Concordia Beverage Systems Xpress 6 User Manual
XPRESS
Technician’s Manual
Concordia Beverage Systems
1287 120th Avenue NE
Bellevue, WA 98005
(425) 453-2800
(800) 778-0990
(425) 453-2167 Fax
http://www.concordiacoffee.com/
Technical Writer and Editor: Shana McKibbin
Technical Support: Gary Williams, Gery Jaggars, Chris Collier, Dana
Klatt, Allen Moore, Dave Davis
Graphic Engineers: Dan Gilbert, Quan Nguyen
Edition: December, 2012
2900-300B
Revision Change Log
Replace
Old Section
With New
Section
Brief Description
Date
Revision
Number
All
All
Manual completely updated
1/28/13
2900-300B
Table of Contents
Section 1 :: Xpress Overview ......................................................................1-1
Xpress Overview ................................................................................................. 1-2
Xpress Components............................................................................................ 1-3
Flavor System Overview ..................................................................................... 1-4
Flavor System Components ................................................................................ 1-5
Section 2 :: Installation and Removal ....................................................... 2-1
Technical Specifications and Site Requirements ................................................ 2-2
Machine Dimensions ........................................................................................... 2-3
Installation ........................................................................................................... 2-4
Configuring the Machine for Supply Voltage ................................. 2-4
Espresso Machine Electrical Settings ........................................... 2-4
Setting the DC Jumper Plug .......................................................... 2-4
Configuring Transformer Auxiliary Connector #1 .......................... 2-5
Plumbing ............................................................................................................. 2-6
Connecting the External Drain ...................................................... 2-6
Water Supply ................................................................................. 2-6
Problems with Reverse Osmosis Water System ........................... 2-7
Flavor System ..................................................................................................... 2-7
Flavor System Installation ............................................................. 2-7
Prime the Flavor System ............................................................... 2-7
Chocolate Sauce ........................................................................... 2-7
Verify Flavor Pour Rate ................................................................. 2-7
Additional Tasks Required at Installation ............................................................ 2-8
Power Up the Machine .................................................................. 2-8
Install Bean Hoppers ..................................................................... 2-8
Install Cup Stand (Optional) .......................................................... 2-8
Operational Configuration ................................................................................... 2-8
Placing Milk in the Refrigeration Unit ............................................ 2-8
Machine Calibration ............................................................................................ 2-9
Customer Training ............................................................................................... 2-9
Installation Checklist ........................................................................................... 2-9
Removal Procedures........................................................................................... 2-9
Section 3 :: Electrical ................................................................................. 3-1
Electrical Block Diagram ..................................................................................... 3-2
Fuses .................................................................................................................. 3-3
Backplane ........................................................................................................... 3-4
AC Drawer Assembly .......................................................................................... 3-5
DC Board Assembly ............................................................................................ 3-6
CPU Board .......................................................................................................... 3-7
J4 ................................................................................................... 3-8
J2 ................................................................................................... 3-8
P3 .................................................................................................. 3-9
P4 .................................................................................................. 3-9
Peripheral Connections Configuration .............................................................. 3-10
Transformer ....................................................................................................... 3-11
Power Into the Machine .................................................................................... 3-15
DC Power Supply Board LEDs ......................................................................... 3-18
Heating Element Wiring Diagrams .................................................................... 3-20
Jumper Plug Connector Detail .......................................................................... 3-21
Section 4 :: Software .................................................................................. 4-1
Software Overview .............................................................................................. 4-2
Software Menu Informational Screens .......................................... 4-2
Categories ..................................................................................... 4-2
Service Switch ..................................................................................................... 4-3
