Download Service manual - Cafitesse 300 - English

CAFITESSE 300
SERVICE MANUAL
620919571
Rev A
Copyright © All Rights Reserved. This manual may not be translated or copied or reproduced in any form
or by any means in whole or in part without the prior written consent of Douwe Egberts Coffee Systems.
This manual is intended for internal use only.
Douwe Egberts Coffee Systems issues no explanation or guarantees with regard to the contents of this
publication and expressly disclaims all responsibility for any implied guarantees. Douwe Egberts Coffee
Systems reserves the right to revise and change the contents of this manual without notice.
Published by Douwe Egberts Coffee Systems
June 2003
© 2003 Douwe Egberts Coffee Systems
Introduction
1
Specifications
2
Operating Principles
3
Operating Controls
4
Installation
5
Programming Dispensers equipped with
the Cafitesse 300 Flexi MP Control board
6
Flexi Interface Adjustments
7
Flexi-Pak™ Concentrate Packs
8
Cleaning & Maintenance
9
Circuit Diagram
10
Fault Diagnosis
11
Troubleshooting Reference
12
Spare Parts List
13
Technical Service Bulletins
14
© 2003 Douwe Egberts Coffee Systems
Service Manual Cafitesse 300
Introduction
1 Introduction
Contents
1.1
June 2003
Introduction .............................................................................................. 2
1-1
Introduction
Service Manual Cafitesse 300
1 Introduction
1.1 Introduction
•
This updated service manual applies to all
Cafitesse 300 H/K models equipped with the
Flexi Dosing System and incorporating the Safety
Standard of the manufacturer. These dispensers
are model coded H71, K72, K73 in U.S./Canada
versions.
•
The model range is divided into two groups,
different control systems being employed to
operate the Flexi Dosing System. The type of
control system used can be identified by looking
at the control board which is visible when the
main door of the dispenser is opened. It is located
on the right-hand side, behind a transparent door.
•
Some dispensers are equipped with the newly
developed Cafitesse 300 Flexi MP Control Board.
This control board is equipped with a counter
display (1) and heat sink (2).
This control board is standard on the models
coded H71 and optional on models coded K72
and K73.
Fig. 2
1-2
June 2003
Service Manual Cafitesse 300
Specifications
2 Specifications
Contents
2.1
June 2003
Specifications ........................................................................................... 2
2-1
Specifications
Service Manual Cafitesse 300
2 Specifications
2.1 Specifications
Dimensions:
Height: 745 mm / 29-1/4"
Width: 430 mm / 17"
Depth: 525 mm / 21"
Stainless steel housing
Weight:
48 kg / 105 lbs. empty
Water supply:
1/2’’ or 3/8’’ supply line
Hot water supply through copper tubing.
Maximum inlet temperature: 90C / 194F
Minimum dynamic line pressure: 11 psi
Maximum static line pressure: 100 psi
Electrical supply:
Models for mains voltages AC:
208 to 240 V, 60 Hz, single phase 30A
Permissible voltage tolerances ± 10%
Boiler:
Open system, capacity 9 liters / 2.4 gallons
Water temperature controlled by thermostat.
Protection against dry operation by heating element temperature
limiter.
Protection against boil-over by safety thermostat.
Heating element nominal ratings:
2 x 3 KW/220 V + 1 x 2.7 KW/240 V (multiple element)
Cooling:
Compressor type, controlled by thermostat.
Operating voltages 208/220/240 V
Power consumption 100 VA
Dosing system:
Positive Displacement Flexi Impulse Dosing System.
Dosing coils electronically controlled, impulse driven pump integrated
in disposable Flexi-Pak™ concentrate packs. Electronically operated
empty indication for each concentrate pack, with optional automatic
switch-over to second pack.
2-2
June 2003
Service Manual Cafitesse 300
Specifications
Concentrate capacity:
2 Flexi-Pak™ Concentrate Packs – coffee/coffee, coffee/decaf.
Delivery rate:
Dependent on water outlet valves fitted.
Typical rates: 2 seconds per cup (150 cc)
20 seconds per pot (1500 cc)
Delivery capacity:
Dependent on heating power and other variable factors.
Approximately 100 cups (150 cc) or 10 pots (1500 cc) per hour per
1000 W heater output. (Values for cold water supply inlet temperature
of 20C / 68F)
Delivery modes:
Mode, portion volume and beverage strength of deliveries with right-or
left-hand delivery button individually adjustable.
Delivery modes: Portions, Portions Repeat or Continuous Flow.
Hot water delivery, portion or Continuous Flow.
Control board:
Models equipped with Cafitesse 300 Flexi MP Control Board:
Microprocessor control. Dosing functions externally programmable with
service device. Monitoring of concentrate and water delivery coil.
Options:
3 outlet version – designated Cafitesse 300
2.2 Machine numbers
Type:
Cafitesse 300 AS2 H71 Cafitesse 300 AS2 K72 Cafitesse 300 AS2 K73 -
June 2003
Designation:
PRESS BUTTON 8,7 KW STANDARD EUROPE
TOMLINSON 3 OUTLETS FLEXI MP
TOMLINSON 3 OUTLETS FLEXI MP 8 (Marine Version)
2-3
Specifications
2-4
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Functional Description
3 Functional descriptions
Contents
3.1
Functions .................................................................................................. 2
3.2
Diagrammatic view of dispenser ............................................................ 3
3.3
Water inlet system ................................................................................... 4
3.4
Water heating system .............................................................................. 5
3.5
Water dispensing system ........................................................................ 6
3.6
Cooling system ........................................................................................ 7
3.7
Flexi-Pak™ concentrate dosing system ................................................ 8
3.8
Electrical circuits ..................................................................................... 9
June 2003
3-1
Functional Description
Service Manual Cafitesse 300
3 FUNCTIONAL DESCRIPTIONS
3.1 Functions
•
The Cafitesse 300 dispensers utilize a drinking water supply and liquid concentrate to deliver hot beverages.
Three main functions are required of the dispenser to combine these two components into a ready-to-drink
beverage, and to maintain freshness of the concentrate. The dispenser must carry out the following
functions:
• HEAT the water
• COOL the concentrate
• DOSE concentrate and water in the respective ratio
•
These functions are carried out by the:
• Water inlet system
• Water heating system
• Water dispensing system
• Cooling system
• Flexi dosing system
• Electronic control
• Electrical circuitry
The operating principles of these systems are explained in this section.
3-2
June 2003
Service Manual Cafitesse 300
Functional Description
3.2 Diagrammatic view of dispenser
1
2
3
4
5
6
7
23
22
24
21
8
25
9
20
19
10
18
11
12
17
LEGEND
Mains Voltage
Low Voltage
Water Flow
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
16
15
14
Temperature Limiter
Thermostat (heating)
Float Microswitch
Float
Safety Thermostat
Main Switch
MP Control Board
Flexi Paks Concentrate Pack
Flexi Dosing Coil
Deliver Buttons
Delivery Trough
Drip Tray
13
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Drain Hose
Water Outlet Valve
Overflow Hose
Compressor
Power Pack
Water Inlet
Water Inlet Valve
Heating Element
Water Outlet Pipe
Water Inlet Pipe
Condenser
Evaporator
Thermostat (cooling)
Fig. 1
June 2003
3-3
Functional Description
Service Manual Cafitesse 300
3.3 Water inlet system
24 VAC
Water inlet and level control
•
3-4
A float (1) is suspended from a stainless steel
wire mounted on the spring loaded activating
arm of the float microswitch (2). The float rises or
falls when water flows into or out of the tank,
moving the microswitch arm. The microswitch is
activated when the water level falls to a
predetermined level, 24V AC is then routed to
the water inlet valve (3). The inlet valve opens,
letting water flow from the mains supply line and
through the inlet pipe (4) which directs it to the
bottom of boiler tank. (Fig. 2)
•
As the water level increases, the float rises,
permitting the microswitch arm to move up. The
microswitch opens the water inlet valve circuit
when the water level reaches a predetermined
level. The inlet valve closes, stopping the water
flow into the tank.
•
The water inlet circuit is protected by the fuse
marked F02 (see Section 3.8, Fuse Values and
Location) located on the front on the power pack.
June 2003
Service Manual Cafitesse 300
Functional Description
Fig. 3
Opening and closing the valve
•
Water pressure is on both sides of the
•
The pressure on the upper side of the
diaphragm decreases in contrast to the water
pressure on the lower side.
•
This causes the diaphragm to move upwards
and open the outlet spout.
•
Water is running from the water supply line
through the valve.
•
As soon as the current supply to the coil is
interrupted, the tappet closes the centre
opening which causes the pressure on the
upper side of the diaphragm to increase.
•
The valve closes.
diaphragm. A compensation of the pressure is
affected by a very small opening in the diaphragm.
•
This compensation hole (1) is pierced by a
cleaning needle (2). (Fig. 3) Thus every time the
valve opens, i.e. every time the diaphragm moves,
the compensation hole is cleaned.
•
There is a higher pressure on the upper
diaphragm side (3) than on the lower diaphragm
side, as there is no water pressure on that part of the
lower side which is covered by the outlet spout.
(Fig.3)
•
In this way, the diaphragm keeps the outlet
spout closed.
•
•
Additional spring
If an electric current is applied to the coil, the
tappet (4) is withdrawn and the bore (5) in the middle
of the diaphragm is opened. (Fig. 3) Water can flow
through it from the upper part.
•
The additional spring (6) which presses onto the
upper side of the diaphragm, only slightly
influences the function of the valve. (Fig. 3)
As the pressure compensation hole is much
•
The spring effects, however, a faster closing
which enables a more precise level regulation in
the boiler.
•
The additional spring also prevents water from
flowing out of the boiler if the water supply line is
smaller than the opening in the middle of the
diaphragm, the pressure cannot be compensated
any more.
disconnected.
June 2003
3-5
Functional Description
Service Manual Cafitesse 300
3.4 Water heating system
Fig. 4
The boiler tank
•
•
The boiler tank, with a capacity of 9 liters / 2-1/4
gallons, is made of polypropylene (PPN) or polysulfon
(PSU) material. The boiler lid and outlet valves are
polysulfon. These materials are neutral plastics which
do not affect the taste of the water and are able to
withstand high temperatures.
•
surface and boiler cover due to level control. The airgap is in communication with the outside air through
the overflow tube (2), preventing a pressure build up
in the tank (no danger). (Fig. 4)
•
Further advantages are:
• good insulation against loss of heat
•
•
•
Further safety features are a temperature limiter
(3) to prevent dry operation of the heating element
and a safety thermostat to prevent excessive steam
generation and boil-over. (Fig. 4)
A high tube within the tank feeds the outlet valve
and ensures that only the hottest water is delivered.
An additional advantage of the high tube is that the
water level cannot drop below the outlet opening. The
heating element (1) is thus always immersed in water.
(Fig. 4)
An air-gap is provided between the inlet tube,
which guides the incoming water to the bottom of the
tank, and the inlet elbow. This ensures that hot water
from the boiler cannot be siphoned to the water mains
in case of lower pressure on that side.
• less scale build up
• no rusting
An air-gap is always present between water
•
The sides of the boiler tank are covered with a
mat of fiber-glass material to prevent heat loss.
The hot water tank has been constructed
according to the so-called "open" boiler system
(as opposed to "pressure" boiler).
3-6
June 2003
Service Manual Cafitesse 300
Functional Description
Fig. 5
Water heating and temperature control
•
Mains voltage is supplied to the heating element
through dual power relays K01 and K02, two
independent control circuits having to be closed for
power to reach the heating element.
•
K01 is activated through the main switch and
boiler thermostat. K02 is permanently activated
through the closed contacts of the temperature limiter
and the safety thermostat, which are connected in
series, when the power switch is on.
•
The element reheats the water until the
temperature set on the thermostat is reached and
increased pressure in the sensor capillary opens the
contacts of the thermostat, switching off relay K01.
•
•
Any attempt to modify, alter or bypass
heating circuit safety devices may create
the possibility for fire or electrical shock.
Dispenser should only be serviced by a
qualified technician.
The safety thermostat sensor is located at the
bottom end of the boiler overflow tube. Its contacts
open if steam is generated for a period of several
minutes, breaking the control circuit of relay K02 and
switching the heating off. Safety thermostat function is
reliable down to a boiling point of 87oC/188oF.
Mains current flows to the heating element via
the main contacts of relays K01 and K02 which are
connected in series.
•
WARNING:
The thermostat sensor is located in a protective
tube which is filled with silicone grease to improve
conductivity. Flowing water at low temperature
causes a reduction of pressure in the sensor capillary,
causing the thermostat contacts to close and route
24V AC to the coil of relay K01.
•
rises to 160οC/320οF, breaking the control circuit of relay
K02 and thus switching the heating off. The temperature
limiter is a safety device to prevent dry running.
•
The heating circuit is protected by the external
mains fuse that should be provided in the supply line
to the machine, the control circuits of the power relays
by Fuse F02 (see Section 2, Fuse Values and
Location) on the power pack.
The temperature limiter capillary is clipped onto
Important Note:
the heating element. The contacts open if the heating
element temperature
After repair work, carry out procedure in Section 5 to check
June 2003
boiler functions.
3-7
Functional Description
Service Manual Cafitesse 300
3.5 Water dispensing system
•
The boiler is equipped with two outlet valves, one of
which is shown in Fig. 6 (3 valves on 3-outlet-Tomlinson).
They are screwed to the water outlet tubes which draw
water from the top of the tank, where it is at its highest
temperature.
•
The outlet valve consists of a plastic body (1) which
contains a hollow stainless steel plunger (2) with outlet
holes on its tapered bottom end, and an externally
mounted actuator coil. The weight of the plunger and the
water column in the tank holds the plunger in its seat. A
silicone seal on the plunger tip prevents water flow. (Fig.
7)
•
Operation of a delivery button starts the
microprocessor (MP), which energizes the coil for the
period programmed.
•
The magnetic field of the coil lifts the plunger (2),
allowing water to flow through the plunger and valve body.
An elbow which is clipped onto the valve body directs the
water through a silicone hose (3) to the trough (4). The
water mixes with concentrate pumped into the trough by
the Flexi dosing system, and flows out through the
delivery spout.
•
At the end of the programmed period the MP cuts off
the current to the coil and the plunger falls down into its
seat, stopping the flow.
•
The volume of water delivered during the valve open
period depends on the bore diameter of the fixed outlet
fitted to the valve body, several different types being fitted
to suit application and the water pressure. The latter,
about 25cm water column is constant, as the water level is
controlled by the float.
•
An air-gap is provided between the elbow and the
valve body, to ensure that the water flows out quickly and
to prevent dripping when the valve closes. The delivery
valve body is equipped with a Teflon seat which prevents
the formation of lime scale.
3-8
June 2003
Service Manual Cafitesse 300
Functional Description
3.6 Cooling system
7
8
6
•
•
•
•
The sensor (4) of the thermostat (5) is mounted
inside the cooling compartment (2), which holds
a maximum of two concentrate packs (3). Too
high a temperature causes an increase of
pressure in the sensor capillary, causing the
thermostat to close and activate the mains
supply circuit of the compressor.
Mains current flows through the PTC starting
device (8) and the compressor (6) start winding,
and the compressor run winding which is
connected in parallel. The compressor starts
up, the start winding providing the extra torque
required for starting. It remains in circuit until
the PTC warms up and resistance increase in
the PTC cuts off the current flow.
The compressor (6) continues to run on its run
windings, drawing heat from the cooling
compartment (2) through the evaporator (1) and
giving it up to the atmosphere through the
condenser (7) on the rear of the dispenser.
The pressure in the thermostat capillary
reduces with decreasing cooling compartment
temperature. The thermostat (5) contacts open
when the preset temperature is reached, cutting
off the mains supply to the compressor.
June 2003
•
The normal thermostat setting of 3-4 set at
factory ensures the correct concentrate temperature
of 2ο-6οC / 36-43οF.
•
The compressor (6) can be turned off completely
only by disconnecting the mains plug or by turning
the thermostat switch to zero. Restarting should be
attempted only after a rest period of at least 5
minutes. This allows the PTC to cool down, ensuring
that the start winding of the compressor will be
activated when switching on.
