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HYDRAULIC SYSTEM

Overview

The hydraulic system in the Synesso™ is comprised of all parts through which water flows starting

with where it enters the machine from the water treatment/filtration system. This chapter will detail the
flow of water and some of the associated electrical components.

Synesso™ utilizes 3/8” braided stainless hoses (supplied with machine) to connect to the water treat-
ment system. Once the machine is set up and the water quality is checked, the machine is ready to
connect to the water treatment system. The water then passes to the pump and motor.

On single inlet machines, the water then travels through one hose to the machine and supplies both
the coffee boiler system and the steam boiler.

On dual inlet machines, the water diverts at the pump: the water for the coffee boiler goes through the
pump and the water for the steam boiler travels through a separate line. The next 3 pages show the
dual, single, and Hydra inlet water paths.

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Содержание Cyncra

Страница 1: ...Technical Manual ...

Страница 2: ...ration 14 Hydraulic System Water Inlet System 17 22 Water Outlet System 25 Electrical System Electrical box 27 29 Programming Machine Functions Level1 Brew Temperature Control 32 33 Auto Bypass and Auto Flush 34 Steam Temperature Control 35 Hot Water Tap 36 Error Code Key 37 Error Code Flow Charts 38 Programming Level 2 46 Programming Level 3 52 Volumetric Programming 56 Maintenance 57 Troubleshoo...

Страница 3: ...z 90ml shot glass JoeGlo cleaning kit 58mm tamper 4 rubber leg pads Electrical plugs are ONLY included on CSA Certified machines Canada For all other machines the owner of the machine must purchase an appropriate plug end for their machine Please see the installation instructions starting on page 8 for more information Serial Number Your espresso machine has a unique serial number located on the l...

Страница 4: ...ot as 210 F 99 C Avoid exposure to this water The hot water mix valve can be adjusted to deliver water as hot as 212 F 100 C which can cause severe burns please use caution when activating this water source Safety Label Locations Synesso complies with UL regulations by posting the following labels on its machines Electrical box California only Electrical cord Under drain tray inside right frame Th...

Страница 5: ...age readings or otherwise instructed in the directions ensure that the machine is switched off at the electri cal box and the machine is unplugged To depressurize the steam tank Turn off the element circuit breaker located under the machine Open the steam valve by moving the steam wand lever forward The steam tank is depressurized once the steam gauge reads zero Note the steam gauge is rated at 60...

Страница 6: ... Small Punch and Chisel Small Files Round and Triangular Small Picks Straight and Curved great for replacing portafilter gaskets Die and Tap 1 8 NPT and 1 4 NPT Tap for Threads 10 32 and 3 8 16 Set of Allen Wrenches 3 32 brass flow jet 9 64 brew valves 1 4 steam valve seat Wrenches 2x11 32 1 4 5 16 3 8 2x7 16 1 2 2x9 16 5 8 11 16 3 4 12mm 17mm Large Medium and Small Adjustable Wrench es Crescent W...

Страница 7: ...the boilers Total Alkalinity Less than 100 ppm Chlorine 0 ppm Iron 0 ppm In Synesso s experience Everpure Claris and Cirqua formulator systems can produce a result that can damage the Synesso boilers Use of either of these systems is discouraged and will void the water related parts of the machine warranty Any part which is determined to be defective in materials or workmanship should be returned ...

Страница 8: ...Water treatment requirements will vary and it is important to use a system designed to match the needs of your specific area Water filtration systems require periodic maintenance including cartridge or filter replacement Proper filtration and service is vital to the function of the machine and the quality of the espresso served Follow the instructions provided by your water treatment system for pr...

Страница 9: ...9 INSTALLATION ...

Страница 10: ...th th raided hose s and pump tions snug for leaks mum of 50 P eam tank fu tact Syness e adaptor pipe fitting rences betw REQU h the applic SERVE THE 10 he warranty e connect t ps are 3 8 t but do not PSI 3 5 ba unction pro so for alte hose and fi suitable fo ween the st IREM cable federa E FULL MA y requireme the pump to tube compr over tighte ar of line pr operly Plea ernative me itting part n or...