Navigating the Software Menu ...................................................... 4-4
Accessing a Sub-Category ............................................................ 4-4
Exiting the Menu System ............................................................... 4-5
Accessing the Grand Total Drink Count ........................................ 4-5
Accessing Total Drink Count Statistics ......................................... 4-5
Accessing Daily Drink Count Statistics ......................................... 4-5
Software Quick Reference Table ........................................................................ 4-6
Calibration ......................................................................................................... 4-13
Calibrating Pump Pressure ......................................................... 4-14
Calibrating Espresso ................................................................... 4-14
Configuring the Bean Hoppers .................................................... 4-14
Espresso Extraction and Temperature Parameters .................... 4-15
Drink Temperatures ..................................................................... 4-15
Verifying Espresso Extraction ..................................................... 4-15
Calibrating Milk Timings .............................................................. 4-16
Calibrating Brewed Coffee .......................................................... 4-16
Calibrating Flavor Timings ........................................................... 4-17
Espresso Extraction Pre-Treatment Options .................................................... 4-17
Pre-Treatment Options ................................................................ 4-17
CPU Board ........................................................................................................ 4-19
Loading New Software to a Machine ................................................................ 4-20
Required Equipment .................................................................... 4-20
Configuring HyperTerminal ......................................................... 4-20
Connecting a Laptop to a Machine ............................................. 4-27
Updating Software for Customers with Custom Drink Recipes ... 4-30
Section 5 :: Plumbing ................................................................................ 5-1
The Water System .............................................................................................. 5-2
Line Pressure ................................................................................ 5-3
Check Valve .................................................................................. 5-3
Water Filtration System ................................................................. 5-3
Hot Water Tank ................................................................................................... 5-4
Temperature/Level Probe .............................................................. 5-5
Level Probe ................................................................................... 5-5
Temperature Probe ....................................................................... 5-6
Pressure Relief Valve .................................................................... 5-6
High Temperature Limit Switch ..................................................... 5-6
Water Inlet ..................................................................................... 5-6
Flowmeter ...................................................................................... 5-7
Heating Elements .......................................................................... 5-7
Brew Valve .................................................................................... 5-7
Hot Water Valve ............................................................................ 5-7
Draining the Hot Water Tank ......................................................... 5-8
Water Pump and Motor ....................................................................................... 5-8
Water Pressure Gauge .................................................................. 5-9
Setting Pump Pressure ................................................................. 5-9
Expansion Valve ............................................................................ 5-9
Check Water Flow Message ......................................................... 5-9
The Steam System............................................................................................ 5-10
Steam Tank – Front View ............................................................ 5-10
Steam Tank – Rear View ............................................................ 5-11
Steam Tank Fill Valve ................................................................. 5-12
Steam Tank ................................................................................. 5-12
Water Level Probes ..................................................................... 5-12
Pressure Gauge .......................................................................... 5-13
Heating Elements ........................................................................ 5-13
Pressure Relief Valve .................................................................. 5-13
High Temperature Limit Switch ................................................... 5-13
Steam Valves .............................................................................. 5-14
Left Steam Valve ......................................................................... 5-14
Center Steam Valve .................................................................... 5-15
Right Steam Valve ....................................................................... 5-15
Air Purge Process ....................................................................... 5-15
Captive Water Purge System ...................................................... 5-15
Draining the Steam Tank ............................................................. 5-15
Section 6 :: Coffee System ......................................................................... 6-1
