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01-2018 5035 01

MAINTAINING THE BREWING

UNIT

z4000

After 10 000 dispensed items or every 6

months, the coffee group requires a small

amount of maintenance work in order to

optimise how it works over time.

To perform the maintenance work, the unit

needs to be removed as follows:

1. Disconnect the coffee outlet nozzle from

the unit by rotating it 90° away from the

connecting rod and pull it outwards.

2. Turn the unit end stop lever, rotating it un-

til it is in a horizontal position.

3. Remove the coffee unit.

5
6
7

7
9

Fig. 44

1. Upper piston

2. Coffee outlet nozzle

3. Lower scraper

4. Connecting rod

5. Lateral screw

6. Key

7. Upper seal

8. Unit end stop lever

9. Upper filter

10. Lower filter

11. Lower scraper

12. Lower piston

13. Lower seal

14. Piston guide ring

15. Upper scraper

16. Unit cover

Содержание Kalea

Страница 1: ...INSTALLATION USE MAINTENANCE Translation of the original instructions EN English Doc No H5035EN01 Edition 1 01 2018 Kalea Kalea Plus...

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Страница 3: ...Technical specifications 2006 95 CE 2014 35 EU LVD EN 60335 1 2012 A11 2014 EN 60335 2 75 2004 A1 2005 A11 2006 A2 2008 A12 2010 EN 62233 2008 2006 42 EC MD EN60335 1 2012 A11 2014 97 23 EC 2014 68 U...

Страница 4: ...tial requirements of the 2014 53 EU RED Directive As a matter of fact the integration of radio modules in other products can influence the compliance of the end product with the essential requirements...

Страница 5: ...se the VM for use The machine can be used by children over 8 years and by people having reduced physical sensorial or mental skills under the supervision of people responsible for their safety or spec...

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Страница 9: ...moving the panels 22 water supply 23 if the appliance uses a water tank appropriate filter cartridges can be used 24 electrical connection 25 wi fi connections 26 initial start up 27 first sanitisatio...

Страница 10: ...equires the use of tools to access potentially dangerous areas The operations described in chapter 2 and chapter 3 must solely be carried out by personnel with specific knowl edge of the appliance s o...

Страница 11: ...of a specific serial number which can be found on the nameplate located on the internal side of the door The nameplate is the only one recognised by the manufacturer and contains all the information t...

Страница 12: ...iance must be placed on a level surface Important In the event of unscheduled maintenance work and or repairs the appliance must be able to be accessed from all sides Therefore make sure that the appl...

Страница 13: ...s temperature reached safety measures Product containers present Residue containers present Closed door sensor Boiler safety thermostats with a manual reset Main electric circuit protection device wit...

Страница 14: ...ccessories and kits which can be at tached to the appliance are available from the manufacturer The accessories and kits are supplied with installation and test instructions which should be scrupulous...

Страница 15: ...liance and is positioned behind the solid residue container When carrying out normal cleaning and product loading tasks the appliance does not have to be switched off If the appliance needs to be swit...

Страница 16: ...ng disinfectants taking care to mechanically remove the residues and visible films using swabs and or brushes Do not use solvents and or strong scented detergents Some parts of the appliance can be da...

Страница 17: ...with the manufacturer instructions regarding storage storage temperature and expiry date The dispensed drinks should be con sumed immediately and must under no circumstances be stored and or pack age...

Страница 18: ...ner lid using the key if present 2 Fill the container with coffee beans 3 Carefully close the lid Do not exceed the maximum capacity of the containers the maximum level of the containers coincides wit...

Страница 19: ...ollow the manufacturer s holding tempera ture instructions and check the product s expiry date To prevent flow problems place the milk container on the same surface as the appliance The suction hose m...

Страница 20: ...om the external parts of the brewing units and mixers which need to be cleaned so that any powder residue is removed especially in the funnel area the parts of the mixer which come into contact with t...

Страница 21: ...sidue counters to zero solid residue container empty function 2 1 3 Fig 7 1 Nozzle moving handle 2 Solid residue container 3 Liquid residue container models with solid residue discharge on the bench P...

Страница 22: ...everage hose from the connection of the water funnel 2 Turn the water funnel locking ring anti clockwise and remove the mixer from the appliance 3 Separate all the components the instant products funn...

Страница 23: ...disconnect the hoses from the nozzles 3 Disconnect the coffee dispensing hose from the flow divider nozzle 4 Unhook the flow divider nozzle from the nozzle support 5 Remove the flow divider milker noz...