•
The starting device (8) is located on the side
of the compressor housing. An overload
protection cut-out is integrated in the
compressor winding. An abnormally high current
draw or overheating causes the overload cut-out
to break the circuit, a cooling down time of up to
45 minutes being necessary for automatic reset.
•
The refrigeration unit is connected to the mains
through the cooling thermostat and the plug and
socket, ST21/BU21 (see Section 5.3, Electrical
Connections), on the front of the power pack. The
circuit is protected by the fuse in the mains supply
line.
3-9
Functional Description
Service Manual Cafitesse 300
3.7 Flexi-Pak™ concentrate dosing system
•
•
Concentrate is dosed from a maximum of two
Flexi-Pakª concentrate packs placed in the
cooling compartment of the dispenser. Two
dosing coils, one for each pack, are fitted to the
base of the cooling compartment.
The dosing tubes of the concentrate packs,
which contain the pumping mechanism, are
placed in the concentrate coils.
•
Operation of a beverage delivery button on the
door of the dispenser activates a pulse
generator on the control board, energizing one
of the concentrate coils intermittently.
•
The magnetic field of the coil, which is built with
each pulse, moves the plunger in the dosing
tube up and down, compressing the bellow and
pumping concentrate into the trough.
3 - 10
•
The boiler outlet valve is also activated when
the beverage delivery button is operated, allowing
water to reach the trough at the moment of
concentrate dosing and mix to the concentrate.
•
The number of concentrate pulses per portion,
and thus the beverage strength, is dependent on the
ratio and volume settings on the control board.
•
The pulses are spread over the entire opening
period of the water outlet valve to ensure consistent
beverage strength.
June 2003
Service Manual Cafitesse 300
Functional Description
The Flexi-Pak™ concentrate pack
•
The Flexi-Pack concentrate pack is a CLOSED
system, air being excluded from the collapsible
bag-in-box during use. No air-borne bacteria can
gain entry, improving the keeping quality of the
product in the dispenser and extending the life of
the product to three weeks at 60C / 430F maximum.
•
The concentrate dosing pump is built into the
transparent dosing tube of the pack (Fig.10). Pump
and pack form a disposable unit.
•
The plunger is composed of the plunger ring, ring
carrier and inlet valve. The pump bellow is fitted
into grooves in the ring carrier and the outlet
sleeve, in which the outlet valve is located.
•
Each pulse fed to the concentrate coil of the
dispenser draws the plunger down, compressing
the bellow and pumping concentrate through the
outlet valve into the trough.
•
During the pulse intervals suction is created by the
bellow returning to its original form: concentrate is
then drawn in through the inlet valve replacing the
volume pumped out.
•
The concentrate volume delivered per pulse and
pump stroke is 0.105 cc.
LEGEND
1. Dosing Tube
2. Plunger Ring
3. Ring Carrier
4. Outlet Sleeve
5. Outlet Nozzle
6. Bellow
7. Inlet Valve
8. Outlet Valve
9. Black Float
1
9
Flexi-Pack™ dosing control
•
Dosing functions of the Cafitesse 300 are governed
by the Cafitesse 300 Flexi MP control board.
Section 6 contains detailed programming
instructions.
3
2
Water delivery times/volumes:
•
The period of water valve operation required to
deliver the correct water component of a portion is
calculated by the MP based on the flow-rate value.
This value, which must be known, must be
programmed on the control board with the Service
Device 2.
7
6
4
8
5
Fig. 10
June 2003
3 - 11
Functional Description
Service Manual Cafitesse 300
Ratio (beverage strength)
•
The ratio depends on the volume of water
delivered and number of pulses given to the
concentrate delivery coil during the period of
water outlet valve operation.
•
Pulses are given to the concentrate dosing coil
over the entire period of water delivery, but with
a starting time lag and stopping time lag of 0.5
seconds each (Fig. 11). The volume of
concentrate delivered during this time depends
on the number of pulses given (pulse rate).
•
As water delivery and concentrate delivery
times are fixed, alteration of the pulse-rate
increases or decreases the concentrate delivery
volume -shorter intervals resulting in more
pulses over the same period of time, and thus a
stronger beverage (Fig.12)
•
The pulses are evenly distributed over the entire
period, pulse interval duration being longer at
lower pulse rates. This ensures thorough mixing
and consistent color of the beverage during
delivery, irrespective of the mix-ratio set.
•
The correct pulse rate is automatically selected
when values for ratio and beverage delivery
volume are programmed.
Control characteristics:
• Pulse rate range: 10-60 pulses/sec.
• Pulse duration constant at 7.2 milliseconds
• Initial time lag before first pulse: 0.5 sec
• Cutting off time lag after deactivation of water
coil: 0.5 seconds
3 - 12
June 2003
Service Manual Cafitesse 300
Functional Description
•
_ The flexi system delivers 0.105 ml concentrate per pulse and stroke, giving a delivery range of 1.05-6,3 ml/
second.
•
_ The inital time lag of 0.5 second allows water from the boiler outlet valve to reach the trough at the moment
concentrate delivery commences. The cut-off time lag of 0.5 seconds ensures that a large part of the water
present in the outlet hose at the time of valve closure also mixes with concentrate, the remainder being
sufficient to ensure a split-second flushing of the trough and delivery spout.
•
Steps during dosing:
• 1. Delivery button depressed.
• 2. Water delivery valve opens.
• 3. Concentrate delivery starts after a delay of approximately 0.5 seconds, a number of pulses dependent
on the ratio (beverage strength) set on the control board are given to the concentrate coil at equal
intervals. Water and concentrate issue simultaneously from the delivery spout.
• 4. Water delivery valve closes after a period set for the portion volume or delivery time set on the control
board, or when the delivery button is released (continuous-flow mode).
• 5. Concentrate dosing ends approximately 0.5 seconds after water valve closes and the rest of water
present in the water valve outlet hose flows through the trough.
June 2003
3 - 13
Functional Description
Service Manual Cafitesse 300
Empty control:
•
A photodiode and phototransistor are mounted
on each concentrate delivery coil unit. (Fig. 13)
•
When concentrate is in the dosing tubes of the
packs, the infra-red beam from the photodiode is
obstructed and the empty indicator LEDs on the doorfront are off.
•
When a pack is empty and no concentrate is
present in the transparent plastic dosing tube, the
beam reaches the phototransistor which activates the
empty indicator circuit, switching on the
corresponding empty indicator LED (1) on the doorfront. (Fig. 14)
•
The dispenser can be programmed to
automatically switch-over to the full pack. All delivery
functions then remain activated and the empty pack is
indicated by a steady glow of the corresponding LED.
All beverage delivery buttons are locked and both
LEDs are both illuminated when the second pack is
also empty.
•
1
Programming automatic switch-over is unsuitable
for same application, e.g., when coffee and decaf
packs are used. In these cases the corresponding
delivery buttons are locked and the empty indicator
illuminates when a concentrate pack is empty.
•
Due to the difference in transparency of coffee
and tea concentrates, the sensitivity of the empty
indicator circuit has to be adjusted to suit. This takes
place during programming.
1
NOTE: The empty indicator LEDs also function as fault
indicators on dispensers equipped with a
Cafitesse 300 Flexi MP control board,
simultaneously flashing indicating a dispensing
fault. Fault diagnosis can be carried out with
the Service Device 2 as set down in Section 11.1.
3 - 14
Fig. 14
June 2003
Service Manual Cafitesse 300
Functional Description
Empty indication setting:
•
All Flexi-Paksª are equipped with a black float
in the dosing system. This black float will prevent
empty indication as long as the coffee pack is filled
with coffee.
•
The drawings in Figure 15 explain three
possible situations: Situation 2 the present one in
the field with the problem of incorrect empty
indication caused by some IQ-coffee-extract at the
inside walls and/or coffee foam. In this situation,
there is not enough transparency for the empty
beam of the empty control system.
•
To overcome this problem we strongly advise to
set the dispenser to the more sensitive Tea-Setting,
Situation 3.
•
Attention: In case of non IQ-Flexi products
the Coffee-Setting in the machine should be
continued.
June 2003
Situation 1
* Black float up.
* System filled with
coffee
Situation 2
* Black float down.
* System empty
* No empty
indication
Coffee setting
Situation 3
* Black float down.
* System empty
* Empty indication
Tea setting
3 - 15
Functional Description
Service Manual Cafitesse 300
3.8 Electrical circuits
Supply voltages
•
The Cafitesse 300 can be operated on voltages of 208, 220 and 240V AC, configuration for the various
voltages being through bridge wires as described in Section 5.3, Electrical Connections. The dispenser
utilizes mains voltage for operation of the cooling system and the water heating element in the boiler. The
mains terminal in the power pack supplies the cooling unit directly via the cooling thermostat, the heating
element over dual power relays which are switched with 24 V AC through a control and safety circuit.
•
The power pack is equipped with a step-down transformer and having two secondary windings which provide
9V AC and 20/24V AC for all other dispenser functions. 9 and 24V AC are used on dispensers fitted with the
Cafitesse 300 Flexi MP control board.
•
The AC voltages are used for the following functions:
•
24V AC on dispensers equipped with Cafitesse 300 Flexi MP control board:
• Water inlet valve operation by the float microswitch.
• Is rectified over bridge rectifier V02 to obtain the 24V DC supply for operation of the water outlet valves.
The output of rectifier V02 is also supplied to the control board, ripple filtered and stabilized at 20.5V for
concentrate coil and empty circuit operation. A yellow LED on the control board indicates that the 20.5V
circuit is in order.
•
24V AC on all dispensers:
• Heater control circuit. Two power relays K01 and K02 supply mains voltage to the heating element over
their main contacts which are connected in series. Relay K01 is switched over the main switch and boiler
thermostat, relay K02 over the main switch, safety thermostat, and temperature limiter.
• Refer to Section 3.4, Water Heating and Temperature Control for complete description.
•
9V AC on all dispensers:
• Is rectified over bridge rectifier V01 and supplied to the base circuit board, where it is smoothed over
capacitor C2 and stabilized at 5V DC for microprocessor operation. A Green LED on the control board
indicates that the 5V circuit is in order.
3 - 16
June 2003
Service Manual Cafitesse 300
Functional Description
Fuse values and location
•
Mains circuit:
The circuit is protected by a fuse which should be
provided in the external supply line to the dispenser.
The fuse value must not exceed that specified on the
identification label of the machine.
•
Transformer primary and secondary circuits:
The fuses F01/02/03 are located on the front of
the power pack (Fig. 16), and can be reached after
dismantling the splash panel. The fuse values for the
various versions are listed below:
• 9V Secondary Circuit - Fuse F01
Cafitesse 300 K - 1.5 A/T
Cafitesse 300 H - 0.5 A/T
• 24V Secondary Circuit - Fuse F02
Cafitesse 300 K - 3.0 A/T
Cafitesse 300 H - 3.15 A/T
• Primary circuit - Fuse F03
Alle Cafitesse 300 K - 0.75 A/T
Alle Cafitesse 300 H - 0.5 A/T
Wiring:
•
All cables in the machine carry connection
identification markings on the insulation at each end.
They correspond to those on the wiring diagram,
prefixes ST. and BU. denote Plug and Socket
respectively.
•
It is essential that the correct contact pins,
contact sockets and cables are used and the special
AMP service tools are used when carrying out repairs
on the wiring. The components to be used depend on
cable cross-section and insulation diameter, as
indicated in the table included in the parts lists.
On no condition should cables of smaller crosssection than those originally employed on the
dispenser be used.
June 2003
3 - 17
Functional Description
3 - 18
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Operating Controls
4 Operating Controls
Contents
4.1
June 2003
Operating Controls .................................................................................. 2
4-1
Operating Controls
Service Manual Cafitesse 300
4 Operating Controls
4.1 Operating Controls
•
The dispenser is equipped with following control
elements, depending on the model:
• Main switch,
• beverage delivery press buttons or Tomlinson
handles,
• water press button or handle,
• empty indicators, and
• ON/OFF indicator.
• Main Switch (1):
Controls the 20V and 24V secondary circuits of the
transformer. Switches off all functions except cooling
and the 9V secondary circuit supply for control logic.
(Fig. 1)
3
6
7
3
6
7
4
8
Stop
Button
5
4
8
Stop
Button
5
• Beverage Delivery Press Buttons:
Handles are fitted instead on some versions. Beverage
volume, mix-ratio, and delivery mode for deliveries with
left-hand button (3) and right-hand button (4) are
individually programmable. Delivery is locked when the
Flexi-Pak™ concentrate packs are empty. See Section
3.7, Empty Control.
• Water Button (5):
Handles are fitted instead on some versions. Delivers
portions of or flowing hot water.
• Stop Button:
For Emergency shut down.
• Empty Indicators, Red:
Empty indication for left-hand (6) and right-hand (7)
concentrate packs. The LEDs light steadily. See
Section 3.7, Empty Control.
• ON/OFF Indicator (8):
Lights when main switch is set to ON. All dispenser
functions including the water heating circuit are
activated.
4-2
June 2003
Service Manual Cafitesse 300
Installation
5 Installation
Contents
5.1
Location .........................................................................................2
5.2
Unpacking and Setting Up ...........................................................3
5.3
Electrical Connection ...................................................................4
5.4
Water Connection .........................................................................5
5.5
Testing Water Line Pressure........................................................6
5.6
Starting the Dispenser..................................................................7
5.7
Adjustments ..................................................................................8
June 2003
5-1
Installation
Service Manual Cafitesse 300
5 Installation
5.1 Location
•
The dispenser may be placed on an island
counter or on a counter or table against a wall.
•
A minimum clearance of 5 cm/2 inches at the
rear of the machine is necessary to ensure
efficient cooling.
•
•
5-2
The ambient temperature at the machine
location should be within the range 10....C 32....C / 50- 90 °F.
A suitable grounded electrical outlet should be
available less than 2 m/6 feet away from the
machine location. The supply line should be
provided with a fuse/fuses indicated on the
identification label of the dispenser. It is also
strongly recommended that a residual current
circuit breaker is provided in the supply line.
•
A drinking water mains outlet with stop valve
fulfilling the following conditions should be
available close to the unit:
• Minimum dynamic line pressure 0,8 bar/11 psi
• Maximum static line pressure 100 psi
• Minimum flow rate 6 l/min./1.5 U.S. gal./min.
Original:
10 bar/40 psi
June 2003
Service Manual Cafitesse 300
Installation
5.2 Unpacking and Setting Up
•
The following items are included in the dispenser carton:
• 2 door keys
• 1 cleaning brush
• drip tray and cover
• 4 foot extensions
• 4 foot inserts
• stop plate for drip tray
• a wiring diagram is placed above the concentrate
compartment of the dispenser
•
Place the dispenser on the counter or table. Unlock main
door with the key provided.
•
Remove the fixing screw (1). (Fig. 1)
•
Remove top cover of the dispenser in the center of the
top cover by lifting the front edge and pushing it towards
the rear. Discard the styrofoam block (transport packing)
found on top of the boiler.
•
Free the float wire (2) from its transport position by lifting
it off the locating rod. (Fig. 2).
•
Place hook of float wire (2) in position on actuating arm
(3) of the float microswitch (Fig.3).
•
Switch boiler thermostat (4) OFF by rotating the knob
counterclockwise. (Fig. 4).
June 2003
5-3
Installation
•
Service Manual Cafitesse 300
Dispensers with newer style press buttons (Fig. 5):
• Remove the switch cover on the rear of the main door by
pushing towards the door lock.
• Remove the button (1) completely with the transparent
button cover by lifting the two locating lips and pushing them
outward.
• Dismantle the button cover (2) and stick on the label (3)
selected from the set supplied with the machine.
1
3
•
2
Dispensers with older style press buttons (Fig. 5):
• Remove the switch cover on the rear of the main door by
pushing towards the door lock.
• Remove the button (1) completely with the transparent button
cover by lifting the two locating lips and pushing them
outwards.
• Dismantle the button cover (2) and stick on the label (3)
selected from the set supplied with the machine.
• When refitting make sure that the spring blade (4) is located
correctly in the frame (5).
5
4
3
1
2
5-4
June 2003
Service Manual Cafitesse 300
•
Leg inserts (3) can be inserted into the drip tray (4) if
needed. Place the cover (2) onto the drip tray. (Fig. 6)
•
If pots are to be used:
Check whether the pot fits under the delivery spout. If it is
too tall, insert the foot extensions (5) and the drip tray stop
plate (6) to the dispenser. (Fig. 7, 8)
•
The foot extensions and the stop plate may also be fitted
if extra room for cleaning under the dispenser is required.