The Coffee System ............................................................................................. 6-2
Espresso Path ............................................................................... 6-2
Grinders .............................................................................................................. 6-3
Double Grinder Assembly ............................................................. 6-3
Calibration: Espresso Grind .......................................................... 6-4
Grinder Adjustment Panel ............................................................. 6-4
Grinder Adjustment Diagram ......................................................... 6-5
Measuring the Coffee Powder Dose ............................................. 6-5
Coffee Powder Channel ................................................................ 6-6
Removing the Grinder ................................................................... 6-6
Replacing the Grinder Burrs/Blades .............................................. 6-7
Setting the Grinder Adjustment Indicator to Mid-Scale ................. 6-7
Bean Hoppers ..................................................................................................... 6-8
Filling a Bean Hopper .................................................................... 6-8
Inserting the Hopper Stopper ........................................................ 6-8
Removing a Bean Hopper ............................................................. 6-8
Brew Group ......................................................................................................... 6-9
Brew Group Initialization ............................................................. 6-10
Brew Group Components ................................................................................. 6-10
Hall-Effect Sensors ...................................................................... 6-11
Left Piston.................................................................................... 6-12
Right Piston ................................................................................. 6-12
Piston Movement ......................................................................... 6-12
Viewing the Left Piston Movement .............................................. 6-13
Removing the Left Piston ............................................................ 6-13
Removing the Right Piston .......................................................... 6-14
Gearbox Removal and Installation .................................................................... 6-15
Removing the Gearbox ............................................................... 6-15
Installing the Gearbox ................................................................. 6-16
Section 7 :: Milk System and Refrigeration Unit ...................................... 7-1
The Milk Delivery System ................................................................................... 7-2
Milk Delivery System Components ..................................................................... 7-2
Milk Pump Assembly ..................................................................... 7-2
Milk Pick-Up Tube ......................................................................... 7-2
Milk Pump ...................................................................................... 7-2
Milk System Theory of Operation ........................................................................ 7-3
Basic Terminology ......................................................................... 7-3
Initial Setup of the Milk System ..................................................... 7-4
Milk System Capabilities ............................................................... 7-5
A Common Milk Timing Mistake .................................................... 7-5
Air Gate Valve Assembly .................................................................................... 7-5
Air Gate Valves ............................................................................. 7-6
Air Purge Valves ............................................................................ 7-6
Air Vent Needles ........................................................................... 7-6
Connection of Milk Pump Assembly and Air Gate Valve Assembly 7-
6
Alt Milk Valve ....................................................................................................... 7-6
Steam Delivery Components .............................................................................. 7-7
Steam Valves ................................................................................ 7-7
Mixing TEE Assembly ................................................................... 7-7
Refrigeration Unit Overview ................................................................................ 7-8
Placing Milk in the Machine ........................................................... 7-9
Checking the Refrigeration Unit Temperature ............................... 7-9
Refrigeration Cooling Module Assembly ..................................... 7-10
Fan Control Board ....................................................................... 7-11
Cold Sink Deflector ...................................................................... 7-11
Interior Circulation Fan Assembly ............................................... 7-12
Exterior Cooling Module Fan Assembly ...................................... 7-12
Temperature Probe Assembly..................................................... 7-12
Milk Weight Trays ........................................................................ 7-13
Adjusting a Milk Weight Tray ....................................................... 7-15
Milk Level Sensors ...................................................................... 7-16
Auto Milk Select ........................................................................... 7-16
Section 8 :: Steam Wands ......................................................................... 8-1
Steam Wand Overview ....................................................................................... 8-2
Automatic Steam Wand ...................................................................................... 8-2