Страница 11: ...ctions Make sure that the red electronics switch and the heating element breaker on the front of the electrical box are in the OFF position then plug the power cord into the receptacle OPTIONAL If recovery time is slow install an In Line Buck Boost transformer to increase voltage below 208v to optimize machine recovery time Buck boost transformers come in different sizes Please choose the appropri...

Страница 12: ...s Hybrids Hydra Installation requirements Electrical The Hydra package has a slightly greater amp draw than the single pump machines please note the max amp draws and plan your electrical installation accordingly See table on page 11 Each pump motor has a distinct color association which is indicated throughout the machine by colored wires and zip ties The colors are as follows Group 1 Grey Group ...

Страница 13: ...indi cates the desired pressure 7 bar is our factory setting Adjust to taste The Stage 1 Pre infusion time and Stage 2 By pass time are set on the Temperature Control screen of the display by following the directions on page 33 Stage 1 time is set to 7 seconds and Stage 2 is set to 3 seconds at the factory Adjust to taste Once these settings are in place you will be able to taste the effects of fo...

Страница 14: ...er button again to stop the water 5 Wait until the steam tank has stopped filling and the level in the sight glass reads at least full Turn the heating element breaker to the ON or 1 position All the heating elements brew and steam are now activated 6 To adjust the pump pressure activate the pump by turning the brew group to the BREW position On volumetric machines activate the pump with the pitch...

Страница 15: ...temperature setting for this espresso roast and pull firmly to the right to set the seal Manual 5 Pre infuse the coffee puck by turning the brew group clockwise to the center position This allows line pressure to saturate the puck NOTE If a stage 1 or 2 time is set on the display they will begin automatically whenthe actuator is switched to the brew position so the pre infusion position should be ...

Страница 16: ...o the milk This will continue the heating process and minimize further foaming Do not touch the steam wand to the bottom of the milk pitcher this can create an inaccurate temperature measurement 7 Heat milk to approximately 150F to 170F 65 C to 76 C If you are using your hand to help determine the temperature it will feel about as hot as you can stand without burning yourself Milk thermometers are...

Страница 17: ...the water treat ment system Once the machine is set up and the water quality is checked the machine is ready to connect to the water treatment system The water then passes to the pump and motor On single inlet machines the water then travels through one hose to the machine and supplies both the coffee boiler system and the steam boiler On dual inlet machines the water diverts at the pump the water...

Страница 18: ...NLET 18 1 322 1 225 1 225 1 225 1 451 1 452 1 453 STEAM TANK STEAM TANK 1 321 BREW TANK 3 1 313 1 320 BREW TANK 1 1 313 BREW TANK 2 1 313 WATER FLOW THROUGH BREW GROUP WATER PATH LAYOUT DUAL INLET CONFIGURATION MB 10 31 08 1 22X ...

Страница 19: ...HYDRAULIC SCHEMATIC SINGLE INLET 19 ...

Страница 20: ...HYDRAULIC SCHEMATIC HYDRA 20 ...

Страница 21: ...ion is the standard Hydras have a separate pump and motor per group there fore 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 elec...

Страница 22: ...uge for the entire brew system on a Hydra each brew tank has its own brew gauge The gauge normally moves between 3 5 bar line pressure to 9 bar brewing pressure and up to 12 bar expansion pressure at which point the expansion valve releases the excess pressure Brew Tank Check Valve Check valves are one way valves which ensure that pressurized water cannot overwhelm the incoming water pressure and ...

Страница 23: ...ciency and thermal stability of the brew system Cold Water Valve Synesso machines have 2 valves which provide water to the americano tea spout the hot and cold water valves Mixing in cold water allows the user to moderate the temperature at the spout Boiling water is not appropriate for all beverages Hot Water Valve This valve supplies hot water from the steam tank which is mixed with cold water f...

Страница 24: ...ll Line Combined with Brew Inlet on single inlet machines This is the incoming 3 8 steel braided line which supplies the steam tank with water May be labelled with a pink tag on Hydras Vacuum Breaker Prevents steam tank pressure from dropping below atmospheric pressure As the tank heats the pressure from the steam pushes an internal rod and o ring up sealing the vacuum breaker When the tank cools ...

Страница 25: ...lly to be water tight and thermally stable Each brew tank has its own temperature probe and element which allows the user to set different temperatures on each group as well as operate without a group if a serious service issue arises Attached to each group is a 3 way brew valve which controls the flow of water from the group head to the brew chamber Brew Tank Drain Tube Each group head is fitted ...