Страница 24: ...ernal parts of the brewing unit by removing any powder residue especially in the funnel filter and scraper areas CLEANING THE MILK TANK For models with a cappuccino maker only Every day or at the end...

Страница 25: ...cons and the invitation to select a beverage WASH CYCLES The appliance has been designed to per form wash cycles on the main functional units During the wash cycles hot water comes out of the nozzles...

Страница 26: ...performed Only use cappuccino maker specific products When using these products strictly follow the manufacturer s instructions on storage handling dosing and use carefully read the safety instructio...

Страница 27: ...appliances that do not have a liquid residue drainage system place a container with a capacity of at least 3 litres under the nozzles in order to collect the wash resi dues It takes several minutes f...

Страница 28: ...E SUSPENSION If for any reason the appliance remains switched off for a long period of time it is necessary to 1 Completely empty the containers and wash them carefully with the sterilising products 2...

Страница 29: ...nded polystyrene nails etc must be kept out of the reach of children as they are a potential source of danger The packaging materials need to be dis posed of in authorised waste disposal cen tres Recy...

Страница 30: ...obstacles solid residues The solid residues can be emptied directly into a bucket using the solid residue chute supplied as standard by inserting it into the drain hole The solid residue bucket must...

Страница 31: ...p on the water mains out side the appliance and in an accessible position is recommended Only use new seal and pipe sets and do not reuse any existing materials overflow device Only for standard versi...

Страница 32: ...rer is not liable if non ap proved components are used The installation and subsequent test operations must be performed by quali fied personnel with specific knowledge of the appliance s operation bo...

Страница 33: ...placed in an accessible position The appliance is to be considered electri cally safe only when it has been correctly connected to an efficient earthing system in accordance with the current safety r...

Страница 34: ...e equipment will be connected It is not possible to enable Ethernet and Wi Fi connections at the same time Bluetooth instructions Verify that the Bluetooth function is active on the equipment and on t...

Страница 35: ...the boilers When the heating cycle has finished the beverages will be available FIRST SANITISATION When the appliance has been installed a thorough food circuit disinfection needs to be performed bre...

Страница 36: ...nks 6 Pinion 7 Exhaust pad slide At the end of the coffee dispensing phase the upper piston goes down in order to me chanically squeeze the coffee pod facilitat ing the expulsion of excess water throu...

Страница 37: ...ion chamber The doses of coffee that the brewing unit can handle depend on the model of the brewing unit The upper piston positions itself automati cally Brewing unit doses Z4000 HRC 43 7 13 5 gr Z400...

Страница 38: ...esso type selections this de pends on the quantity of ground coffee inside the infusion chamber or For fresh brew selections this is fixed and at the highest possible position inside the infusion cham...

Страница 39: ...e 2 Upper piston 3 Espresso nozzle 4 Infusion chamber 5 Scraper 6 Lower piston volume of the infusion chamber Brewing unit doses Z4000 ESFB 46 7 14 g The upper piston automatically positions itself ac...

Страница 40: ...the dose Each notch changes the dose by approx 0 35 g Two different doses are managed in each doser the volumetric dose for single cof fees and the timed dose for double cof fees The coffee unit can a...

Страница 41: ...ng pushed by the pump The air solenoid valve is operated inter mittently at a determined frequency The milk goes into the milker nozzle pushed by the milk pump The steam passes through the milker noz...

Страница 42: ...type of selection determines the amount of water to be dispensed Adjusting the coffee grammage The dose adjustment lever can be posi tioned on one of the 10 reference marks whilst taking into consider...

Страница 43: ...oss the network and send email notifications The equipment also allows you communi cating with the Bluetooth over a short dis tance Bluetooth is a standard for exchanging information through a short r...

Страница 44: ...B flash drives for import export operations and for software updates The device recognizes USB flash drives with FAT32 file system Compatibility with all USB memory devices available on the market is...

Страница 45: ...the menu APPLIANCE STATUS The appliance status can be displayed e g faults etc via the status panel The status panel Displays fault error notifications Displays the nutritional information of the sele...

Страница 46: ...ication software allows you using the equipment features and to changing the settings via the graphical user interface GUI The application software does not work without the operating system Updating...

Страница 47: ...provided ac cess to the programming menus Enter the password to access the enabled menus The default passwords are Technician 4444 Distributor 3333 Loader 2222 User 1111 menu Touch menu to view the ap...