Automatic Steam Wand Theory of Operation ............................... 8-2
Automatic Steam Wand Selections ............................................... 8-3
Automatic Steam Wand Programming .......................................... 8-4
Air Pump ........................................................................................ 8-4
Steam and Vacuum Valve Assembly ............................................ 8-4
Automatic Steam Wand Wiring ........................................................................... 8-5
Replacing an Automatic Steam Wand ................................................................ 8-5
Manual Steam Wand........................................................................................... 8-6
Replacing a Manual Steam Wand ...................................................................... 8-6
Removing a Steam Wand ............................................................. 8-8
Installing a Steam Wand ..................................................................................... 8-8
Cleaning a Steam Wand ..................................................................................... 8-8
Section 9 :: Flavor System ......................................................................... 9-1
The Flavor System .............................................................................................. 9-2
Chocolate Sauce Delivery Path..................................................... 9-2
Syrup Delivery Path ....................................................................... 9-3
Flavor Tubes.................................................................................. 9-3
Flavor Storage Area ...................................................................... 9-4
Chocolate Sauce ........................................................................... 9-4
Chocolate Heater Assembly .......................................................... 9-4
Connecting Flavor Tubing ............................................................. 9-4
Changing the Flavor Pour Rate ..................................................... 9-5
Verifying Proper Syrup Flow .......................................................... 9-6
Changing Flavor Boxes ................................................................. 9-7
Peristaltic Pumps ................................................................................................ 9-8
Syrup Manifold .................................................................................................... 9-8
Chocolate Rinse Purge Valve ....................................................... 9-9
Milk Bowl ....................................................................................... 9-9
Removing the Syrup Manifold ....................................................... 9-9
Replacing the Syrup Manifold ..................................................... 9-10
Cleaning the Flavor Delivery System ................................................................ 9-10
Priming the Flavor Delivery System .................................................................. 9-12
Section 10 :: Vending ............................................................................... 10-1
Vending Overview ............................................................................................. 10-2
Vending Backpack ....................................................................... 10-2
Replacing a Card Reader ................................................................................. 10-2
Installing a Vending Unit ................................................................................... 10-3
Removing a Vending Unit ................................................................................. 10-3
Troubleshooting ................................................................................................ 10-3
Section 11 :: Cleaning and Maintenance .................................................. 11-1
Daily Maintenance............................................................................................. 11-2
Concordia Cleaning Products...................................................... 11-2
Cleaning Timers ................................................................................................ 11-3
Preventive Maintenance ................................................................................... 11-3
Section 12 :: Concordia Procedures ........................................................ 12-1
Service Call Process ......................................................................................... 12-2
Arrival to Site ............................................................................... 12-2
Machine Repair ........................................................................... 12-2
Hold for Parts Procedures ........................................................... 12-2
Departing from Site ..................................................................... 12-2
Required Immediately for Call Closeout ...................................... 12-3
Complete Call Protocol ..................................................................................... 12-3
Machine Appearance .................................................................. 12-3
Milk System ................................................................................. 12-3
Brew Group ................................................................................. 12-3
Water Tank .................................................................................. 12-3
Water Pump................................................................................. 12-3
Steam Tank ................................................................................. 12-3
Refrigeration Unit ........................................................................ 12-4
Espresso Extraction .................................................................... 12-4
Milk Pour ...................................................................................... 12-4
Service Call Checklist ....................................................................................... 12-5