June 2003
Installation
5-5
Installation
Service Manual Cafitesse 300
5.3 Electrical connection
•
Procedure and materials used should be in accordance
with local requirements and regulations.
CAUTION: The electrical connection must include a ground
wire (Protective Earth).
•
Remove the splash panel (1) on the dispenser front (Fig.
1). Check the position of the bridge wire on the 6 pole
voltage selector plug St 20 (2), identified with "MAINS
VOLTAGE", on the power pack (Fig. 2).
The correct bridge positions are:
208V - Pins 3/6 - Bridge position left
220V - Pins 2/5 - Bridge position center
240V - Pins 1/4 - Bridge position right
•
If necessary, draw plug out and install the correct plug to
suit local voltage. The pin numbers are marked on the plug
housing.
CAUTION: Machines supplied for operation on 208-240V
(U.S.A./Canada) are set for 240V. Exchange the plug if
operating on 208V.
•
Check the wiring of 9 pole heater plug St22 (3), identified
with "HEATING", on the power pack (Fig. 2).
•
If 3 wires are connected:
The boiler is equipped with a single heating element rated
at 220V/3KW.
No adjustment of the heating is possible (Not for USA
version).
•
If 7 wires are connected:
The boiler is equipped with a compound heating element
consisting of 2 elements rated at 220V/3KW and 1 element
rated at 240V/2.7KW.
5-6
June 2003
Service Manual Cafitesse 300
•
Installation
If the compound heating element is fitted, remove the
power pack cover which is located with two screws on
the rear of the dispenser.
Check whether the bridge configuration of the mains
terminal X01 (Fig. 3) is suitable for the power supply and
the heating power required.
The dispenser can be adapted for the range of heating
capacities indicated on the identification label by
rearranging/adding bridges, and changing the mains
cable and plug where necessary.
The possibilities are indicated in Fig. 4.
Extra bridges, if applicable, are supplied with the
dispenser.
WARNING: Observe local regulations regarding maximum
permissible power supply loads. Do not connect
machine to electricity until the water connection has
been made -See Section 5.4.
•
Check the fuse values in the supply line to which the
dispenser is to be connected. Install the fuse/fuses
indicated on the identification label of the dispenser.
•
The fitting of a residual current circuit breaker between
the electrical outlet and the machine is strongly
recommended in cases where such breakers are not
incorporated in the wiring of the building.
Fig. 4
June 2003
VOLTAGE
1 ELEMENT
2 ELEMENT
208
2.7 KW / 12.9 A
4.7 KW / 22.7 A
220
3.0 KW / 13.7 A
5.3 KW / 24.0 A
240
3.6 KW / 15.0 A
6.3 KW / 26.2 A
5-7
Installation
Service Manual Cafitesse 300
5.4 Water connection
•
Procedure and materials used should be in
accordance with local requirements and
regulations.
•
The unit may be connected to a cold or hot water
supply line, depending on the delivery capacity
required. If a hot water supply is used, the inlet
temperature should not exceed 194οF and copper
tubing and metal fittings must be used for the
supply line.
•
Checking the line pressure with the Inlet-Pressure
Tester as described in Section 5.5 is
recommended, to ascertain whether dynamic and
static pressure are within the tolerances listed in
the specification.
•
U.S.A./CANADA: Connect the inlet valve on the
underside of the machine to a 3/8" water supply
line using a flared adapter, obtained locally.
•
Open the mains stop valve and check for leaks in
the supply line.
5-8
June 2003
Service Manual Cafitesse 300
Installation
5.5 Testing water line pressure
•
Static and dynamic pressure can be checked with the
Inlet-Pressure Tester, Part No. M-2215 (Fig. 1), which is
available as an optional service tool.
•
The pressure should be checked under the least
favorable conditions, i.e., with all other user outlets open
(dynamic), and closed (static).
•
Connect manometer to the water supply line using
pressure hose and the most suitable of the four unions A,
B, C and D supplied with the pressure tester.
Alternatively, use the water inlet hose which will be used to
connect up the dispenser.
•
Close Tap E on the pressure tester and open the stop valve
in the water supply line fully.
•
Hold the outlet nipple over a bucket and open Tap E.
Read dynamic pressure on the monometer. The value
should be more than 0,8 bar/11 psi under all conditions.
NOTE: If it is necessary to fit in extension to the outlet nipple, use
hose with an internal diameter of no less
than 15 mm.
•
Close Tap E and read static line pressure on manometer.
The value should be less than 100 psi.
•
Close tap valve in supply line and disconnect pressure
tester. Connect dispenser to the line.
June 2003
5-9
Installation
Service Manual Cafitesse 300
5.6 Starting the dispenser
1. Set main switch of the dispenser to OFF.
2. Make sure that the boiler thermostat (1) which is
located on the boiler lid is set to position OFF.
(Fig. 1)
NOTE: The temperature limiter (2) will open the
heating circuit if the main switch and thermostat (1)
are switched on when the boiler is empty. The circuit
can be reactivated by pressing the reset button (3)
on the limiter (Fig. 1).
7. Set the thermostat (1) to maximum position. The
heating circuit is now activated, water in the boiler
starts warming up. (Fig. 1)
8. Wait until heater switches off, indicated by the
contactor on the power pack switching off with an
audible click. The thermostat setting need not be
altered if excessive steaming does not occur, and
heating switches off. Steps 9-11 may then be
ignored.
9. Observe the dispenser for several minutes. If
It should only be reset after carrying out Steps 1 to 6.
steam issues continually from the boiler overflow
3. Plug in the power cord. The compressor starts
outlet, the safety thermostat should open the
running and the evaporator plate in the refrigeraheating circuit.
tion compartment starts cooling down.
Exceptions: dispensers located at elevations
4. Open the Stop valve of the mains water supply
higher than 400 metres/1200 feet above sea level
line and set mains switch to ON.
see Section 5.7, Adjustments.
5. Water should now begin to flow into the boiler
10. Reduce thermostat setting. Depress water delivtank.
ery button and draw at least 8 liters/2 gallons of
If no water flows, switch main switch off and on
water in order to reduce boiler temperature. Set
several times to drive out air in the inlet valve.
main switch OFF.
Observe the movement of the float switch acti11. If safety thermostat has cut off heating, press
vating arm (4). It should rise and deactivate the
reset button (3). Set main switch ON and repeat
microswitch when the boiler is full, shutting the
Step 8. (Fig. 1)
water supply. (Fig.1)
12. Replace top cover and splash panel. Carry out
6. Place a vessel under the delivery spout and hold
control board programming procedure detailed in
the water delivery button depressed. (On disSection 6 or Section 7 as applicable.
penser with safety-door switch, push in the door 13. Depress water button and draw at least 8 liters/2
switch). Observe the movement of the float
gallons of water to flush the boiler, hoses etc.
switch activating arm. It should fall initially and
Peel off the protective foil on the housing before
then rise, indicating that water flows in faster
putting the dispenser into service.
than it flows out of the delivery spout and that the
supply is adequate.
5 - 10
June 2003
Service Manual Cafitesse 300
Installation
5.7 Adjustments
•
The following adjustments must be carried out/
checked when installing the dispenser.
•
- Emerson 90οC/194οF, set according to the scale on
the thermostat.
• Mains voltage selection/Heater configuration
• Water temperature setting/Safety thermostat
test
The permissible maximum settings are
•
• Cooling thermostat setting
• Settings for beverage type, strength and
delivery volumes
Mains voltage selection/Heater configuration:
As the boiling point of water reduces with height
above sea level, the permissible boiler
thermostat settings reduce accordingly. The
relationship between elevation and boiling point
is shown in the table below. The thermostat
should be set such that the maximum water
temperature is at least 5oF lower than the boiling
point.
See Section 5.3, Electrical Connection.
Water temperature setting/Safety thermostat test:
•
The setting of water temperature is described in
Section 5.6, Starting the Dispenser. The following
points should be taken into account when adjusting
the boiler thermostat.
Relationship between elevation and boiling point.
Height (Ft)
Height (Ft)
Boiling Point oF
Boiling Point oF
202
5500
212
0
201
6050
211
550
200
6600
210
1100
199
7150
209
1650
198
7700
208
2200
197
8250
207
2750
196
8800
206
3300
195
9350
205
3850
194
9900
204
4400
193
10450
203
4950
Relationship between elevation and boiling point.
Height (m)
100
200
300
400
500
600
700
•
Boiling Point oC
99.4
98.6
98.2
97.5
97.0
96.3
95.7
The safety thermostat cuts off heating in the
event of excessive steam generation. Heating
cannot be restored by the user as the top cover of
the dispenser must be removed to reach the
manual reset button. Therefore the boiler
thermostat setting procedure (see Section 5.6),
which is also a test for the safety thermostat,
must be followed.
June 2003
Height (m)
800
900
1000
2000
3000
4000
5000
Boiling Point oC
95.0
94.5
93.8
87.9
82.0
79.2
70.5
Note: Safety thermostat function is reliable down to a
boiling point of 87oC/188οF.
•
High thermostat settings shorten the service life
of several dispenser components. It is therefore
advantageous to operate at the minimum
beverage temperature acceptable to the customer.
5 - 11
Installation
Service Manual Cafitesse 300
Cooling thermostat setting:
•
Concentrate compartment temperature is
regulated by the thermostat (1) located behind the
splash panel (Fig. 1)
•
The thermostat is set at position 2 at the factory.
This setting ensures the correct concentrate
temperature of 2oC-6oC/36o43oF at ambient
temperatures of approximately 22oC/72oF. It
should not normally be altered.
•
The thermostat setting will need adjustment if
ambient temperature deviates considerably from
the above value at the machine location.
Adjustment should be carried out in small
increments as the full effect will be noticeable only
after several hours.
•
The cooling compressor is fitted with a PTC
starting device, restarting being possible only after
the PTC cools down. Do not switch on/reconnect
for a period of at least 5 minutes if the cooling
system compressor was switched off with the
thermostat or by disconnecting the power supply.
Settings for beverage type, strength and delivery
volumes:
•
The Service Device 2 (Part No. H-0913), a special
service tool, is required for adjustment of these
dispensers. (Fig. 2)
•
Detailed adjustment procedure, including the
service tools necessary and their use, is set down
in Section 6.
5 - 12
June 2003
Service Manual Cafitesse 300
Programming Dispensers
6 Programming dispensers equipped with the
Cafitesse 300 Flexi MP Control Board
Contents
6.1
The service device
6.2
Programming Cafitesse 300 Flexi MP control board ............................ 3
6.3
Circuit board switches............................................................................. 4
6.4
Flow rate values ....................................................................................... 5
6.5
Determining flow rate .............................................................................. 6
6.6
Permissible maximum ratios .................................................................. 7
6.7
Delivery counters ..................................................................................... 8
6.8
Calculating water and concentrate volumes per portion
and number of pulses .............................................................................. 9
6.9
Programming control board with flow chart ....................................... 10
June 2003
................................................................................ 2
6-1
Programming Dispensers
Service Manual Cafitesse 300
6 PROGRAMMING DISPENSERS EQUIPPED WITH THE
CAFITESSE 300 FLEXI MP CONTROL BOARD
6.1 The Service Device 2
•
The Service Device 2 is required for
programming Cafitesse 300 dispensers which
are equipped with the Flexi MP Control Board.
It must be an example which is equipped with
Eprom version V 1.4 or higher. To check Eprom,
press activating button.
Display on
service device:
•
service devise 2
V 1.4 (15-04-88)
•
The CAFITESSE 300 programming adapter is to
be connected up when programming the control
board. The complete programming procedure is
described in Chapter 6.3.
•
The clock function of the service device has to be
set as described in Chapter 6.1.1, before using it for
the first time. Time indication is in the twelve hour
system, e.g. 1300 hours = 01:00 p.m.
The service device is available under Part
Number H-0913. It is supplied with a series of
adapters for programming several types of
dispensers manufactured for Douwe Egberts. Of
the items included under this part number,
shown in Fig. 1, the Service Device 2 (item 1),
and CAFITESSE 300 programming adapter
(item 2) are necessary when programming the
CAFITESSE 300.
9 pole/optical
6-2
June 2003
Service Manual Cafitesse 300
Programming Dispensers
Setting service device clock
June 2003
6-3
Programming Dispensers
Service Manual Cafitesse 300
6.2 Programming the CAFITESSE 300 Flexi MP Control Board
1. Plug CAFITESSE 300 Programming Adapter into Service Device
2 and plug adapter cable into the 9-pole socket on the Flexi MP
control board (Fig. 4).
Concentrate packs need not be placed in the dispenser during adjustment.
2. Switch the main-switch of the dispenser ON and press the activating button on the service device:Display on service device:
•
service device 2
V 1.4 (15-04-88)
Press and release door frame switch.
The display indicates that the service device is fitted with EPROM Version V
1.4 introduced on 15.04.1988. If the display indicates -low battery- change the
9V battery in the service device.
Programming Socket
The following applies to all further steps of the programming procedure:
A. The dispenser automatically leaves the programming mode and
the service device display indicates - ERROR values not saved - if the
keyboard of the service device is not operated for a period of over 25
seconds. The programming procedure has then to be started again with
Step 2.
B. The service device switches itself off if the keyboard is not operated for a period of over 30 seconds. The activating button on the
service device has then to be pressed and the procedure has to
be restarted with Step 2.
C. The arrow-down key on the service device can be used instead of
the INPUT key.
DISPENSER WITHOUT SAFETY DOOR SWITCH
Switch dispenser OFF. After a few seconds:Display on service device:
AS II Flexi V 1.4
# 123456789012
(serial no.)
3.
Press INPUT or key on service device for next step:
3a. DISPENSER WITH SAFETY-DOOR SWITCH
Be sure dispenser is switched on
Hold safety-door switch for 1-2 seconds depressed:Display on service device:
AS II Flexi V 1.4
# 123456789012
(serial no.)
Press INPUT or key on service device for next step:The display indicates that the control board is fitted with EPROM V1.4. Refer to 6.2/10 if ERROR -bad dosing info- is displayed. The dispenser is now in programming mode and the keyboard of the service device is activated for programming the
6-4
June 2003
Service Manual Cafitesse 300
Programming Dispensers
control board. Applies to all further steps: the previous adjustment parameter can be recalled for checking or correction by
pressing the arrow-up key.
1. FLOWRATE (left boiler outlet valve)
Display on service device:
Flow (l) = 87 cc/s
Min: 30 Max: 99
(standard setting)
If flow rate value is correct, press INPUT key for next step:-ORTo change flow rate value: Press CLR, key-in correct value, press INPUT for next step:The display indicates that the flow-rate value presently programmed on the control board is 87 cc/sec and that the adjustment
range is 30 to 99 cc/sec. The value 87 cc/sec is correct for boilers fitted with 9,5mm outlet valves. IMPORTANT: An incorrect
flow-rate leads to display of wrong values in Steps 5/6 and if CAFITESSE 300 is a 1 product machine in step 13/14(18), and
inaccurate programming of ratios and portion volumes. Refer to Chapter 6.4 for flow-rates of other valves. The method for
determining flow-rate in Chapter 6.5 can be applied if the type of valves which are installed is not known.
2. RATIO LEFT
Display on service device:
Ratio (l) = 1:20
Min:12 Max:99
(standard setting)
If ratio indicated is ok, press INPUT for next step:-ORTo change left-hand ratio value: Press CLR, key-in required value, press INPUT for next step:The adjustment range of the Concentrate:Water ratio is 1:12 to 1:99 for deliveries with the left-hand delivery button.
IMPORTANT: Refer to Chapter 6.6 for permissible maximum ratios.
3. PORTION VOLUME LEFT
Display on service device:
Prod.(l) = 0150cc
Min: 40 Max: 2000
(standard setting)
If portion volume indicated is ok, press INPUT for next step:-ORTo change left-hand portion volume: Press CLR, key-in required value, press INPUT for next step:Adjustment and display range is 40 to 2000cc for deliveries with the left-hand delivery button. The volume displayed is
actual delivery volume, concentrate + water. The counter will advance by 1 each time the volume set in this step is delivered, even if continuous flow mode is selected in Step 7.