Страница 26: ... 250 F Steam Shut off Valve Shuts off steam to the steam valve for safety during field repairs Steam Tube Delivers steam from 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 Must be manually reset if triggered Thermal probes Send thermal data to the controller board to regulate the temperature wit...

Страница 27: ...ior 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 and various parts of the CPU rocker and brew pre infusion switches pump and moto...

Страница 28: ...ICAL SYSTEM TEMPERATURE PROBE TWISTS AC TO PUMP RELAYS 5v SIGNAL TO LID RELAYS SIGNAL FROM SWITCHES 5v SIGNAL TO SOLENOID SWITCHES FROM FLOW METERS POWER CONTROL BOARD 5v COMMON TO SWITCHES AC IN TO BOARD GROUND ...

Страница 29: ...nning to and from the Synesso machine Since the 2 boxes represented below have many of the same components they have been labeled with numbers for matching components and the descriptions follow in the next pages 3 Group Hydra Electrical Box 1 14 top of lid 13 2 3 12 4 11 5 9 8 7 3 9 6 2 12 10 1 5 13 6 7 4 1 Group Electrical Box ...

Страница 30: ... into an electrical source the switch will be illuminated when in the On position 8 Conduit Tube Protects power and signal lines from abrasion and other damage 9 Power Board Controls all automated systems throuout the 2nd generation machine In 1st generation machines the controller was in the display not the power board 10 Ribbon Cable Transfers signals from display board to power board Volumetric...

Страница 31: ...31 ELECTRICAL SYSTEM ELECTRICAL SCHEMATIC ...

Страница 32: ...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 range of measurement 170F 270F 76 6C 132 2C Readings above the indicated range will show as HIGH The lowest programmable temperature for a brew group is 180F 82 2C and the highest programmable temperature for a brew group is 220F 104 4C The fact...

Страница 33: ...either a pressure regulator or 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 Setting the Stage 1 timer to 00 will automatically set the Stage 2 timer if present to 00 Once the de sired time is set press the line 3 button to save the new St...

Страница 34: ...tton associated 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 wi...

Страница 35: ...ble 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 lin...

Страница 36: ... 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 let it reach the desired level and then press the hot water button again This will automatically set the amount of water just dispensed as the Program Time...

Страница 37: ...ntil group is turned off 01 02 or 03 Indicate which brew group is reporting an error ST Steam System Codes LW Low Water probe is not in contact with water an audible alarm will also sound FP Fill Probe is not in contact with water for 1 minute FV Fill Valve has been held on for 5 minutes Valve will be disabled until machine is turned off OT Over Temperature 270F 01 All Steam System Codes end in 01...

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Страница 42: ...evel to drop below the LOW LEVEL probe and post the LOW H2O error depends upon the water and steam usage of the machine during operation The following flowchart will begin with the LOW H2O heading because that is the error likely to be seen on a machine that has ceased to heat the boilers However the flowchart will cover all three of these Error codes as they are all tied to the same general issue...

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Страница 46: ... allowing the pressure to be bled from the brew group s Once the pressure is bled turn the Brew Valve setting back to NORMAL and attach the appropriate drain hose to the brew groups drain tube Set the Brew Valve indicator back to ON once the drain hoses are securely attached This will allow the water in the brew group s to fully drain in approximately 5 minutes When the brew groups are finished dr...

Страница 47: ...creen 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 to the left of line 1 ...

Страница 48: ...e 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 reading This reading ...

Страница 49: ...xt display screen press the button to the left of line 1 Menu Level 2 System Clock Line 1 indicates that you are currently on the System Clock screen Line 2 indicates the programmable time for the machine in a 24 hr format Line 3 indicates 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 appro...

Страница 50: ... 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 also allow the machine a shorter amount of time to reach full t...

Страница 51: ...occurrence To clear the Error Log press the button associated with line 4 See page 37 for descriptions of the error codes you may see To cycle to the next display screen press the button to the left of line 1 Menu Level 2 Return To Level 1 Line 1 and 2 indicate that you are on the Return To Operation Mode screen Pressing the line 1 button will cycle back to the Temperature Display screen on menu l...

Страница 52: ...e only applicable on machines with volumetric hardware If the machine has volumetric hardware installed this indicator should be left ON 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 ...