Parts Return Policy ........................................................................................... 12-6
Non-Consignment Agents ........................................................... 12-6
Consignment Agents ................................................................... 12-6
Return Material Tag ..................................................................... 12-7
Parts Replenishment Form ............................................................................... 12-8
Section 13 :: Customer Service and Training .......................................... 13-1
Training the Customer....................................................................................... 13-2
User Guide .................................................................................. 13-2
Starting and Resetting the Machine ............................................ 13-2
Filling Machine with Beans and Milk ........................................... 13-2
Pouring Drinks and Cancelling Drinks ......................................... 13-2
Restocking and Changing Flavor Boxes ..................................... 13-2
Cleaning ...................................................................................... 13-3
Serial Number ............................................................................. 13-3
Accessing Software Menu ........................................................... 13-3
Troubleshooting Tips ................................................................... 13-3
Contacting Concordia for Assistance .......................................... 13-4
Concordia Beverage Systems’ Value-Added Service ....................................... 13-5
Value-Added Service ................................................................... 13-6
G.U.E.S.T. ......................................................................................................... 13-7
Greet the Customer ..................................................................... 13-7
Understand your Customer ......................................................... 13-8
Empathize with Your Customer ................................................... 13-9
Solve the Problem ..................................................................... 13-10
Train the Customer .................................................................... 13-10
Section 14 :: Messages ............................................................................. 14-1
Troubleshooting Display Messages .................................................................. 14-2
Section 15 :: Troubleshooting ................................................................... 15-1
Troubleshooting Quick Reference Guide .......................................................... 15-2
Machine Failure ........................................................................... 15-2
Coffee System ............................................................................. 15-3
Flavor System ............................................................................. 15-3
Milk System ................................................................................. 15-4
Troubleshooting Trees ...................................................................................... 15-5
Brew System: Right Drive Timeout ............................................. 15-6
Brew System: Invalid Stop L ....................................................... 15-7
Brew System: Invalid Stop R ....................................................... 15-9
Brew System: Left Drive Timeout .............................................. 15-11
Grinder System: Out of Beans .................................................. 15-13
Milk System: Overpouring Milk .................................................. 15-15
Milk System: Cold Milk Pour...................................................... 15-17
Milk System: No Milk Pour ........................................................ 15-19
Milk System: Short Milk Pour .................................................... 15-21
Refrigeration System: Temperature Above 40˚F ...................... 15-23
Steam System: Steam Temperature High ................................ 15-25
Steam System: Check Sensor Voltage ..................................... 15-26
Steam System: Check Steam Probes ....................................... 15-27
Steam System: Check Steam Tank .......................................... 15-28
Steam System: Steam Temperature Low ................................. 15-29
Water System: Water Temperature Too High ........................... 15-30
Water System: Water Temperature Too Low ............................ 15-31
Water System: Check Water Supply ......................................... 15-33
Water System: Water Tank Limit Switch Open ......................... 15-35
Flavor System: Cross-Contamination of Syrup Lines ............... 15-37
Flavor System: Too Much Flavor in Drink ................................. 15-38
Flavor System: Not Enough Flavor in Drink .............................. 15-39
Flavor System: No Flavor in Drink ............................................ 15-41
Electrical System: Check Analog Board .................................... 15-43
Electrical System: Incorrect Software for Touchpad ................. 15-44
Electrical System: Milk Pump Running Continuously ............... 15-45
Electrical System: Front Panel Failed ....................................... 15-46
Electrical System: Check Clock................................................. 15-47
Electrical System: Check Stats ................................................. 15-48
Electrical System: CPU Load Disp and Seq Error .................... 15-49
Electrical System: AC Voltage Error ......................................... 15-51
Electrical System: DC Voltage Failure ...................................... 15-53
Vending System: Card Swipe or Tap Not Authorized ............... 15-55
Vending System: Not Configured .............................................. 15-56
Vending System: No Display on Card Reader .......................... 15-57
Section 16 :: Parts Lists & Diagrams ....................................................... 16-1
Recommended Tools List ................................................................................. 16-2