4. DELIVERY MODE LEFT
Display on service device:
Left dosing = port
1=cont 2=repeat
-ORLeft dosing = cont
2=rep 3=portion
-ORLeft dosing = rep.
1=cont 3=portion
(standard setting)
If delivery mode indicated is ok, press INPUT to reach next step:-ORTo change left-hand delivery mode to continuous flow press key 1, to change to portions repeat press key 2,
for portioned press key 3, change choice by pressing the correct key if selection was wrong, press INPUT for next step:Delivery Modes - left-hand delivery button:
Dosing = cont (Continuous Flow Mode) - Continuous and uninterrupted delivery for as long as the left hand delivery button is held depressed.
Dosing = port (Portioned Mode) - One portion per left hand delivery button operation.
Dosing = rep. (Portions-Repeat Mode)- Repeated delivery, with intermediate pauses of 0.4sec. duration, of the portion
volume set in Step 6 when the left hand delivery button is held depressed.
June 2003
6-5
Programming Dispensers
Service Manual Cafitesse 300
5. PRODUCT LEFT
Display on service device:
Left prod = Coffee
(standard setting)
2 = tea
-ORLeft prod = Tea
1 = coffee
If left-hand product indicated is ok, press INPUT to reach next step:-ORTo change left-hand product to tea press key 2, to change to coffee press key 1, change choice by pressing the correct
key if selection was wrong, press INPUT for next step:
6. 1-PRODUCT/2-PRODUCTS
Display on service device:
ASII = 1 product
(standard setting)
2 = 2 product
-ORASII= 2 product
1 = 1 product
If number of products indicated is ok, press INPUT to reach next step:-ORTo change to 2 products press key 2, to change to 1 product press key 1, change choice by pressing the correct key if
selection was wrong, press INPUT for next step:1 Product:
Step 10/12 are automatically bypassed when “1 product” is selected and the display for step 11 appears when INPUT is
pressed. Automatic switch-over to the second concentrate pack is operative when “1 product” is programmed. The dispenser must be operated with concentrate packs of the same type.
2 Products:
The program continues with step 10 when “2 products” is selected and Input is pressed. Automatic switch-over to the second concentrate pack is inoperative when “2 products” is programmed. Two types of concentrate can then be used.
7. PRODUCT RIGHT
Display on service device:
Right prod = Coffee
2 = tea
-ORRight prod = Tea
1 = coffee
(standard setting)
If product indicated is ok, press INPUT to reach next step:-ORTo change to tea press key 2, to change to coffee press key 1, change choice by pressing the correct key if selection was
wrong, press INPUT for next step:-
6-6
June 2003
Service Manual Cafitesse 300
8. DELIVERY MODE RIGHT
Display on service device:
Programming Dispensers
Right dosing = por
(standard setting)
1=cont 2=repeat
-ORRight dosing = con
2=rep 3=portion
-ORRight dosing = rep
1=cont 3=portion
If delivery mode indicated is ok, press INPUT for next step:-ORTo change the delivery mode to continuous flow press key 1, to change to portions repeat press key 2, for portioned press
key 3, change choice by pressing the correct key if selection was wrong, press INPUT for next step:Delivery Modes - right-hand delivery button:
Dosing = cont (Continuos Flow Mode) - Continuous and uninterrupted delivery for as long as the right hand delivery button is held depressed.
Dosing = port (Portioned Mode) - One portion per right hand delivery button operation.
Dosing = rep. (Portions-Repeat Mode) - Repeated delivery, with intermediate pauses of 0.4sec. duration, of the portion
volume to be set in Step 14 when the right hand delivery button is held depressed.
9. FLOWRATE (right boiler outlet valve)
Display on service device:
Flow (r) = 87 cc/s
(standard setting)
Min: 30 Max: 99
If flow rate value is correct, press INPUT key for next step:-ORTo change flow rate value: Press CLR, key-in correct value, press INPUT for next step:-
The display indicates that the flow-rate value presently programmed on the control board is 87 cc/sec and that the setting
range is 30 to 99 cc/sec. The value 87 cc/sec is correct for boilers fitted with 9,5mm outlet valves. IMPORTANT: An incorrect flow-rate leads to display of wrong values in Steps 13/14 (18) and inaccurate programming of ratios and portion volumes. Refer to Chapter 6.4 for flow-rates of other valves. The method for determining flow-rate in Chapter 6.5 can be
applied if the type of valves which are installed is not known.
10. RATIO RIGHT
Display on service device:
Ratio (r) = 1:20
Min: 12 Max: 99
(standard setting)
If ratio indicated is ok, press INPUT for next step:-ORTo change the ratio value: Press CLR, key-in required value, press INPUT for next step:The adjustment range of the Concentrate:Water ratio is 1:12 to 1:99 for deliveries with the right-hand delivery button.
IMPORTANT: Refer to Chapter 6.6 for permissible maximum ratios.
11. PORTION VOLUME RIGHT
Display on service device:
Prod. (r)=1500cc
(standard setting)
Min: 40 Max: 2000
If portion volume indicated is ok, press INPUT for next step:-ORTo change right-hand portion volume: Press CLR, key-in required value, press INPUT for next step:Adjustment and display range is 40 to 2000cc for deliveries with the right-hand delivery button. The volume displayed is
actual delivery volume, concentrate + water. The counter will advance by 1 each time the volume set in this step is delivered, even if continuous flow mode is selected in Step 11.
June 2003
6-7
Programming Dispensers
Service Manual Cafitesse 300
12. WATERVALVE
Display on service device:
Watervalve = left
2= right 3 = 3
-ORWatervalve= right
1= left 3 = 3
-ORWatervalve= 3
1= left 2= right
(standard setting)
(only for machine
with Flexi-MP and 3 outlets)
If water valve is ok, press INPUT for next step:-ORTo change to water valve right press key 2, to change to water valve 3 press key 3, change choice by pressing the correct
key if selection was wrong, press INPUT for next step:Water delivery can be selected for the left, right and the third water valve.
Step 16 is automatically bypassed when "left" or "right" is selected. And the display for step 17 appears when INPUT is
pressed. The program continues with step 16 when "3" is selected and INPUT is pressed.
13. FLOW (3) - ONLY FOR DISPENSERS WITH 3 OUTLETS
Display on service device:
Flow (3) = 87 cc/s
(standard setting)
Min: 30 Max: 99
If flow rate value is correct, press INPUT key for next step:-ORTo change flow rate value: Press CLR, key-in correct value, press INPUT for next step:The display indicates that the flow-rate value for outlet valve 3 presently programmed on the control board is 87 cc/sec
and that the setting range is 30 to 99 cc/sec. The value 87 cc/sec is correct for boilers fitted with 9,5mm outlet valve.
IMPORTANT: An incorrect flow-rate leads to display of wrong values in Step 18 and inaccurate programming of portion
volumes. Refer tom Chapter 6.4 for flow-rates of other valves. The method for determining flow-rate in Chapter 6.5 can be
applied if the type of valves which are installed is not known.
14. WATER DELIVERY MODE
Display on service device:
Water = cont. fl
(standard setting)
2 = portion
-ORWater= portion
1= cont. fl
If delivery mode indicated is ok, press INPUT for next step:- ORTo change to portioned delivery press key 2, to change to continuous flow press key 1, change choice by pressing the
correct key if selection was wrong, press INPUT for next step:Water Delivery Modes - water button:
Water = cont (Continuous Flow Mode) - Continuous and uninterrupted delivery for as long as the water button is held
depressed.
Water = portion (Portioned Mode) - One portion per water button operation. Portion volume is equal to the water volume
which is programmed in step 18.
6-8
June 2003
Service Manual Cafitesse 300
Programming Dispensers
15. WATER VOLUME
Display on service device:
Water = 150cc
Min: 40 Max: 2000
If portion volume indicated is ok, press INPUT for next step:-ORTo change water volume: Press CLR, key-in required value, press INPUT for next step:-
(standard setting)
Adjustment and display range is 40 to 2000cc for the water delivery button. The counter will advance by 1 each time the
volume set in this step is delivered, even if continuous flow mode is selected in Step 17.
16. DELIVERY LOCK
Display on service device:
Pause = 01sec
Min: 0 Max: 5
If a one second pause between coffee deliveries is ok, press INPUT for next step:-ORTo change pause duration press CLR, key-in desired value, press INPUT for next step:-
(standard setting)
The display indicates that coffee delivery buttons are deactivated for a period of 1 second between successive deliveries.
The delivery pause can be set in the ranges 0 to 5 seconds, in steps of 1 second.
17. COUNTER DISPLAY MODE
Display on service device:
Counter enabled
(standard setting)
1 = disabled
-ORCounter disabled
2 = enabled
If display mode is indicated is ok, press INPUT for next step:-ORTo change display OFF mode press key 1, to change to display ON mode press key 2, press INPUT for next step:Counter Display Modes:
Counter enabled - Display ON when dispenser is switched ON and when dispensing.
Counter disabled - Display OFF when dispenser is switched ON and when dispensing.
Details of counting modes and displays are contained in Chapter 6.7.
18. SAVING VALUES
Display on service device:
Press key 1 to store and secure all programmed values:Display on service device:
Save values?
1 = yes 2 = no
Values saved
ASII ready
(Standard machine)
(Machine with safety-door switch)
Disconnect service device and switch dispenser ON.
Disconnect service device and close door.
-ORPress key 2 to retain the previously programmed values unchanged:Display on service device:
Values not saved
ASII ready
Disconnect service device and switch dispenser ON.
(Standard machine)
Disconnect service device and close door.
(Machine with safety-door switch)
-ORPress INPUT key to return to Step 4 (flow rate), run through and check/correct values, store with key 1 when Step 18
is reached.
Circuit board switches
June 2003
6-9
Programming Dispensers
Service Manual Cafitesse 300
6.3 Base circuit board
•
On dispensers equipped with the CAFITESSE 300 Flexi
MP control board, all switches (if present) have to be kept in
the off (UP) position.
•
Plug connection (Fig. 5)
BU02 = main (2)
BU03 = main (3)
BU04 = operation panel (4)
BU06 = concentrate coil (6)
BU09 = temperature limiter (9)
BU10 = float switch (10)
BU11 = inlet valve (11)
BU12 = water coil left (12)
BU13 = water coil right (13)
controlboard (16, 17)
6.4 Flow-rate values
•
It is essential that the correct flow-rate value is
used when programming the control board, as
it serves as the basis on which the
microprocessor calculates ratios and delivery
volumes. Dispensers equipped with the
CAFITESSE 300 Flexi MP control board are
fitted with a boiler which has three identical
water outlet valves, the flow-rate being
dependent on the type of valve body fitted. In
standard condition CAFITESSE 300 H/K-Type
machines, are equipped with 5.0 mm valve
bodies.
6 - 10
•
Typical figures for a range of outlet valves are
given in the table below. The procedure set down in
Chapter 6.5 should be employed to determine the
flow-rate in cases where the type of valve fitted is not
known.
OUTLET VALVE
mm
WATER FLOW RATE
liter/min
cc/sec
5.0
7.0
9.5
2.3
4.0
5.2
38
67
87
June 2003
Service Manual Cafitesse 300
Programming Dispensers
6.5 Determining flow-rate (dispensers fitted with CAFITESSE
300 Flexi MP control board)
•
The flow-rate can be determined by calculation, using values displayed on the service device. Prior programming of
the control board is not necessary, any set of values already programmed being suitable.
•
Three steps are necessary:
1. Measure actual water volume delivered Do not connect service device. Disable empty sensing circuit of left-hand
Flexi coil. A rolled up piece of paper can be inserted in the coil well for this purpose. Measure volume of water delivered
on operation of the left -hand delivery button, using a measuring glass graduated in cc. Example 143 cc
2. Note service device display values Run through the programming procedure and note following displays:
3. Calculate flow-rate with formula
Water volume measured x Flow-rate displayed
Actual Flow-rate =
x (Ratio+1)
Potion volume displayed x Ratio displayed
143 x 87 x (20 + 1)
Actual flow-rate for example figures =
= 87 cc/sec
150 x 20
June 2003
6 - 11
Programming Dispensers
Service Manual Cafitesse 300
6.6 Permissible maximum ratios
•
Thorough mixing of concentrate is partly dependent
on the flow-rate of the boiler outlet valves. The water
and concentrate dosing time for any given beverage
volume and ratio reduces with increasing flow-rate. A
higher pulse rate is then required of the Flexi dosing
system to deliver the same volume of concentrate in a
shorter period, if the mix-ratio is to remain unchanged.
As very high pulse rates can lead to valve flutter in the
Flexi pump and inconsistent dosing, the maximum
ratios (highest concentration) listed in the table below
should not be exceeded.
FLOW RATES
MAXIMUM RATIO
cc/sec
concentrate:water
30 - 75
1 : 12
76 - 81
1 : 13
82 - 88
1 : 14
89 - 94
1 : 15
95 - 99
1 : 16
6.7 Delivery counters
Counting modes - electronic delivery counter:
•
The Flexi MP Control Board has an optional electronic counter board (Fig. 6) which individually registers the
sum of deliveries effected with each delivery button. The total corresponding to the delivery button being
operated is displayed during dispensing. The display reverts to the delivery total from the left-hand button
after each dispensation. The counter registers as follows:
• Deliveries with left-hand button:
In portioned mode - registers every delivery.
In continuous-flow mode - registers the number
of times the portion volume set for the left-hand
button is delivered. In portions repeat mode registers every portion.
• Deliveries with right-hand button:
similar to left-hand button.
• Portions water:
In portioned mode - registers every delivery.
In continuous-flow mode - registers the number
of times the water component of the portion
volume set for the water button is delivered.
•
Place main switch of dispenser in OFF position. Hold the delivery button corresponding to the total to be read
depressed. The display total remains on for as long as the button is depressed.
6 - 12
June 2003
Service Manual Cafitesse 300
Programming Dispensers
Zeroing electronic counter:
•
Place main switch of dispenser in OFF position.
Holding the delivery button corresponding to the total to
be zeroed depressed (item 1), push reset button (item 2)
on control board (Fig. 6).
1
2
June 2003
6 - 13
Programming Dispensers
Service Manual Cafitesse 300
6.8 Calculating Water and Concentrate Volumes per Portion
and Number of Pulses
•
If required, these values can be calculated with the “Ratio” and the corresponding “Prod.” (portion volume) figures
displayed on the service device when running through the steps of the programming procedure. Ratios are displayed in
Steps 5 and 12, the corresponding portion volumes in Steps 6 and 13.
VP
Water volume V W (cc) =
x Ratio
(Ratio + 1)
VP
Concentrate volume V C (cc) =
(Ratio + 1)
Concentrate volume V C
Number of pulses =
0.105
V P = Portion volume displayed in programming procedure Step 6 or 13
Ratio =
Water volume
displayed in the corresponding
Concentrate vol.
programming procedure Step 5 or 12
Example:
For Ratio 1:20 and Portion volume 150 cc in Steps 5 an 6 of the programming procedure:
150
Water volume V W =
x 20 = 142.9 cc
21
150
Concentrate volume V C =
= 7.1 cc
21
7.1
Number of pulses =
= 68
0.105
6 - 14
June 2003
Service Manual Cafitesse 300
Programming Dispensers
6.9 Programming control board with flow-chart
Program the machine serial number and the customer account number as described in Chapter 6.2 when initially installing the
control board or putting a new machine into service!
June 2003
6 - 15
Programming Dispensers
6 - 16
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
June 2003
Programming Dispensers
6 - 17
Programming Dispensers
6 - 18
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Programming Dispensers
7 Programming Dispensers with MP Control Board
and Flexi Interface
Programming Dispensers with MP Control Board and Flexi Interface –
NOT RELEVANT TO U.S. VERSION
June 2003
7-1
Programming Dispensers
7-2
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Flexi-Pak Concentrate
8 Flexi-Pack ™ Concentrate Packs
Contents
8.1
8.2
June 2003
Loading Dispenser ................................................................................... 2
Handling and Storage ....................................................................................... 3
8-1
Flexi-Pak Concentrate
Service Manual Cafitesse 300
8 Flexi-Pack ™ Concentrate Packs
8.1 Loading Dispenser
•
Open the dispenser door.
•
Open the cooling compartment door.
•
Remove the empty concentrate pack.