Страница 48: ...ING VALUES The values in the programming menu can be entered modified as follows keyboard 1 2 3 4 9 5 6 7 8 Fig 33 1 Uppercase shift 2 Key to switch the number symbol keyboard to the letter keyboard 3...

Страница 49: ...change giver function Check the total amount of money in the coin box SELECTION SETTINGS display layout Select the layout of the selections from the default ones which are displayed in normal user mo...

Страница 50: ...test beverage recipes It is possible to Create a new recipe The newly created recipe is saved in the not available category Then associate the recipe to the bever age The software checks that there is...

Страница 51: ...screen tap to add other ingredients and or customisations To change the settings of individual ingre dients e g the amount of water powder etc touch the ingredient bar to open the context menu Fig 38...

Страница 52: ...and the milk is dispensed It can help the beverage be presented bet ter pod squeezing The squeezing is carried out by the upper piston which by mechanically compressing the pod favours the expulsion...

Страница 53: ...kes place at low pressure fresh brew and how long it takes place at high pressure espres so to be established Modifying the parameter will result in the absence or a change in the quantity of cream in...

Страница 54: ...ating the Hot choc olate with milk recipe a time delay can be set between when the powder and the milk is dispensed It can help the beverage be presented bet ter mixer delay Sets a start delay time fo...

Страница 55: ...e the pump speed is automati cally adjusted according to the set flow rate enabling steam It is possible to enable disable the steam dispensing function whilst the milk is being dispensed The steam he...

Страница 56: ...elete an ingredient Duplicate and customise an ingredi ent containers According to the machine layout how the product containers have been arranged can be shown Choose a container in order to Assign a...

Страница 57: ...ted from a configuration file that has been saved onto a USB stick The import function can be used to clone the settings of another appliance make sure that the two appliances set tings are compatible...

Страница 58: ...he following modes random or cyclic input sensor settings The functional unit allows the operation of some of the appliance s sensors to be set container level Enables disables the container level con...

Страница 59: ...e lowest speed 2 Weigh the dispensed instant powder 3 Enter the value of the measured weight 4 Dispense the powder at the fastest speed 5 Weigh the dispensed instant powder 6 Enter the value of the me...

Страница 60: ...is always active OFF the fan is active whilst the beverage is being prepared The fan stays on until the dispensing is complete and for the time that has been set lighting Allows the appliance s lighti...

Страница 61: ...ntervals number of hours and or selections for each type of wash rinse When the set values have been reached the appliance will display a wash rinse message Each wash rinse can be made compulsory the...

Страница 62: ...imum steam boiler pressure sets the minimum pressure for making beverages which require steam available If the boiler pressure is lower than the pressure that has been set a low pres sure error messag...

Страница 63: ...otor doser will be disabled mixer 1 6 fault If the current absorption of a motor mixer does not fall within the range of default values all the selections which involve that mixer will be disabled sol...

Страница 64: ...microswitch indicates that the brewing unit did not go back to the idle po sition after the discharge of the pod overheating water pump The water pump has been activated fre quently for more than 10...

Страница 65: ...event of a blockage due to foreign bodies etc the grinder is shutdown and the espresso based selections are disa bled This option can be used to enable disable the grinder rotation check machine boar...

Страница 66: ...elected function to access it remove a function from favourites From the list of favourites tap the bin icon Tap the function to be removed from fa vourites clear the list of favourites Removes all fu...

Страница 67: ...Set the maintenance temperature of the boiler s in the energy saving mode Enable disable the appliance s lighting Select the touchscreen brightness level from those that have been predefined deep mode...

Страница 68: ...e system type is changed common parameters immediate change Usually the amount for a selection is cashed in after the appliance sends the Selection made signal By enabling this function which is disab...

Страница 69: ...equent selec tion parameter kept overpay timeout Makes it possible to set the time when the credit will be released if a selection hasn t been made maximum credit This function allows the maximum cred...

Страница 70: ...and C 1 A and B and C 2 only A and B 3 A and B or C 4 only A 5 only A or B default 6 A or B or C 7 only A or B 8 only A or C 9 only B and C 10 only B 11 only B or C 12 only C E g algorithm 6 will disp...

Страница 71: ...VA DTS data to be exported onto a USB stick and or onto data transmission devices RS232 IrDA telemetry etc USB Saves a EVA DTS file onto the USB stick Serial communication protocol From this function...

Страница 72: ...r rights related to the content itself Make sure to comply with the copyright laws that are in force in the country where the appliance is installed images Allows images to be imported exported from t...

