the option to return to menu level 2 s settings mode PROGRAMMING PROGRAMMING ...

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