•
Take a thawed concentrate pack out of the
refrigerator. Shake it very well. (Fig. 1).
•
Check the pack for damage and shake it
vigorously before use (10 times). (Fig. 2)
•
Remove the cellophane cover and pull off the
flap along the perforated line. Then pull out the
dosing tube. (Fig. 3).
•
Slide the dosing tube into the slotted opening of
the pack so that the pack fits well into the red groove
of the dosing tube. (Fig.4)
•
Slide the dosing tube backwards until it rests
against the edge of the pack opening. (Fig. 4)
•
Place concentrate pack in the cooling
compartment of the dispenser. If dispenser was
programmed for two different beverages (automatic
switch-over to second pack off), place pack
accordingly in the left or right-hand side of the
cooling compartment.
•
Load second concentrate pack and check
dispensing functions.
•
If no concentrate is dispensed check whether
• Dosing tube is correctly fitted to the cutout in the
box
• Dosing tube is correctly engaged in the dosing coil.
• Box is damaged or deformed.
8-2
June 2003
Service Manual Cafitesse 300
Flexi-Pak Concentrate
8.2 Handling and Storage
•
Store the concentrate pack in a deep freezer at
-18ο C / 0ο F or colder.
•
Let it thaw in a refrigerator at + 2o C/ 36ο F to + 6o
C /43οF (approx. 3 - 5 days). When filled into the
dispenser, the concentrate should be consumed
within 3 weeks.
•
Do not thaw the concentrate in hot water or in a
microwave oven.
•
Always consume the oldest concentrate pack
first. (first in - first out) (Fig. 1)
•
Use only appropriate concentrates.
•
Storage temperatures
•
Refrigerator: +6oC/43oF
Deep freezer: -18oC/0oF or colder
•
Observe the user instructions on the pack.
•
Mark the actual date and the "best before date”
on the pack. (Fig. 2)
•
Use packs within the recommended time period
(see indications on the pack)
June 2003
8-3
Flexi-Pak Concentrate
8-4
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Cleaning and Maintenance
9 Cleaning and Maintenance
Contents
9.1
General Instructions ....................................................................2
9.2
Maintenance Time Schedule ........................................................2
9.3
Daily cleaning - Cleaning the outside of the dispenser.............3
9.4
Daily cleaning - Cleaning the drip grid and the drip tray .........3
9.5
Weekly cleaning - Cleaning the outlet trough ...........................4
9.6
Weekly cleaning - Cleaning the trough support ........................5
9.7
Weekly cleaning - Cleaning the cooling compartment .............6
June 2003
9-1
Cleaning and Maintenance
Service Manual Cafitesse 300
9 Cleaning and Maintenance
9.1 General Instructions
•
Switch off the power switch before starting to clean the dispenser.
Observe the cleaning instructions at the dispenser.
•
Carry out all instructions given in the maintenance time schedule. Observe the indicated intervals. Otherwise
any warranty claims will not be fulfilled.
•
To guarantee proper execution of all procedures, read the corresponding sections in these operating
instructions before starting to carry them out.
When cleaning the dispenser, be aware of sharp edges. There is
danger of injuries! Never clean the dispenser under running water.
It suffices to clean it with a wet cloth.
•
Use only cleaning agents approved by the food industry. Do not use any scouring agents to clean the outlet
troughs and the housing.
Make sure that all parts are installed properly after having
cleaned the dispenser.
9.2 Maintenance Time Schedule
Interval
Kind of work
Daily cleaning
Cleaning the outside of the dispenser
Cleaning the drip grid and the drip tray
Weekly cleaning
Cleaning the outlet trough
Cleaning the trough support
Cleaning the cooling compartment
9-2
June 2003
Service Manual Cafitesse 300
Cleaning and Maintenance
9.3 Daily cleaning - Cleaning the outside of the dispenser
•
Clean the outside of the dispenser daily with a wet, clean cloth.
9.4 Daily cleaning - Cleaning the drip grid and the drip tray
•
•
Remove the drip grid (1) and the drip tray (2)
and clean them in hot water to which a small amount
of detergent has been added. (Fig. 1)
Rinse the drip grid (1) and the drip tray (2) with
clean water, dry and then reinsert them. (Fig. 1)
After cleaning, mount the drip tray with the
drip grid in the correct position on the dispenser. Otherwise water can drop on the
floor (danger of injuries).
Fig. 1
June 2003
9-3
Cleaning and Maintenance
Service Manual Cafitesse 300
9.5 Weekly cleaning - Cleaning the outlet troughs
•
Open the dispenser door.
•
Pull out the outlet troughs (1) to the front. (Fig. 2)
•
Separate the troughs cover (1) from the troughs (2).
(Fig. 3)
•
Clean both parts in hot water to which a small
amount of detergent has been added.
•
Rinse both parts with clean water and dry them.
•
Place the trough covers on the troughs. (Fig.3)
First let the front part of the cover snap in and then
the back part.
Do not press too strong. There is danger of
breaking.
•
Check that the rim of the cover has snapped in
completely.
Fig. 2
Fig. 3
9-4
June 2003
Service Manual Cafitesse 300
Cleaning and Maintenance
9.6 Weekly cleaning - Cleaning the trough support
•
Loosen 2 knurled-head screws (1) and remove them
with the trough support (2). (Fig. 4)
•
Clean the trough support in hot water to witch a small
amount of detergent has been added.
•
Rinse the trough support with clean water, dry and then
reinsert it.
•
Retighten the knurled-head screws.
•
Only the left and middle through supports are
removable. The support for the water through (K72)
should not be removed.
Fig. 4
June 2003
9-5
Cleaning and Maintenance
Service Manual Cafitesse 300
9.7 Weekly cleaning - Cleaning the cooling compartment
•
Open the dispenser and the cooling compartment
door, and take out the concentrate packs (Fig. 5).
If the cooling compartment is not
operated for more than 10 min., e. g.
when defrosting, store the concentrate
packs in a separate refrigerator.
•
Clean the cooling compartment with a wet cloth
and the brush which has been delivered with the
dispenser. (Fig.6).
•
•
If the refrigerator is iced up, proceed as follows:
- Open the dispenser door.
- Switch the power switch to "0".
- Pull out the power supply plug. Do not close the
cooling compartment when you let the compartment
defrost.
- Clean the cooling compartment with a wet cloth and
the brush which has been delivered with the
dispenser.
Fig. 5
Dry the cooling compartment.
Do not pour any water into the cooling
compartment.
•
Reinsert the concentrate packs.
•
Make sure that the drip tray is positioned
correctly.
Fig. 6
9-6
June 2003
Service Manual Cafitesse 300
Circuit Diagram
10 Circuit Diagram
June 2003
10 - 1
Circuit Diagram
10 - 2
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Fault Diagnosis
11 Fault Diagnosis
Contents
11.1
Dispensing Fault Diagnosis by using the Service Device .....2
11.2
General Fault Diagnosis ............................................................3
June 2003
11 - 1
Fault Diagnosis
Service Manual Cafitesse 300
11 Fault Diagnosis
•
The fault diagnosis list on the following pages is divided into two sections. Section 11.1 applies only to
dispensing faults on machines fitted with the Cafitesse 300 Flexi MP Control Board. Section 11.2 applies to
general faults on all dispensers.
•
It is recommended that a known good control board of each type and an interface be kept at hand to be used
as test boards. They can be applied in cases where "Replace control board" and "Replace interface" are
listed in the fault diagnosis tables.
11.1 Dispensing Fault Diagnosis by using the Service Device
•
Dispensing defects on machines fitted with the Cafitesse 300 Flexi MP Control Board can be diagnosed with
the aid of the Service Device 2. The diagnosis is based on a combination of the following:
- The type of error display on the service device
- The type of dispenser malfunction
- Fault indication on the dispenser (EMPTY indicator LEDs flashing)
• To diagnose the fault:
1. Connect and switch service device ON.
2. Switch dispenser power switch OFF (on model K72, leave the dispenser ON and press and release the door
frame switch. The service device fault display then comes on. To reset fault indication after the defect has
been repaired, disconnect and reconnect power supply to dispenser.
Before using the service device, check whether the Yellow and Green LEDs on the control board
are ON. If both indicators are not ON, check Fuses F01 and F02 and power pack for defects.
11 - 2
June 2003
Service Manual Cafitesse 300
Fault Diagnosis
Indication / Display
1.
Empty indicators flashing
Dispensing: only concentrate
Possible Cause
Remedy
Fault in water delivery coil
circuit (a safety circuit breaks off
the supply to all coils after 5
seconds)
A.
Water coil defective.
A.
Check resistance of all
water coils. Proper
resistance is 12-15 ohms.
Replace out-of-tolerance
coils.
B.
Control board defective.
B.
Replace control board.
Cooling: OK
Display:
-ERRORWater valve control
2.
Indication: None
Impulse form not within
tolerance during the last
dosing
Dispensing: OK
A.
Concentrate pack dosing
tube defective
A.
Correct/Replace.
B.
Control board defective.
B.
Switch dispenser ON and
dispense several times. If
display is repeated,
replace control board.
Empty indicators flashing
A.
Flexi-pack dosing the
defective.
A.
Replace pack.
Dispensing: Only water
B.
Fault in concentrate coil
circuit (a safety circuit
breaks of the supply to all
coils after 5 seconds)
Concentrate coil or control
board defective.
B.
Check resistance of
product coils. Proper
resistance is 0.95 ohms.
Replace out-of-tolerance
coils.
C.
Replace control board.
Display:
-ERRORLast dosing
(To be regarded as a defect only
if displayed after every delivery.)
3.
Display:
-ERRORLast dosing
4.
Empty indicators flashing
A.
The parameters have not
been programmed in the
board
A.
Program board.
B.
Data in board lost after
programming.
B.
Reprogram board.
C.
Control board defective.
C.
Replace board.
Dispensing: No Dispensing
Display:
-ERRORLast dosing
June 2003
11 - 3
Fault Diagnosis
Service Manual Cafitesse 300
11.2 General Fault Diagnosis
Indication / Display
Possible Cause
Remedy
General
1.
2.
11 - 4
No function.
Only cooling system functions.
A.
Mains fuse blown or
defect in supply line.
B.
Connections on supply
line/mains plug loose or
mains cable defective.
A.
Replace with fuse of
correct value. Check
mains outlet for power with
a voltmeter
B.
Check power line/mains
plug and mains terminal
X01 connection.
A.
Dispenser not switched
ON.
A.
Switch ON.
B.
Fuse F03 on power pack
blown.
B.
Replace fuse.
C.
Bridges on voltage
selector plug ST20 or
mains terminal X01 in
power pack not positioned
correctly.
C.
Check and connect as set
down in Section 5.3.
D.
Transformer defective.
D.
Check for 9/20/24V AC on
BU 01; replace if no
voltage.
3.
Apart from cooling and heating,
no function.
A.
Defect in control board
supply. Fuse F01 blown or
defect in power pack.
A.
Check yellow LED on
control board. If OFF,
check fuse F01 and power
pack output on BU 01.
4.
No delivery with one delivery
button.
A.
Button microswitch
defective.
A.
Replace microswitch.
June 2003
Service Manual Cafitesse 300
Indication / Display
Fault Diagnosis
Possible Cause
Remedy
Water
1.
2.
3.
4.
June 2003
Water runs from overflow when
dispenser is ON or OFF.
Water runs from overflow only
when dispenser is ON.
Water leaks out of trough.
Water leaks out into dispenser.
A.
Inlet valve jammed or
membrane damaged.
A.
Clean/Replace valve.
B.
Water line pressure too
low.
B.
Correct defect in water
mains.
A.
Float wire jammed or
boiler lid deformed.
A.
Descale boiler/Replace
boiler lid.
B.
Float switch defective or
not correctly installed.
B.
Check whether arm is
bent, spring is in place or
fixed too high. If OK,
check inlet valve for
voltage with arm raised to
maximum. If voltage
present, replace switch.
A.
Outlet valve plunger not
seating due to scale
deposits.
A.
Descale boiler. Dismantle
and clean outlet valves.
B.
Plunger seal damaged.
B.
Replace.
C.
Outlet valve body
damaged.
C.
Replace.
A.
Outlet elbow or trough inlet
incorrectly fitted.
A.
Rectify.
B.
Outlet elbow blocked.
B.
Clean.
C.
Seal on outlet tube, valve
body or heating element
damaged.
C.
Replace.
D.
Boiler tank damaged.
D.
Replace.
11 - 5
Fault Diagnosis
Service Manual Cafitesse 300
Indication / Display
5.
6.
11 - 6
No water delivery, boiler empty
or partially empty.
Irregular water dosage.
Possible Cause
Remedy
A.
Mains valve closed, water
line blocked or supply
inadequate.
A.
Open valve. Check water
supply line with tester
M-2215.
B.
Sieve in water inlet valve
blocked.
B.
Clean.
C.
Fuse F02 blown or defect
in power pack.
C.
Check fuse. Check
voltage on BU 01; if no
voltage, check power pack.
D.
Float switch defective.
D.
Check voltage on inlet
valve with float switch arm
completely lowered. If no
voltage, replace float
switch.
E.
Inlet valve defective or
jammed.
E.
Check resistance of coil. If
not approx. 24 ohms,
replace coil. If resistance
is OK, clean valve.
F.
Float wire jammed.
F.
Clean/Descale boiler.
A.
Water level in boiler
fluctuating, supply
inadequate.
A.
Check water supply with
tester M-2215.
B.
Control board defective.
B.
Replace.
June 2003
Service Manual Cafitesse 300
Fault Diagnosis
Indication / Display
Possible Cause
Remedy
Heating
1.
2.
June 2003
No heating.
Water boils.
A.
Dispenser not switched
ON.
A.
Switch ON.
B.
Thermostat is OFF.
B.
Set thermostat.
C.
Boiler not full.
C.
As under “WATER, 6”
D.
Thermostat defective.
D.
Set to maximum and
check continuity. Replace
if no continuity.
E.
Temperature limiter
contacts open or limiter
defective.
E.
Press reset button. If still
no heating, check
continuity. Replace if no
continuity.
F.
Safety thermostat contacts
open or thermostat
defective.
F.
As “D” above.
G.
Heating element defective.
G.
Check for continuity and
short circuit. Replace if no
continuity or shorting.
H.
Power relay defective.
H.
Check/Replace.
A.
Thermostat set to high.
A.
Reduce.
B.
Thermostat switches off
too late. Scale deposits on
sensor.
B.
Descale boiler.
C.
Thermostat does not
switch OFF.
C.
Turn thermostat OFF and
check continuity. If not off,
replace thermostat.
D.
Power relay defective.
D.
Check/Replace.
11 - 7
Fault Diagnosis
Indication / Display
Service Manual Cafitesse 300
Possible Cause
Remedy
Cooling
1.
2.
3.
4.
11 - 8
No cooling.
Insufficient cooling.
Cooling unit does not switch off.
Cooling unit running but does
not cool.
A.
Thermostat OFF.
A.
Switch ON.
B.
Thermostat defective.
B.
Set to maximum and
check for continuity.
Replace if no continuity.
C.
Back pressure in system.
C.
Disconnect dispenser from
mains for at least 10
minutes.
D.
Starting devise on
compressor defective.
D.
Replace
A.
Cooling compartment door
seal damaged or door not
closing properly.
A.
Replace door seal or door
latch.
B.
Thermostat set to low.
B.
Adjust.
C.
Evaporator iced up.
C.
Defrost by disconnecting
dispenser from mains.
D.
Condenser covered or
dusty.
D.
Clean and vacuum
cleaner.
E.
Ambient temperature at
dispenser location too
high.
E.
Relocate dispenser.
A.
Thermostat sensor has
slipped from mounting in
cooling compartment.
A.
Fix sensor.
B.
Thermostat defective.
B.
Set to minimum and check
continuity. Replace if
continuity present.
A.
Capillary tubes in the
cooling system blocked.
A.
Switch OFF cooling for at
least 2 hours. If still no
cooling, replace unit.
June 2003
Service Manual Cafitesse 300
Fault Diagnosis
Indication / Display
Possible Cause
Remedy
Empty Indicators
1.
2.
June 2003
No empty indication, concentrate
pack empty.
Indicates empty, concentrate pack
full, no delivery.
A.
Dried concentrate on guide
tube of concentrate coil.