Standard Tools ............................................................................ 16-2
Concordia Stocked Tools ............................................................ 16-2
Consumables .............................................................................. 16-2
Parts Lists and Diagrams .................................................................................. 16-3
Diagram 1: Machine Overview .................................................... 16-4
Diagram 1, Parts List: Machine Overview ................................... 16-5
Diagram 2: Grounds Bin Door, Refrigerator Door with Hot Water
Button Assembly ......................................................................... 16-6
Diagram 2, Parts List: Refrigerator Door with Hot Water Button
Assembly ..................................................................................... 16-7
Diagram 3: Refrigerator Door with Steam Wand Assembly ........ 16-8
Diagram 3, Parts List: Refrigerator Door with Steam Wand
Assembly ..................................................................................... 16-9
Diagram 4: Front Panel ............................................................. 16-10
Diagram 4, Parts List: Front Panel ............................................ 16-11
Diagram 5: Top Panel ............................................................... 16-12
Diagram 5, Parts List: Top Panel .............................................. 16-13
Diagram 6: Grinder Assembly ................................................... 16-14
Diagram 6, Parts List: Grinder Assembly .................................. 16-15
Diagram 7: Grinder Adjustment Assembly ................................ 16-16
Diagram 7, Parts List: Grinder Adjustment Assembly ............... 16-17
Diagram 8: Group Upper and Lower Piston Assembly ............. 16-18
Diagram 8, Parts List: Group Upper and Lower Piston Assembly 16-
19
Diagram 9: Group Drive System ............................................... 16-20
Diagram 9, Parts List: Group Drive System .............................. 16-21
Diagram 10: Milk Pump Assembly ............................................ 16-22
Diagram 10: Parts List, Milk Pump Assembly ........................... 16-23
Diagram 11: Product Delivery Assembly, Xpress 6 .................. 16-24
Diagram 11, Parts List: Product Delivery Assembly, Xpress 6 . 16-25
Diagram 12: Product Delivery Assembly, Xpress 0 .................. 16-26
Diagram 12, Parts List: Product Delivery Assembly, Xpress .... 16-27
Diagram 13: Refrigeration Unit Assembly ................................. 16-28
Diagram 13, Parts List: Refrigeration Unit Assembly ................ 16-29
Diagram 14: Chocolate Sauce Delivery System ....................... 16-30
Diagram 14, Parts List: Chocolate Sauce Delivery System ...... 16-31
Diagram 15: Syrup Delivery System ......................................... 16-32
Diagram 15, Parts List: Syrup Delivery System ........................ 16-33
Diagram 16: Refrigeration Unit Cooling Assembly .................... 16-34
Diagram 16, Parts List: Refrigeration Unit Cooling Assembly ... 16-35
Diagram 17: Steam Tank, Front ................................................ 16-36
Diagram 17, Parts List: Steam Tank, Front ............................... 16-37
Diagram 18: Steam Tank, Rear ................................................ 16-38
Diagram 18, Parts List: Steam Tank, Rear ............................... 16-39
Diagram 19: Water Pump and Motor ........................................ 16-40
Diagram 19, Parts List: Water Pump and Motor ....................... 16-41
Diagram 20: Hot Water Tank..................................................... 16-42
Diagram 20, Parts List: Hot Water Tank ................................... 16-43
Diagram 21: Water/Steam Gauge/ Air Valve Assembly ............ 16-44
Diagram 21: Parts List: Water/Steam Gauge/Air Valve Assembly 16-
45
Diagram 22, Parts List: Drain Valve Bridge Web Assembly ..... 16-46
Diagram 22, Parts List: Drain Valve Bridge Web Assembly ..... 16-47
Section 17 :: Index .................................................................................... 17-1
Section 18 :: Service Bulletins ................................................................. 18-1
Table of Contents – Service Bulletins ............................................................... 18-2
Service Bulletins .......................................................................... 18-3
Page Intentionally Left Blank
Page Intentionally Left Blank
T E C H N I C A L S U P P O R T
Section 1 :: Xpress
Overview
1. Xpress Overview
2. Xpress Components
3. Flavor System Overview
4. Flavor System Components
Section 1: Xpress Overview 3033-001B
Xpress Overview
1-2 Concordia Xpress Technical Support Manual
2900-300B
3033-001B Section 1: Xpress Overview
Xpress Components
Front Panel Touch Pad
The front panel touch pad provides a user interface for selecting and
pouring drinks.
Electrical Enclosure and CPU
The electrical enclosure houses the CPU, AC drawer, and DC board.
Bean Hoppers
Each bean hopper holds whole espresso roast beans and feeds the
beans to the grinders.
Water Pump and Motor
The water pump regulates the water pressure to 135-140psi during the
espresso extraction process. The motor supplies power to the pump.
Hot Water Tank
The hot water tank stores and heats the water used to brew espresso.
Brew Group
The brew group assembly brews espresso and automatically discards
the used coffee into the grounds bin.
Steam Tank
The steam tank provides steam used for steaming the milk.
Grinders and the Grinder Adjustment Assembly
The grinders are calibrated to grind espresso beans according to the
customer’s recipe. The grinder adjustment assembly changes the grind
of espresso beans.
Exhaust Fan
NOT SHOWN
The exhaust fan removes excess heat build-up from the machine interior.
Refrigeration Unit
The refrigeration unit stores the milk used for drinks.
Refrigeration Module Assembly
The refrigeration module assembly regulates the temperature inside the
refrigeration unit.
Milk Pump and Milk Pump Box Assembly
The milk pump assembly draws milk from the milk container.
Syrup Manifold
Xpress 6 only
Flavor is infused into drinks via the syrup manifold.