Страница 73: ...vice tests Displays the status of the appliance s vari ous sensors and or controls probes micro switches etc For devices with ON OFF functions the status is shown using colour green is used if the app...

Страница 74: ...tests Sets the activation time of the components during the self test restore factory settings Allows the appliance to be restored to its factory settings All the statistical data fault lists and sett...

Страница 75: ...to the Wi Fi network must be set manually The MAC address is a unique address assigned by the manufacturer that identifies the network card of the equipment The MAC address cannot be changed bluetooth...

Страница 76: ...ivery The parameters vary depending on the email server used e mail service provider The equipment provides a set of preconfig ured parameters for the major email service providers on the Internet It...

Страница 77: ...f use i e water hardness envi ronment humidity and temperature type of product used etc The operations described in this chapter do not include all of the maintenance interven tions The more complex i...

Страница 78: ...let nozzle from the unit by rotating it 90 away from the connecting rod and pull it outwards 2 Turn the unit end stop lever rotating it un til it is in a horizontal position 3 Remove the coffee unit 1...

Страница 79: ...ing replacing the lower filter and seal In order to remove or replace the lower filter and seal proceed as follows 1 Manually bring the unit to the discharge position with the lower piston 12 2 Unscre...

Страница 80: ...twards 2 Disconnect the fresh brew coffee outlet nozzle from the unit by rotating it 90 and pulling it out 3 Turn the unit end stop lever rotating it un til it is in a horizontal position 4 Remove the...

Страница 81: ...3 Upper piston filter support 4 Screw removing replacing the lower filter and seal In order to remove or replace the lower filter and seal proceed as follows 1 Manually bring the unit to the discharg...

Страница 82: ...cuit and the parts which come into con tact with the food products SANITISATION All the components which come into con tact with the food products including the tubes must be removed from the appli an...

Страница 83: ...s block the disk fitted on the motor mixer shaft with one finger then unscrew the mixer fan Fig 50 5 Dip the parts for approx 20 minutes in a recipient containing the previously pre pared sterilising...

Страница 84: ...ZZLES AND SPOUTS Weekly or more frequently depending on how often the appliance is used and the quality of incoming water it is necessary to sanitise the instant beverage dispensing ducts and nozzles...

Страница 85: ...l electronics If the sensor does not detect the con tainers the grinders are disabled To remove the product containers coffee beans or instant products simply remove the handle and then lift the conta...

Страница 86: ...MAL PROTECTION A safety thermostat protects the boiler s from overheating by deactivating the boiler heating element should a fault occur in the control system The thermostat intervenes if the interna...

Страница 87: ...he boards need replacing the circuit board configuration must be checked and the suitable software loaded 1 2 3 4 Fig 58 1 Noise filter 2 Terminal board 3 Activation board 4 Power supply version with...

Страница 88: ...and or maintenance Warning The power supply is connected to the pow er distribution network If it is necessary to intervene on the pow er supply for example for replacement make sure you disconnect t...

Страница 89: ...lus H 5V L 0V H 5V Kalea Plus cappuccinatore H 5V H 5V L 0V RL1 J8 J19 J21 J12 J10 J5 J7 J2 J1 J13 J4 J20 J17 J11 J14 J16 J22 J6 J23 J18 J15 J9 RL3 RL2 RL4 RL9 RL11 RL6 RL5 RL7 1 2 3 4 5 6 7 8 9 10 11...

Страница 90: ...k into the CPU touch screen 4 turn on the appliance 5 some messages on the progress of the update are displayed The update takes a few minutes 6 at the end of the updated a message will appear prompti...

Страница 91: ...01 2018 5035 01 83 Appendix...

Страница 92: ...noid valve 3 filter 4 pressure reducer 5 air break 6 pump 7 flow meter 8 boiler 9 solenoid valves 10 dispensing nozzles 11 mixer 12 liquid residue container for models with a mains water mixer only KA...

Страница 93: ...alves 10 dispensing nozzles 11 mixer 12 liquid residue container 13 steam boiler 14 thermostat 15 safety valve 16 milk tank 17 milk pump 18 steam boiler filling solenoid valve 19 steam solenoid valve...

Страница 94: ...4 pressure reducer 5 air break 6 pump 7 flow meter 8 boiler 9 solenoid valves 10 dispensing nozzles 11 diffuser nozzle 12 mixer 13 liquid residue container for models with a mains water mixer only HYD...