A.
Clean with dampened brush.
B.
LED on door, transmitter or
receiver on concentrate coil
defective or control board/
interface (if fitted) defective.
B.
Replace control board and
LED in turn. If not cured,
replace diode carrier
completely.
A.
Concentrate pack, dosing
tube incorrectly positioned or
pack defective.
A.
Correct/Replace.
B.
Receiver on concentrate coil
defective or control board/
interface (if fitted) defective.
B.
Replace control board. If not
cured, replace diode carrier
completely.
11 - 9
Fault Diagnosis
11 - 10
Service Manual Cafitesse 300
June 2003
Service Manual Cafitesse 300
Troubleshooting
12 Troubleshooting Reference
Contents
12.1
Primary Check List......................................................................2
12.2
Inlet Water ...................................................................................3
12.3
Water Dispense ..........................................................................4
12.4
Product Dispense .......................................................................5
12.5
Empty Circuits ............................................................................6
12.6
Refrigeration Not Cooling .........................................................7
12.7
Unit Is Not Heating a)..................................................................8
12.8
Unit Is Not Heating b) .................................................................9
12.9
Power Pack ...............................................................................10
June 2003
12 - 1
Troubleshooting
Service Manual Cafitesse 300
12 Troubleshooting Reference
12.1 Primary Check List
1. Is the unit connected to a water supply?
Check the shut off valve. Is it open?
Check for line pressures at the unit.
2. Is the unit connected to a power source?
Check for the presence of line voltage 208 to 240V AC at the unit.
3. Check the line cord and plug connections.
4. Check the power pack fuses.
5. Check the power pack and base board for loose or disconnected plug(s).
6. 6. Is the MP-Board installed correctly, unplugged or loose?
7. Check the main (front) door. Is it closing correctly?
Is the safety door switch being activated?
8. Check the position of the overnight switch (Down = ON).
9. Check the MP-Board yellow and green LEDs. Are they ON?
10. Check the main (front) door. Is the green lamp ON?
11. Check the red empty LEDs located next to the dispense handles on the main door. Are they ON?
12 - 2
June 2003
Service Manual Cafitesse 300
Troubleshooting
12.2 Inlet Water
WHEN CHECKING THE INLET CIRCUIT, THE THERMOSTAT MUST BE OFF! THE UNIT WILL COOL AND
DISPENSE PRODUCT, BUT NO WATER.
FLOAT WIRE CHECK - It should be placed (hung) on the float switch arm pulling it DOWN. Check the float switch
arm and wire for free movement.
FLOAT SWITCH - Check the float switch harness and 3-pin male plug. The plug used to connect the float wire switch
to the base (main) board is BU 10.
WATER SUPPLY - Check the water supply. Is the shut off valve OPEN? Check for water pressure at the inlet valve.
If there is a line filter it may be clogged.
SWITCH ARM - With the thermostat OFF and the overnight switch ON with the float switch arm DOWN, check for 23
to 26V AC at the inlet valve coil. Do not unplug or remove the wires!
HARNESS VOLTAGE - Check plug BU 11, located along the lower left edge of the base board. This 2-pin male plug
supplies 23 to 26V AC to the wire harness and the inlet valve coil when it is plugged in.
COIL - Remove the inlet valve coil from the valve body. Hold a metal screwdriver DOWN into the coils center (core).
Move the float switch arm UP and DOWN. The screwdriver should pull or move when a voltage reading is present at
the coil.
COIL OHMS - No magnetic field when AC voltage is present at the coil. Remove the coil wires to take a resistance
reading. A reading of 28 to 32 ohms is acceptable.
SWITCH VOLTAGE - No AC voltage present at the coil with the overnight switch ON and the float switch arm
DOWN. Check across the float switch plug BU 10 pins 1 and 2. A reading of 23 to 26 Volts AC indicates a defective
(OPEN) float switch. Do not unplug from the base board when performing this test.
SWITCH CONTINUITY - Remove the float switch plug BU 10 from the base board. Use pins 1 and 2 of the male plug
to test for switch continuity.
VOLTAGE CHECK - A jumper wire can be inserted between pins 1 and 2 of plug 10 on the base, to momentarily test
the 23 to 26V AC being supplied to the inlet coil. Test for voltage at the coil with the wires connected and with the
jumper in place.
BOARD CIRCUIT - A defective coil or shorted wire can damage the foil traces of the base board creating an open
circuit.
VALVE - A defective valve should be rebuilt or replaced.
June 2003
12 - 3
Troubleshooting
Service Manual Cafitesse 300
12.3 Water Dispense
THE UNIT WILL DISPENSE PRODUCT, NO WATER
The float wire and switch arm should be UP when the tank is full.
WATER ONLY - The unit will dispense water only from the white water switch or the red Tomlinson handle.
NOTE: Are the red empty LEDs ON?
FLEXI-PACKS™ - Check the product. Are the Flexi-Packs™ empty? The coffee handles will not dispense water if
the red LEDs are ON.
COIL - Check the unit to dispense product from the left and right coffee handles. No water with the float wire and
switch arm UP and the tank full.
LT-COIL VOLTAGE - Check the DC voltage being supplied to the water outlet coils. Plug BU 12 on the base board
supplies 15 to 20 Volts DC to the left outlet water coil. pin 1 = - and pin 2 = +.
RT-COIL VOLTAGE - Plug BU 13 on the base board supplies 15 to 20 Volts DC to the right outlet water coil.
pin 1 = - and pin 2 = +. DO NOT REMOVE PLUGS from the base board when taking Voltage Readings.
OHMS CHECK - Remove the water outlet coil plugs 12 and 13 from the base board when taking resistance readings.
A reading of 12 to 15 ohms is acceptable.
PLUG NUMBERS - To take an ohms reading, use the 2-pin brown male plug located at the end of the coil harness.
Plug BU 13 = RIGHT and plug BU 12 = LEFT water coil(s).
LT-COIL - Check on Cafitesse 300 3 handle units. When taking an ohms reading of the left water coil, it will be
necessary to locate its plug BU 12. Follow the left coil wire harness over to the right. Remove the 2-pin male plug
from the jumper harness. Take the ohms reading at the 2-pin male plug marked 12.
HOT WATER COIL OHMS - Check on Cafitesse 300 3 handle units. When taking ohms reading of the 3rd hot water
coil, it will be necessary to locate the coils wire harness. This outlet water valve and coil is mounted in the center rear
bottom portion of the water tank. Follow the coils wire harness across and to the right. Remove the 2-pin male plug
from the jumper harness. Take the ohms reading at the 2-pin male plug marked 50.
HOT WATER COIL VOLTAGE - Check on Cafitesse 300 3-handle units. To take a reading of the DC voltage being
supplied to the 3rd hot water coil, use pin 2 of plug BU 12 = + and pin 6 of plug BU 15 = -. Pull the handle down to
test. 15 to 20 volts DC is acceptable.
12 - 4
June 2003
Service Manual Cafitesse 300
Troubleshooting
12.4 Product Dispense
THE UNIT WILL DISPENSE WATER ONLY, NO PRODUCT.
Check for a magnetic pulse action in the coil when the handle or push button is activated and the unit is dispensing
water.
PULSE AND DOSER CHECK - When a pulse action is present in the coil, check the dosing tube. It may be clogged.
Place the tip of the dosing tube in a cup of hot water for approximately 1 minute. Replace the Flexi-Pak™ and try to
dispense product.
VOLTAGE SUPPLY (COILS PLUGGED IN) - Check the voltage being supplied to the product coils. Set the ratio on
both the left and right sides for 19 to 1. Next, program the deliver for continuous flow. Use pins 3+ and 6- for the left
coil and pins 9+ and 12- for the right coil. An AC analog meter reading of approximately 3 to 5 volts is acceptable.
BASE BOARD VOLTAGE (COILS UNPLUGGED) - No voltage being supplied to the product coil(s). Remove the
12-pin product coil(s) plug from the base board. Test for voltage at the 12-pin female plug 6, located in the lower right
corner of the base board. Use pins 3+ and 6- for the left coil and pins 9+ and 12- for the right coil. An AC analog
meter reading of approximately 5 to 7 volts is acceptable.
BASE BOARD CHECK - No voltage being supplied to the product coils from the base board may indicate a
defective plug in circuit MP-Board or a defective main base board. With the product coils unplugged, try another
circuit board first.
COIL(S) CHECK - A reading of approximately 7 volts AC is being supplied to the product coil(s), with the 12-pin male
plug in the base board. It will be necessary to take an ohms reading of the product coils.
COIL OHMS CHECK - Remove the product coil(s) 12-pin plug from the base board. Take the ohms readings at the
male harness plug. Use pins 3 and 6 for the left coil and pins 9 and 12 for the right coil. A reading of .95 to 1 ohm is
acceptable.
COIL OHMS RANGE - A reading higher than 1 ohm or below .95 indicates a defective coil that should be replaced.
COIL REPLACEMENT - When changing a product coil assembly, note the double numbering system printed on the
wires. Examples: 1 and 7, 2 and 8, 3 and 9, 4 and 10, 5 and 11, 6 and 12. When replacing a coil located on the left
side of the cooling compartment, use the low numbers, 1 to 6. When replacing a coil located on the right side use the
high numbers, 7 to 12.
COIL REPLACEMENT - Check coil wire numbers and components, eye 1 and 7- 4 and 10+, lamp 2 and 8- 5 and
11+, prod coil 3 and 6- 9+ and 12-.
June 2003
12 - 5
Troubleshooting
Service Manual Cafitesse 300
12.5 Empty Circuits
THE UNIT WILL ONLY DISPENSE HOT WATER FROM THE WHITE ROCKER SWITCH OR THE
RED TOMLINSON HANDLE.
No product or water delivery from the coffee dispense buttons or handles.
EMPTY LEDS - Check the main front door. Are the red Empty LEDs ON?
FLEXI-PACKS™ - Remove and shake the Flexi-Pack(s)™. Also check for coffee product in the doser. Replace the
Flexi-Pack and try to dispense product and water with the Red empty LEDs out.
CLEAN AND TEST - Check that the red empty LEDs are ON. Remove the Flexi-Pack(s)™ and clean the upper
center portion of the product coil. Block the coil with an opaque object to see if the Empty LEDs go out. Try to
dispense water if the LEDs are OFF.
COIL PLUG - Check after cleaning the coil(s) and replacing the Flexi-Pack(s)™. If the Red LEDs stay ON, remove
the 12-pin male product coil plug 6 from the base board. This plug is located in the lower right corner.
EMPTY EYE RECEIVER - Check with the 12-pin plug removed, check the red empty LEDs. If they are OUT, try to
dispense water from the left and right product handles or buttons. If water can be dispensed, the problem may be a
defective or shorted photo receiver.
EYE CHECK - Remember to plug the product coil(s) into the base board before checking the photo eye receiver and
lamp transmitter circuits.
LEFT EYE VOLTAGE CHECK - To check the left eye receiver, use pins 1 and 4 of the product coil(s) 12- pin plug.
Pin 1 (-) and pin 4 (+) reading of 2-1/2 volts DC is acceptable with the coil blocked when using an analog meter. A
reading of 3-3/4 volts DC with the coil blocked is acceptable when using a digital meter.
RIGHT EYE VOLTAGE - To check the right eye receiver, use pins 7 and 10 of the product coil(s) 12-pin plug. A pin
7 (-) and pin 10 (+) reading of 2-1/2 volts DC is acceptable with the coil blocked when using an analog meter.
A reading of 3-3/4 volts DC with the coil blocked is acceptable when using a digital meter.
VOLTAGE CHECK - With the coil unblocked (OPEN), look for a voltage drop from 2-1/2 to 1/2 volt DC or 3-3/4 to 1
volt DC, depending on the type of meter being used.
LAMP VOLTAGE CHECK - To check the left lamp transmitter, use pins 2 and 5 of the product coil(s) plug. pin 2(-)
and pin 5 (+), use pin 8 (-) and pin 11 (+) to check the right transmitter. A reading of 1 to 1-1/4 volts DC is acceptable.
A reading of 18 to 20 volts DC indicates an open or defective lamp.
12 - 6
June 2003
Service Manual Cafitesse 300
Troubleshooting
12.6 Refrigeration Not Cooling
Check the thermostat setting. Turn the knob clockwise to lower the cooling compartment temperature.
Set the dial indicator at 2. The numbers should be located on the dials lower portion, centered,
and facing down.
POWER PACK VOLTAGE - Check the compressors AC supply voltage. Use BU 21 a 3-pin plug. It is located in the
center of the power pack along the lower edge. Use pins 1 and 3 to take line voltage reading. The compressor
operates on voltages between 208 to 240V AC.
START RELAY CHECK- Check for AC voltage at the start relay. If line voltage is present at pins 1 and 3 of BU 21, do
not unplug from power pack. Loosen the 6mm hex screw and remove the start relay cover by lifting up and tilting it
forward at the same time.
START RELAY VOLTAGE - With the thermostat turned up full clockwise until it stops, check for line voltage between
contacts N and C of the start relay. N is located in the upper left corner and C is located in the center, along the
bottom edge. A line voltage reading of 208 to 240V AC should be present between contacts N and C if the thermostat
is operational.
THERMOSTAT CHECK - If no line voltage is present between N and C of the start relay with the thermostat turned
up full, check across the thermostat contacts. If line voltage is present at the thermostat, it is defective and should be
replaced.
START RELAY CHECK- If line voltage is present between contacts N and C but the compressor fails to operate, you
may have a defective start relay or an open circuit in the compressor motor.
RELAY REPLACEMENT - To replace the start relay, unplug BU 21 from the power pack, next remove the start relay
by pulling it straight forward. Align the new start relay with the contact pins mounted on the compressor. Push it
forward until it stops. Replace the wires N and C one by one.
COMPRESSOR VOLTAGE - Plug BU 21 back into the power pack to test the refer unit. If the unit still will not cool,
check for line voltage between contacts N and C. The compressor operates on 208 to 240 volts AC.
COMPRESSOR OHMS CHECK - If line voltage is present between contacts N and C, unplug Bu 21 from the power
pack. Then remove the start relay from the compressor. Take an ohms reading of the motor. Between the lower
center pin and the upper right pin, a reading of approximately 15 to 17 ohms is acceptable. Between the center pin
and the upper left pin a reading of 14 to 16 ohms is acceptable. Across both upper pins, a reading of 29 to 33 ohms is
acceptable. Center and upper right = start winding. Center and upper left = run winding.
June 2003
12 - 7
Troubleshooting
Service Manual Cafitesse 300
12.7 Unit Is Not Heating a)
Check the thermostat setting. Turn the device clockwise to increase the temperature. Adjust the thermostat
counter clockwise to zero then back to its original position. Listen for the contactor dropping out and pulling in.
THERMOSTAT CHECK - The unit is dispensing product and cold water. No sound of the contactor is detected as the
thermostat is adjusted up and back. Turn the thermostat clockwise until it stops. The device should be adjusted to its
highest setting.
THERMOSTAT SWITCH CHECK - Check for 24 volts AC across the contacts of the thermostat with the wires
connected. If voltage is present, the device is defective and should be replaced.
CONTACTOR AND CIRCUIT CHECK - The thermostat is turned up clockwise until it stops. No AC voltage is present
across the thermostat contacts. Also there is no sound of the contactor pulling in. The thermostat contactor wire
circuit or the relay coil may be defective.
THERMOSTAT CONTACTOR TEST - Check thermostat circuit, momentarily insert a bridge between pins 10 and 12
of BU 01. The 12-pin plug is located in the center of the power pack. If the contactor pulls in, check the wires to the
thermostat for continuity. If the contactor can be activated by bridging pins 10 and 12, try using the same bridge
across the thermostat contacts with the wires connected. The contactor should pull in.
CONTACTOR COIL CHECK - If the thermostat contactor will not activate it may be necessary to take an ohms
reading of the relay coil. Remove BU 01, the 12-pin plug located in the center of the power pack. Also remove Plug
BU 20 the 6-pin jumper plug located in the lower right corner of the power pack.
CONTACTOR OHMS READING - To take an ohms reading of the thermostat contactor relay coil, use pin 11 the
common and pin 10. A reading of 5 to 7 ohms is acceptable. At this time, it is possible to take an ohms reading of the
safety contactor relay coil. Use pin 11 the common and pin 9. A reading of 5 to 7 ohms is acceptable. The ohms
reading is taken at plug BU 01, located in the center of the power pack with the male plug removed.