Product Delivery Bracket
The product delivery bracket holds the milk bowl (not shown) and the
syrup manifold.
Product Delivery Nozzle
The finished drink is poured through the product delivery nozzle and into
the customer’s cup.
Concordia Xpress Technical Support Manual 1-3
2900-300B
Section 1: Xpress Overview 3033-001B
CHOCOLATE HEATER
ASSEMBLY
Flavor System Overview
1-4 Concordia Xpress Technical Support Manual
2900-300B
3033-001B Section 1: Xpress Overview
Flavor System Components
Xpress 6 only
Pump Unit
The pump unit contains the six peristaltic pump assemblies that move
the flavors from the boxes to the syrup manifold, and then to the product
delivery outlet.
Control Unit
The control unit houses the electronic board that controls the syrup
pumps.
Power Supply
The power supply provides 24Vdc power to the control unit.
Chocolate Heater Assembly
The chocolate heater assembly provides heat to the chocolate sauce, to
ensure a minimum temperature of 85°F (29.4°C) is maintained.
Concordia Xpress Technical Support Manual 1-5
2900-300B
Section 1: Xpress Overview 3033-001B
Page Intentionally Left Blank
1-6 Concordia Xpress Technical Support Manual
2900-300B
T E C H N I C A L S U P P O R T
Section 2 :: Installation
and Removal
1. Technical Specifications and Site
Requirements
2. Machine Dimensions
3. Installation
4. Plumbing
5. Flavor System
6. Additional Tasks Required at Installation
7. Operational Configuration
8. Machine Calibration
9. Customer Training
10. Installation Checklist
11. Removal Procedures
Section 2: Installation and Removal 3033-002B
Technical Specifications
Weight: 300lbs/137kg
Operating Environment: 55°- 85°F (13°-29°C)
Power Consumption: 24 amps @ 208Vac max
8 amps @ 115Vac max
Compliance:
FCC: Part 15B, Class A, Part 68
UL Listed
NSF Certified
Power and Water Requirements
Power
Located within five feet (1.5 meters) of machine
Single Phase:
200-240Vac, 30amp dedicated circuit
NEMA L14-30 Receptacle
High Leg:
200-240Vac, 30amp, high leg dedicated circuit.
International machines are shipped without a power plug. A
plug must be attached at the time of installation and meet
with all local electrical codes.
Flavor Delivery System
Domestic
Chocolate Heater Assembly
115Vac, 15amp
NEMA 5-15P
Control Unit
115Vac, 15amp
NEMA 5-15P
International
Chocolate Heater Assembly
230Vac
Control Unit
90-260Vac
Water
Cold water source with a 1/4” or 3/8” tube fitting with a
shut-off valve, located within five feet (1.5 meters) of
machine
Pressure
Minimum: 30psi; Maximum: 100psi (min: 2 bar, max 7 bar)
25 gallons per hour (95 liters per hour)
A fresh water bypass is required for sites with a reverse
osmosis filter system
Scalex Water Treatment System
Included with the unit: two cartridges (one carbon, one
softener)
25”H x 11”W x 5.25”D
63.5cmHx28cmWx13.34cmD
Location Requirements
Locate indoors only
Overall Space
23.79”W x 26.75”D x 36.13”H
59.64cm x 67.49cm x 91.44cm
Machine Counter Space
36”W x 29”D x 42”H
91.44cm x 73.66cm x 106.68cm
Flavor Delivery System
30”W x 30”D x 27”H
76.2cmWx76.2Dx68.6H
Drain
Connection for ¾”/1.9cm drain dose
Indirect drain required
Located within five feet/1.5 meters of machine
Technical Specifications and Site
Requirements
To ensure the site is ready, the customer is required to complete and
return a pre-installation checklist. The customer is required to have
electrical, water, and a drain located within a specified distance from the
machine.