Страница 53: ...ion It is highly recommended that you make note of all Synesso programmed settings before doing a full reset of the machine Reset cannot be undone Be careful Menu Level 3 Bypass The Bypass Hardware on the pump can be activated and deactivated from this screen If your machine has bypass hardware installed this setting should be ON as indicated above Menu Level 3 Hydra In the case of a Hydra Hybrid ...

Страница 54: ...Proportional Gain value Line 3 indicates the I Gain Integral Gain value Line 4 indicates the D Gain Derivative Gain value The default values are shown in the picture above Menu Level 3 Serial Number The Machine Serial Number is the designated identification 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...

Страница 55: ...55 PROGRAMMING Menu Level 3 Return Line 1 indicates that you are on the Return screen Line 2 will return to menu level 1 Operation menu Line 3 will return to menu level 2 Settings menu ...

Страница 56: ...tton without leaving programming mode Pressing a previously programmed button overrides the original program To exit the programming mode press any continuous flow button on a deactivated group As noted above pressing a continuous flow button on an active group will deactivate it When you exit programming mode all lit indicators will turn off Notes o The continuous flow pitcher button cannot be pr...

Страница 57: ... rinse the blind filter basket and repeat back flushing several times with clean water to clear the system of any detergent residue Failure to rinse can cause valve problems and bad flavor NOTE NEVER remove the screen and screw when backflushing Remove and clean them after backflushing is complete Do not forget to reinstall General machine cleaning 1 Clean the surface of the machine using a soft d...

Страница 58: ...ng any shots of espresso Failure to do so may plug the drain lines with coffee grounds 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 gaskets and closely ins...

Страница 59: ... coarse o Portafilter baskets are worn or cracked replace o Brew temperature is too cold Crema is thin with large bubbles and tastes astringent o Coffee is old o Grinder burrs are dull o Brew temperature may be set too low Diffuser screen is loose o This is most likely caused by over filling the portafilter basket with coffee This causes the expanding coffee puck to push against the diffuser and b...

Страница 60: ...eplace if necessary o Water supply is inadequate Readout for Brew Water Temperature Varies by a Few Degrees o The control must see the increment just above the set point before it sends a signal to turn off the heating element This will allow the electronics to show a reading just above the set point The energy from the heating element and the tube for the preheated incoming water are within 1 or ...

Страница 61: ...the steam tank are close to their set points o Check the element breaker on the electronics box to make sure the heating elements are ON element switch is to the left Steam Tank is overfilling o Water is too soft this occasionally happens with reverse osmosis water filtration systems The water level auto fill probe needs a minimum mineral content in order to detect water o Debris caught in the wat...

Страница 62: ...eptable 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 senses a continuous signal to stop filling for 5 seconds T...

Страница 63: ...r 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 turn off the heating element This will allow the elec tronics to show a reading just above the s...

Страница 64: ...Steam Tank is not filling error STFP01 Check for STFV01 error which indicates the tank has been filling for over 5 minutes If so power cycle machine check inlet hoses for kinks pinches check filter Debris caught in the water control valve or worn out valve Water level probe auto fill needs to be de scaled or cleaned This probe is located behind the left side panel Make sure level probe auto fill i...

Страница 65: ...If the temperature has risen then S1 is functioning properly Test S2 zone 5 functionality See S1 test above for instructions If either zone is not working properly then see Cold Zone and Tanks will Not Heat to Full Temperature in the Electronics section Calcium and scale buildup can insulate and cause reduced efficiency in heating elements If calcium and scale buildup is an issue be sure to descal...

Страница 66: ...tions 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 remove loose debris Cold Zone Solid State Relays can fail in either the ON or Off position TRAINED OR AUTHORIZED PERSONNEL ONLY Relay ...

Страница 67: ...ould 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 2000 46 to 52 each loop 220v 4000 23 to 26 each loop 220v 5000 18 to 22 each loop Test the element post to the element body and you should not g...

Страница 68: ...s or flat runs will slow or stop the flow of waste water from the machine drain A small amount of water may splash between frame panels during a steam wand purge or when rinsing the drip pan The water will then drip onto the countertop or frame of the machine This is normal Clean water under the machine or on top of the electrical box indicates an internal leak Remove the side panels and facias un...

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