PLUG CHECK - Plug the 6-pin jumper BU 20 and the 12-pin male wire harness plug into the power pack before
checking the safety contactor relay circuit.
SAFETY CIRCUIT CHECK - The boil over and the low water safety limiter are wired in series and terminates in a
6-pin plug 2, located in upper left corner of the base board, the second one down. With the overnight switch ON,
place a bridge between pins 3 and 6 to momentarily test the safety contactor relay circuit.
COMPONENTS CHECK- If the safety contactor pulls in, try using the same bridge across the contacts of the boil
over and the safety limiter. Do not remove the wires from either device when testing. The contactor will activate when
the bridge is placed across a defective device. Reset or replace as needed.
12 - 8
June 2003
Service Manual Cafitesse 300
Troubleshooting
OPEN CIRCUIT CHECK - Check for 24 volts AC across the contacts of the boil over, the safety limiter, and the
adjustable thermostat. A voltage reading indicates a defective device. Do not remove the wires from any device
when testing for voltage.
COMPONENTS TEST - Remove one wire from each device to check the individual components for continuity.
Replace open or defective components. Assume the defective parts have been replaced. If the contactors fail to
function after all the wires are reconnected, with the overnight switch and the thermostat ON and the 12-pin male
plug inserted in BU 01 of the power pack. The next step is to check for voltage.
POWER PACK - Check the AC voltage being supplied to the individual components with the overnight switch and
the thermostat ON.
THERMOSTAT CONTACTOR VOLTAGE - Check between pins 10 and 11 of plug BU 01 for 24V AC. This supply
operates the tank temperature contactor located forward close to the fuse holders. pin 11 is a tie point. A long contact
on the meter probe or a piece of wire may be necessary in taking this reading.
SAFETY CONTACTOR VOLTAGE - Check between pins 9 and 11 of plug BU 01 for 24V AC. This supply operates
the safety contactor located toward the rear of the power pack next to the transformer. If voltage can be checked at
these points, but the contactors fail to operate, the relay coils may be open if you can not get an ohms reading. The
connection between plug 1 and BU 01 of the power pack may need to be checked for continuity.
CONTACTOR ENERGIZED - Both contactors must be energized (down) before the unit will heat. If the unit fails to
heat with both contactors down.
TERMINAL BLOCK CHECK - Check the terminal block. A jumper is always needed between 1 and 2. This will allow
the unit to heat using one 3000 watt element on a 20 amp service. A jumper between sections 3 and 4 will allow the
unit to heat using a second 3000 watt element totaling 6000 watts of heating on a 30 amp Service.
ELEMENT VOLTAGE CHECK - Remove plug BU 22 from the power pack. With the overnight switch and the
thermostat ON, check for line voltage between pins 5 and 8. This is the main element. Check between pins 6 and 9.
They are for the second element. Line voltage should read 208-240 volts.
June 2003
12 - 9
Troubleshooting
Service Manual Cafitesse 300
12.8 Unit Is Not Heating b)
REVIEW THE TANK ELEMENT - ELEMENT CHECK
Check the tanks heating element. Remove plug BU 22 from the power pack when taking an ohms reading
of the element.
ELEMENT PLUG WIRING - Note the wire arrangement in the 9 pin (male) plug.
• The 2 black wires in the upper left corner of the plug.
• The 2 brown wires to the left and in the center.
• The 2 blue wires in the lower left corner of the plug. The 1 green wire in the center along right edge of the plug.
This is the ground wire. It is connected to the elements outer casing. This element contains 3 separate heating
circuits.
MAINS ELEMENT OHMS - Check Between pins 5 and 8, the two brown wires located in the center of the plug. This
is the main heating element and always receives power when the unit is in a heating cycle.
SECOND ELEMENT OHMS - Check between pins 6 and 9, the two blue wires located at the bottom of the plug. A
reading of 14 to 16 ohms is acceptable. This is the second heating element. It only receives power when the jumper
between sections 3 and 4 of the terminal block is in place and the unit is in a heating cycle.
SPARE ELEMENT OHMS - Check between pins 4 and 7, the two black wires located at the top edge of the plug. A
reading of 14 to 16 ohms is acceptable. This is a spare element. It only functions when the contact pins are moved to
positions 5 and 8 or 6 and 9 as needed.
OHMS TO GROUND CHECK - Whenever the spare element is used to replace a defective heating section, it will be
necessary to check all 6 element wires for continuity to ground. An open element may short to ground. If an ohms
reading can be taken between the heater wires and ground, the element should be changed.
SPARE ELEMENT LOCATION - Check in older units; you may find the spare element wires switched with the
second element. In the K-71 units, the top wires for the spare element are blue. In the Cafitesse 300 units, the top
wires for the spare element are black. Both units use the two brown wires in the center for the main element.
!!HEATING CIRCUIT CHECK!! - When changing tanks and elements, always check the position of the wires
in plug BU 22. Tanks from older K-71 units are not wired the same as the latest Cafitesse 300. Switching a
tank in some cases will blow the 220 volt breaker or fuse. A hot leg may be connected to ground. An
interpose adapter cable G-5908 is available to correct this situation.
12 - 10
June 2003
Service Manual Cafitesse 300
Troubleshooting
12.9 Power Pack
CHECK THE 4 SECTION TERMINAL. A jumper plug is always necessary between sections 1 and 2.
Without the jumper, the unit will not heat.
HEATING ELEMENT - Check the power being supplied to the unit, 208 to 240V AC amp service. A jumper bridge
between sections 1 and 2 of the terminal block will allow the unit to heat using a 3000 watt element on a 20 amp
service.
HEATING 2 ELEMENTS - If a 30 amp service is available, a second jumper bridge can be placed between sections
3 and 4 of the terminal block. This will allow the unit to heat using two elements at a total of approximately 6000 watts
on a 30 amp service.
VOLTAGE ADJUSTMENT - Check the voltage at the power source for 208, 220 or 240 volt AC operation. To adjust
the unit to the incoming voltage, use the jumper plug BU 20, a 6-pin connector located in the lower right corner of the
power pack. Position the jumper wire between pins 3 and 6 = 208, 2 and 5 = 220, 1 and 4 = 240, operation. 3 and 6
being left, 2 and 5 center, and 1 and 4 to the far right in the jumper plug.
VOLTAGE CHECK - How to check the voltage after the unit has been installed. Remove the jumper plug BU 20. Use
any of the top 3 contact pins in the power pack for line one, and any of the 3 bottom pins for line two. An AC supply
voltage reading can be taken across these points.
REFRIGERATION VOLTAGE - To check the refrigeration supply voltage, use plug BU 21 located in the center of the
power pack along the lower edge. Use pins 1 and 3 to take a line voltage reading. The compressor operates on
voltages between 208 and 240 volts AC.
AC AND DC SUPPLY VOLTAGES -LEAVE CONNECTED - To check the AC and DC supply voltages, use plug BU
01, a 12 pin connector located in the center along the top edge of the power pack.
WATER INLET CIRCUIT - Check 20 to 25V AC between pins 2 and 8
CONTACTOR HEAT CONTROL - Check 20 to 25V AC between pins 2 and 11, a tie point.
DISPENSE COILS EMPTY CIRCUIT AND ON LAMP - Check 21 to 28V DC between pins 4+ and 5- (Yellow LED).
SOURCE FOR REGULATED 5V DC SUPPLY - Check 11 to 13V DC between pins 6+ and 5- (Green LED).
THE OVERNIGHT SWITCH - Check pins 2 and 3. They control the 20-24V AC and 28V DC.
THE TANK THERMOSTAT - Check pins 10 and 12. They control the thermostat relay.
THE SAFETY CONTACTOR - Check pins 2 and 9. They control the safety relay.
June 2003
12 - 11
Troubleshooting
Service Manual Cafitesse 300
HEATING ELEMENT SUPPLY VOLTAGE - To check the voltage being supplied to the tanks element during a
heating cycle, remove plug BU 22, a 9-pin connector located on the left side of the power pack in the middle (the
white plug). The overnight switch should be ON (down). Turn the thermostat UP (clockwise) until it stops. Check the
both contactors are energized and in a DOWN position. Use the 9-pin female plug located on the left side of the
power packs face plate when checking for line voltage.
MAIN ELEMENT - Check between pins 5 and 8. They supply voltage to the main element and should always be live
during a heating cycle.
NO VOLTAGE - Check that the jumper bridge pin between sections 1 and 2 of the terminal block is in place (never
remove this bridge).
SECOND ELEMENT - Check between pins 6 and 9. They supply voltage to the second element. With this element in
the circuit, the units heating capacity is 6000 watts and a 30 amp service is necessary.
NO VOLTAGE - Check that the jumper bridge pin between sections 3 and 4 of the terminal block is in place. Remove
this bridge when installing the unit on a 20 amp service. The heating capacity will be 3000 Watts.
FUSES - Check the 3 amp fuse F02 in the upper right corner of the power pack. It protects the 20 and 24V AC and
the 28V DC circuits, the Yellow LED on the circuit board.
FUSES - Check the 1-1/2 amp fuse F01 in the upper left corner of the power pack. It protects the rectifier that
supplies DC voltage to the regulated 5V DC logic circuit, the Green LED on the circuit board.
FUSES - Check the .75 amp fuse F03 in the center of the power pack. This fuse is in the primary circuit that supplies
power to the transformer. It protects the transformer from power surges, the Yellow and Green LEDs on the circuit
board.
REVIEW THE JUMPER PLUG BU 20 - To make the voltage adjustment, move the bridge wire and use pins:
- 3 and 6 for 208 (left)
- 2 and 5 for 220 (center)
- 1 and 4 for 240 (right)
THE BASE BOARD - Check the plug and pin positions of the main base board.
POWER SUPPLY - Check plug #3, a pin connector located in the top left corner. It supplies voltages from the power
pack to the base and the programmable plug in board. Take the voltage reading.
(READINGS)
- Between pins 1- and 3+ = 20 to 24V DC
- Between pins 4- and 5+ = 10 to 12V DC
Between pins 2 and 6 = 23 to 25V AC. This voltage reading is taken across the overnight switch circuit and should
only be present when the switch is OFF or in the UP position.
POWER SUPPLY - Check plug #2, a 6-pin connector located directly below plug #3 in the upper left corner of the
base board. It supplies one leg of the AC circuit. Check between pin 4 of plug 2 and pin 2 of plug 3. A reading of 23
to 26V AC is acceptable. The position of the overnight switch has no affect on this circuit.
12 - 12
June 2003
Service Manual Cafitesse 300
Troubleshooting
POWER AND SAFETY CIRCUITS - Remove plug 2 from the base board. Check between pins 4 and 6. A reading of
23 to 26V AC is acceptable. This is taken with the overnight switch ON. Check between pins 3 and 6. A reading of 23
to 26V AC is acceptable. In this mode, the relay coil of the safety contactor is in series. You are checking the voltage
through the coil.
SAFETY CIRCUITS - Check plug 9, a 6-pin connector located directly below plug 2 in the upper left corner of the
base board. Remove plug 9 from the base board. Use pins 2 and 4 of plug 9 to check the boil over and safety
limiter circuits for continuity.
FLOAT SWITCH - Check plug 10, a 3-pin connector located in the upper left corner of the base board. This is the
float switch plug and part of the water inlet circuit. Place a bridge between pin 1 and 2 to momentarily test the inlet
circuit. In newer units, you may find a jumper harness in plug 10. The bridge wire installed between pins 2 and 3
allows the unit to continue heating as the tank is refilled during normal dispense cycles.
DOOR HARNESS - Check plug 4, a 12-pin connector located in the upper center portion of the base board, is the
main door harness plug.
GREEN ON LAMP - Check between pin 3+ and 12- for 29 to 33V DC. This supplies power to the green lamp located
on the front door of the unit.
LEFT DISPENSE - Check the left dispense circuit by momentarily placing a bridge between pins 3 and 10 of plug 4.
RIGHT DISPENSE - Check the right dispense circuit by momentarily placing a bridge between pins 3 and 1 of plug 4.
THE BASE BOARD - Check the plug and pin positions of the main base board.
DOOR HARNESS - Check the water dispense circuit by momentarily placing a bridge between pins 3 and 1 of plug
4.
LEFT EMPTY LED - To check the supply voltage for the left LED, remove the left Flexi-Pack from the unit. Use pins
12+ and 9- of BU 4. A reading of 1 to 3 volts DC is acceptable. A higher reading of 25 to 35 DC indicates an open
LED. No voltage indicates a shorted LED.
RIGHT EMPTY LED - To check the supply voltage for the right LED, remove the right Flexi-Pack from the unit. Use
pins 12+ and 6- of BU 4. A reading of 1 to 3 volts DC is acceptable. A higher reading of 25 to 35 DC indicates
an open LED. No voltage indicates a shorted LED.
THIRD WATER COIL - Check plug 15, a 12-pin connector located directly below the door harness plug 4. Check for
coil supply voltage between pin 6- or plug 15 and pin 2+ of plug 12, a 2-pin male plug located in the lower left corner
of the base board, the 2nd plug to the right. Voltage is only present when the red water handle is activated.
RIGHT WATER COIL - Check plug 13, a 2-pin connector located in the lower left corner of the base board. Check for
coil supply voltage between pin 1+ and 2-. A reading of 15 to 20 volts DC is acceptable. Voltage is only present when
the coffee handle is activated. Unplug the coil to check. A reading of 12 to 15 ohms is acceptable.
June 2003
12 - 13
Troubleshooting
Service Manual Cafitesse 300
LEFT WATER COIL - Check plug 12, a 2-pin connector located in the lower left corner of the base board, the second
plug to the right. Check for coil supply voltage between pin 1+ and 2-. A reading of 15 to 20 volts DC is acceptable.
Voltage is only present when the coffee handle is activated. Unplug the coil to check. A reading of 12 to 15 ohms is
acceptable.
INLET WATER COIL - Check plug 11, a 2-pin connector located in the lower left corner of the base board, the third
plug to the right. Check for the solenoid coil AC supply voltage between pin 1 and 2. A reading of 23 to 26 volts AC is
acceptable. Unplug the coil to check. A reading of 28 to 32 ohms is acceptable.
PRODUCT COIL - Check plug 6, a 12-pin connector located in the lower right corner of the base board. Note the
double numbering system. When replacing the left coil use the numbers 1 to 6. When replacing the right coil, use the
numbers 7 to 12. Coil components eye 1 and 7 (-4) and 10 (+) lamp 2 and 8 (-5) and 11+. Product coil 3 and 6 and 9
and 12.
12 - 14
June 2003
Service Manual Cafitesse 300
Illustrated Parts List
13 Illustrated Parts List
Contents
13.1
Cafitesse 300 Illustrated Parts List............................................2
13.2
Outer Components......................................................................3
13.3
Circuit Board Components ........................................................4
13.4
Transformer and Microcomputer Compartment Components5
13.5
Door Assembly “K”.....................................................................6
13.6
Door Assembly “H”.....................................................................7
13.7
Door Hinge Components............................................................8
13.8
Boiler Tank Components............................................................9
13.9
Boiler Cover Components........................................................10
13.10
Water Valve Assembly Components.....................................11
13.11
Plumbing Components...........................................................12
13.12
Refrigeration System Components .......................................13
13.13
Electromagnetic Coil Assembly Components .....................14
13.14
Inner Components ..................................................................15
13.15
Cabinet Components ..............................................................16
13.16
Power Pack Assembly H2088 ................................................17
13.17
Power Pack Assembly H2077 ................................................18
13.18
Power Pack Assembly H3073 ................................................19
June 2003
13 - 1
Service Manual Cafitesse 300
Technical Service Bulletins
14 Technical Service Bulletins
Contents
Mains Power Plug; K72.......................................................... TP01030
B0207 Door Sticker Replacement; 72................................... TP01031
B-7467 Coil Cover; K72, H71 ................................................. TP01042
G-2762 and G-2730 Valve Housing; K72, H71, K73 ............. TP01043
G-0463 Diode Carrier; K72, H71 ............................................ TP01058
B-7553 Trough and B-1313 Cover; K72, H71 ....................... TP01059
B7472 Refrigeration Chamber; All........................................ TP01060
G-1270 Decor Plate, G-1273 Cover; K72, K73.............. TSB-DE-0001
D-0025, D-0038, D-0785, D-0014; K72, H71, K73 .......... TSB-DE-0002
G-2730, G2762 Valve Housing; K72, H71, K73............... TSB-DE-0003
A-0295 Clip, Heating Element; K72, H71 ........................ TSB-DE-0004
June 2003
14 - 1
Technical Service Bulletins
14 - 2
Service Manual Cafitesse 300
June 2003
Cafitesse 300: K72 - Mains Power Plug
SERVICE BULLETIN
PRODUCT: CAFITESSE 300, K72
SUBJECT: MAINS POWER PLUG
DATE: JULY 16, 2002
Manufacturer: IMI Cornelius, Inc.