Страница 95: ...sing nozzles 11 diffuser nozzle 12 mixer 13 liquid residue container 14 steam boiler 15 thermostat 16 safety valve 17 milk tank 18 milk pump 19 steam boiler filling solenoid valve 20 steam solenoid va...

Страница 96: ...r solenoid valve 2 Pressure switch 3 Pump 4 Boiler 5 Mixers 6 Hot water spout 7 Liquid residue container 8 Safety valve 9 Non return valve 10 Flow meter only some models KALEA PLUS HYDRAULIC CIRCUIT e...

Страница 97: ...Steam solenoid valve 13 Espresso boiler 14 Milker nozzle washinig solenoid valve 15 Steam boiler filling solenoid valve 16 Milk tank 17 Milk pump 18 Air washing solenoid valve 19 Dispensing nozzle 20...

Страница 98: ...J17 8 X4 9 EV H202 X4 2 X4 7 X4 4 J12 10 OUTDEV4 J11 8 GND X4 15 0 F N EARTH FA L N 230 240Vac 50HZ 6 7 1 9 9 5 1 SM J1 1 J1 2 J1 3 0 0 2 J1 1 J1 2 Salim J2 7 24Vdc 1 6 J1 3 45 J2 2 J2 1 1 6 J5 1 J5...

Страница 99: ...H CANL 2 GND 3 4 5 24Vdc GND 6 7 8 9 Optional Hydraulic steam Circuit 3 EV VAP J12 8 OUTDEV2 X7 5 7 91 0 2 9 97 1 8 3 2 J10 5 J10 2 CCG 24Vdc Violett X5 1 X5 4 J15 1 TR_OUT1 J15 3 TR_OUT2 J15 2 VAC_LI...

Страница 100: ...12 11 20 J18 9 6 DOS MOT P7 DOS MOT COM J18 1 20 DOS MOT P8 X13 4 X13 11 J18 10 6 J18 1 DOS MOT COM X12 4 X12 11 MD1 X13 11 X13 4 Optional Instant DOS MOT P1 J18 3 MD1 DOS MOT COM 93 20 J18 2 3 MF1 J9...

Страница 101: ...OL 62 J13 1 Idec 0 J13 15 J17 15 GND 0 X18 2 J17 9 DIG IN15 X18 1 91 MLQD X8 5 X8 6 SLED J17 3 DIG IN9 60 MILK GND OUT EMPTY 12V 0 1 6 J13 14 92 12V X17 2 X17 3 0 J13 15 GND J3 2 RXD J2 11 GND J2 10 T...

Страница 102: ...Vac 50HZ 6 7 1 9 9 5 1 SM J1 1 J1 2 J1 3 0 0 2 J1 1 J1 2 Salim J2 7 24Vdc 1 6 J1 3 45 J2 2 J2 1 1 6 J5 1 J5 2 2 J2 6 1 1 X5 1 X5 4 J15 1 TR_OUT1 J15 3 TR_OUT2 J15 2 VAC_LINE1 J8 2 LINE B OUT_PINZATUBO...

Страница 103: ...3 4 5 24Vdc GND 6 7 8 9 Optional Hydraulic steam Circuit 3 EV VAP J12 8 OUTDEV2 X7 5 8 91 0 2 9 97 1 8 3 2 J10 5 J10 2 CCG 24Vdc X5 1 X5 4 J15 1 TR_OUT1 J15 3 TR_OUT2 J15 2 VAC_LINE1 1 J23 1 LEVEL_REF...

Страница 104: ...T P7 DOS MOT COM J18 1 20 DOS MOT P8 X13 4 X13 11 J18 10 6 J18 1 DOS MOT COM X12 4 X12 11 MD1 X13 11 X13 4 Optional Instant DOS MOT P1 MD1 DOS MOT COM J18 3 3 MF MMA1 MD2 MMA2 Idec 0 J13 15 X8 6 PAYM...

Страница 105: ...15 J17 15 GND 0 X18 2 J17 9 DIG IN15 X18 1 91 MLQD X8 5 X8 6 SLED J17 3 DIG IN9 60 MILK GND OUT EMPTY 12V 0 1 6 J13 14 92 12V X17 2 X17 3 0 J13 15 GND J3 2 RXD J2 11 GND J2 10 TXDMDB J2 9 RXDMDB J2 8...

Страница 106: ...________________ ________________________________________________ ________________________________________________ ________________________________________________ ____________________________________...

Страница 107: ...responsibility for any inaccuracies contained in this publication which can be ascribed to printing and or transcription errors All the instructions drawings tables and information contained in this...

Страница 108: ......

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