From Machine number or Date: Units between 62A0215CD153 and 62A0216CD100.
Serial Number Components:
62A
02
01
CD
001
Mfg. site,
control code
Year
Week: 01 to 52
Coffee Dispenser
3 digit Sequential number,
starts at 001 each week
Modification: None required, information only.
Reason: During production, some of the units between noted machine numbers were delivered with Leviton brand power plugs in place of the Eagle brand power plug. These were used as the Eagle plug was
not available.
During manufacture of the machines, several plugs were noted to have excessive gaps beside the cord
clamping mechanism. The gaps exceeded UL’s requirements for limited access to high voltage components.
A rubber bushing was installed into the clamping mechanism to reduce the gap to a safe distance. This is
the same style of rubber bushing that is currently installed in the Eagle plug.
All Leviton brand plugs were modified to include the bushing before distribution to the field and comply
with all agency requirements. All current production units utilize the Eagle brand plug.
Replaceability: None required.
Assembly: None required.
Release Date: July 16, 2002
© 2002, IMI Cornelius, Inc.
-1-
Revision: A
Publication Number: TP01030
Cafitesse 300: K72 - B0207 Door Sticker
SERVICE BULLETIN
PRODUCT: CAFITESSE 300, K72 ONLY
SUBJECT: B0207 DOOR STICKER IS REPLACED BY NEW STICKER PART
NUMBER 620920634
DATE: JULY 16, 2002
Manufacturer: IMI Cornelius, Inc.
From Machine number or Date: Beginning with machines built mid-July, 2002.
Serial Number Components:
62A
02
01
CD
001
Mfg. site,
control code
Year
Week: 01 to 52
Coffee Dispenser
3 digit Sequential number,
starts at 001 each week
Modification: None required, information only.
Reason: New Sticker requested by DECS US Opco. Additional cleaning information with English/Spanish text.
Replaceability: New sticker will replace old in all production units. New sticker available as spare, use
new part number to order new sticker.
New sticker may be applied over old sticker, be sure surface is clean and remove any loose parts of the
old sticker. Clean with non-abrasive residue-free cleaner before installation.
Assembly: None required, information only.
Release Date: July 16, 2002
© 2002, IMI Cornelius, Inc.
-1-
Revision: A
Publication Number: TP01031
Cafitesse 300: K72, H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71
Serial Numbers affected:
From 62A0209CD001 to 62A0238CD007
Components Concerned:
B-7467 Coil Cover
What Changed:
Molding process, small dimensional changes to areas
on the part. Addition of identifying marks for field reference to new and old parts.
Why:
Cracks in the cover have occurred on some machines
due to the fit of the cover to the mating parts and the
strength of the part. The part has been modified to
eliminate interferences and the mold process changed
to maintain strength.
Interchangeability:
The new coil cover is interchangeable with the old coil
cover and all machines in the field.
What to do:
Visually inspect each unit during normal field service for
cracked coil covers. Replace cracked covers with IMI
new style covers or original Dagma cover
New style covers available from IMI have two small
raised dome areas on the top surface to distinguish
from original (see picture). IMI covers all have the part
number (B-7467) permanently molded into the bottom
of the part, Dagma covers do not.
Domes
How to Replace:
Reference service manual for replacement of B-7467
coil cover.
Warranty:
Machines delivered outside the United States: Coil
assemblies (G-0453) which contain this new part are
being sent to each country where the units in question
have been shipped. The quantity shipped will represent
the quantity of units sent to the respective country.
Replace the delivery coil with this coil and discard the
delivery coil in the machine.
Machines in the United States: Replacement coil
assemblies (G-0453) or coil covers are available at no
charge by contacting Douwe Egberts customer service.
Please obtain a return authorization number to return
defective assemblies.
Release Date: October 21, 2002
© 2002, IMI Cornelius, Inc.
-1-
Revision: A
Publication Number: TP01042
Cafitesse 300: K72, H71, K73
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71, K73
Serial Numbers affected:
From 62A0209CD001 to 62A0237CD080
Components Concerned:
G-2762 and G-2730 Valve Housing
Modification:
Water valve housing changed.
Changes are (see also picture below):
-Added material to the top of the valve body
-An additional O-Ring seal groove area
Reason:
The maximum flowrate will not adjust to 87cc/s when
the valve has been tightened too much thereby
decreasing the effective length of the valve body. Adding material to the top of the valve housing increased
the effective length of the part, allowing a sufficient flow
rate as well as providing additional reinforcement of the
valve housing. This will also assist in torque setting
requirements, prevent cracking of the valve body and
ease removal for service.
DAGMA Original Style Water Valve
IMI Old Style Water Valve and New Style Water Valve
Release Date: October 21, 2002
© 2002, IMI Cornelius, Inc.
-1-
Revision: A
Publication Number: TP01043
Cafitesse 300: K72, H71, K73
Replaceability:
Dagma part, IMI current part and IMI New part will fit all
machines. Machines in the range mentioned above
that will be installed for high volume operation (87cc/s),
it is recommended to replace the current IMI valve
housing by the Dagma part or IMI new part.
Exchange of the part is not required for machines using
flow rates below 87cc/s (standard issue K72 with
G-2730 and 4.9mm restrictor) unless cracks in the
valve housing are causing leakage.
How to Get Parts:
Machines delivered outside the United States: New
water valves are being sent to each country where the
units in question have been shipped. The quantity
shipped will represent the quantity of units sent to the
respective country. Replace the water valve and discard the water valve in the machine.
Machines in the United States: Replacement water
valves are available at no charge by contacting Douwe
Egberts customer service. Please obtain a return
authorization number to return defective assemblies.
Assembly:
Reference service manual for replacement of
G-2762/G-2730.
Replace with IMI New Part or DAGMA part.
Recalibrate machine flow-rate following replacement.
Publication Number: TP01043
-2-
© 2002, IMI Cornelius, Inc.
Cafitesse 300: K72, H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71
Serial Numbers affected:
From 62A0209CD001 to 62A0228CD189
From 62A0228CE220 to 62A0230CD021
This bulletin is applicable for machines in the two
ranges above only.
Parts Concerned:
G-0463 Diode Carrier (part of G-0453 Coil Assembly).
For ease of service, the coil assembly is replaced.
What Changed:
Diode carriers in IMI Cornelius machines were changed
to use the same LED’s as in Dagma machines to provide correct sensing circuit for empty detection.
Why:
The empty detection does not work properly with IMI
Cornelius built machines for serial number range indicated in this bulletin. An empty coffee concentrate
package may not trigger the empty detection indicator
(red LED) on the door.
Do This:
Replace delivery coil G-0453 with Dagma or IMI delivery coil G-0453. All IMI built spare delivery coils use
the same LED set as the Dagma deliver coils.
Machines delivered outside the United States: Coil
assemblies are being sent to each country where the
units in question have been shipped. The quantity
shipped will represent the quantity of units sent to the
respective country. Replace the delivery coil with this
coil and discard the delivery coil in the machine.
Machines in the United States: Replacement coil
assemblies are available at no charge by contacting
Douwe Egberts customer service. Please obtain a
return authorization number to return defective assemblies.
Reference:
Release Date: October 16, 2002
© 2002, IMI Cornelius, Inc.
Coil assemblies delivered by IMI Cornelius both for
replacement and in production are now marked with
paint (green or white) on the orange coil assembly wire.
See Figure 1. This is to identify the coil assemblies that
use the same LED’s as the DAGMA coil assemblies.
-1-
Revision: A
Publication Number: TP01058
Cafitesse 300: K72, H71
Figure 1.
Publication Number: TP01058
-2-
© 2002, IMI Cornelius, Inc.
Cafitesse 300: K72, H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71
Serial Numbers affected:
All units built at IMI Cornelius
Components Concerned:
B-7553 Trough and B-1313 Cover
Why:
High flow machines (settings in excess of 50 cc’s per
second and the H71 series as delivered) will sometimes
overflow coffee at the front of the trough during normal
operation.
This condition is due to a different shape of the trough
and cover. This bulletin is an intermediate remedy
while the final solution is being prepared. The final
solution will be distributed in a later bulletin.
Do This:
If there is an overflow condition during normal operation
of the coffee machine, check the trough and cover. If
they are marked with the part numbers, they are IMI
Cornelius parts. Replace these with Dagma built parts
(no part numbers). See Figure 1.
Figure 1. IMI Cornelius Trough and Cover, Dagma Trough and Cover
Release Date: October 16, 2002
© 2002, IMI Cornelius, Inc.
-1-
Revision: A
Publication Number: TP01059
Cafitesse 300: B7472 Refrigeration Chamber
SERVICE BULLETIN
PRODUCT: CAFITESSE 300, ALL MODELS
SUBJECT: B7472 REFRIGERATION CHAMBER
DATE: JULY 16, 2002
Manufacturer: IMI Cornelius, Inc.
Range of serial numbers subject to this document: 62A0209CD001 to 62A0214CD113.
Serial Number Components:
62A
02
01
CD
001
Mfg. site,
control code
Year
Week: 01 to 52
Coffee Dispenser
3 digit Sequential number,
starts at 001 each week
Modification: From the last machine number in the range noted, all units have been modified per this
instruction in the manufacturing plant. Further, the gluing process has been changed to preclude foam
intrusion and the mold for the plastic compartment has been changed to ensure that there is no excess
plastic in the drain hole.
Reason: Refrigeration compartment condensate drain hole may be partially blocked due to foam insulation and/or excess plastic material at the inlet to the drain hole.
Replaceability: Not affected.
Remarks: For all machines with the numbers in the range mentioned above, it is advised to inspect the
drain hole to ensure hole size is adequate for drain of condensate. This can be done on the next regular
visit to the customer if the machine is installed or prior to installation at the customer location.
Assembly: Perform this operation by hand using a 1/8 inch (3.0mm) drill bit and a standard metal paper
clip.
WARNING: DO NOT USE A DRILL MOTOR AS THIS MAY DAMAGE THE REFRIGERATION COMPARTMENT REQUIRING REPLACEMENT OF THE COMPARTMENT.
1. Remove product BIB’s from machine and place in refrigerator.
2. Disconnect power supply from mains.
Release Date: July 16, 2002
© 2002, IMI Cornelius, Inc.
-1-
Publication Number: TP01060 Revision: A
Cafitesse 300: B7472 Refrigeration Chamber
3. Loosen two screws on splash shield and remove from machine.
4. Remove troughs and trough holders from coffee dispensing nozzles.
Publication Number: TP01060 Revision: A
-2-
© 2002, IMI Cornelius, Inc.
Cafitesse 300: B7472 Refrigeration Chamber
5. Remove drain tube from refrigeration compartment and move away from drain hole to keep any debris
from entering tube. Inspect silicone drain tube for debris or blockage, clean if any present by removing
from cabinet and running water through tube.
6. Open refrigeration cabinet. Push and twist the drill bit by hand in and out of the drain hole until drill bit
passes through drain hole at least one inch (25mm). Remove drill bit.
© 2002, IMI Cornelius, Inc.
-3-
Publication Number: TP01060 Revision: A
Cafitesse 300: B7472 Refrigeration Chamber
7. Straighten a standard paper clip and push in and out of the drain hole to remove any debris. Remove
and repeat until no debris falls from drain tube outlet.
8. Install drain hose onto cooling compartment. Dip the hose end in water to aid in installation. Be sure is
routed through the grommet as shown and there are no kinks or twists in the tube.
9. Install trough holder, troughs and splash shield.
10. Reconnect power to mains.
11. Replace BIB’s in refrigeration compartment and close doors.
Publication Number: TP01060 Revision: A
-4-
© 2002, IMI Cornelius, Inc.
Cafitesse 300: K72 & K73
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius, DAGMA
Model(s):
K72 & K73
Serial Numbers Affected:
All
Components Concerned:
G-1270 Decor Plate, G-1273 Cover
Modification:
New style G-1273 Cover on IMI Cornelius built units.
Availability of G-1270 Decor Plate.
Reason:
G-1270 Decor Plate previously used on DAGMA equipment not available as spare. New style IMI Cornelius
Cover replaces previously used Decor Plate and Cover.
Field Repairs:
In case the DAGMA Cover and/or Decor Plate need to be
replaced, order G-1273 Cover. The G-1270 Decor Plate
may then be discarded.
Dagma G-1273 Cover:
Round with Relieved
area for Decor Plate
Dagma G-1270
Decor Plate
IMI G-1273 Cover:
Round with 10 sides,
not relieved for decor
plate
© 2003, IMI Cornelius Inc.
April 7, 2003
-1www.cornelius.com
TSB-DE-0001
Revision: A
Cafitesse 300: K72, K73, & H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71, & K73
Components Concerned:
D-0025, D-0038, D-0785, & D-0014
Modification:
Unit of measure when ordering these parts.
Reason:
Stocking of spares is now by one meter lengths.
How to get parts:
These parts are now available in one meter lengths.
When an order is placed, the quantity ordered will define
the number of one meter lengths of tubing you will
receive.
Example: If an order is placed for 5 units of D-0025, you
will receive 5 one meter lengths of tubing.
© 2003, IMI Cornelius Inc.
April 7, 2003
-1www.cornelius.com
TSB-DE-0002
Revision: A
Cafitesse 300: K72, K73, & H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71, & K73
Serial Numbers Affected:
All
Components Concerned:
G-2730 and G-2762 Valve Housing, A-0559 Circlip
Reason:
It was found that when the Circlip is not properly
mounted as described below, the risk on dislodging of
the Circlip during transit or rough handling is increased.
What to Do:
When re-assembling the valve housing, make sure the
Circlip opening is positioned as shown in Figure 3
between two of the three plastic clips (See Figure 2) of
the valve housing. All assemblies from factory are built
as shown, no field modifications required.
Figure 1: Bottom of Boiler Tank showing water valves
© 2003, IMI Cornelius Inc.
April 7, 2003
-1www.cornelius.com
TSB-DE-0003
Revision: A
Cafitesse 300: K72, K73, & H71
Circlip and Solenoid
removed for clarity.
There are three clips
around diameter
of part.
Figure 2: Valve Housing
Clip location on
valve housing.
Circlip opening
installed between two
of the three clips
on valve housing.
Figure 3: Valve Housing with solenoid and Circlip installed
TSB-DE-0003
Revision: A
-2www.cornelius.com
© 2003, IMI Cornelius Inc.
April 7, 2003
Cafitesse 300: K72 & H71
SERVICE BULLETIN
Machine Type:
Cafitesse 300
Manufacturer:
IMI Cornelius
Model(s):
K72, H71
Serial Numbers Affected:
The new clip was implemented May 20, 2003 starting
with Serial Number 62A0320CD039
Components Concerned:
A-0295 Clip, Heating Element (Dry Boil Thermostat Element Clip) is being replaced by part number 62070961.
Reason:
The wire formed A-0295 Clip that connects the “Dry
Boil” thermostat to the heater will be replaced by a
stamped flat stainless steel clip part number
620709615. This change will be phased in after existing
inventories are depleted. The new flat clips are compatible with existing units in the field and are completely
interchangeable. This change does not require any
action by the serviceman for units in the field. This bulletin is to inform of the replacement of A-0295 Clip with
the 620709615 Clip.
What to Do:
Hook the small end of the clip around the “Dry Boil”
thermostat capillary and snap the large end of the clip
around the heater coil as shown.
A-0295 Clip
© 2003, IMI Cornelius Inc.
June 11, 2003
620709615 Clip
-1www.cornelius.com
620709615 Clip Assembly
TSB-DE-0004
Revision: A