2-2 Concordia Xpress Technical Support Manual
2900-300B
3033-002B Section 2: Installation and Removal
Machine Dimensions
Concordia Xpress Technical Support Manual 2-3
2900-300B
Section 2: Installation and Removal 3033-002B
IBS6+ Equipped with 4 prong 208 volt plug
L1 120VAC
TO NEUTRAL
NEMA
L1430-R
L2 120VAC
GROUND
NEUTRAL
TO NEUTRAL
Connections
Voltage
L1 to Ground
110Vac – 120Vac
L2 to Ground
110Vac – 120Vac
L1 to Neutral
110Vac – 120Vac
L2 to Neutral
110Vac – 120Vac
L1 to L2
200Vac – 240Vac
Ground to Neutral
0Vac
Confirming Receptacle Voltages
Plug and Receptacle – US only
Xpress equipped with 4 prong 208 volt plug
Installation
Configuring the Machine for Supply Voltage
Before connecting machine to the electrical supply, check and verify
incoming power supply. The following chart displays the required
voltages.
Espresso Machine Electrical Settings
Prior to connecting the machine to the power source, verify the electrical
settings are correct. The DC jumper plug and transformer must be
properly configured.
WARNING: Failure to properly set the DC jumper plug and the
transformer connector can result in machine malfunction, short circuit,
blown fuses, overheating, or damage to circuit boards.
Setting the DC Jumper Plug
1. Measure the source voltage at the NEMA L1430-R receptacle
(refer to the chart above). Record the value in the electrical
section of the installation checklist.
2. Remove the electrical enclosure cover to access the DC power
supply board.
CAUTION: ESD protection required.
3. Remove the DC power supply board using the white ejector
lever.
4. Use the diagram on the next page to configure the DC jumper
plug to the measured source voltage.
5. Insert the free end of the yellow wire into the correct pinhole.
6. Insert the jumper plug into connector J1 located on the DC
power supply board.
7. Re-install the DC power supply board. Ensure the board is fully
seated by firmly pressing the board into connector on the
backplane connector.
8. Re-install the electrical enclosure cover and verify the display
cable is not stressed, pinched, or cut when front panel is
lowered.
2-4 Concordia Xpress Technical Support Manual
2900-300B
3033-002B Section 2: Installation and Removal
VOLTAGE TABLE
MEASURED SOURCE AUX
CONNECTOR CONNECTOR
VOLTAGE RANGE #1 SETTING
200 – 205 200 NO ADJUSTMENT
206 – 215 208 NO ADJUSTMENT
216 – 225 220-240 #3 GREEN WIRE
226 – 235 220-240 #4 WHITE WIRE
236 – 245 220-240 #2 ORANGE WIRE
AUXILIARY
CONNECTOR #1
TRANSFORMER
CONNECTORS #2, #3, #4
BROWN
RED
BLUE
WHITE
WHITE 230V
GREEN 220V
ORANGE 240V
1 2 3
4
Transformer Auxiliary Connector Configuration
Configuring the DC Jumper Plug
50-60Hz
200 VAC
208 VAC
220-240 VAC
L2
200 VAC
208 VAC
220-240 VAC
L2
Configuring Transformer Auxiliary Connector
#1
It may be necessary to configure the auxiliary connector at the
transformer, depending on the measured supply voltage.
1. Remove the machine back panel.
2. Locate the transformer and connectors.
3. Using the voltage table, connect the transformer auxiliary
connector #1 to the appropriate connector labeled 220Vac,
230Vac, or 240Vac.
4. Reinstall the back panel and proceed with machine installation.
Concordia Xpress Technical Support Manual 2-5
2900-300B
Section 2: Installation and Removal 3033-002B
INDIRECT
DRAIN
FLOOR SINK
DRAIN
DRAIN HOSE
FROM MACHINE
DRAIN HOSE
FROM MACHINE
Approved Drain Configurations
Plumbing
Connecting the External Drain
Only a qualified plumber complying with all local codes and requirements
can install the drain at the site. You are responsible for connecting the
machine to the drain.
The following requirements must be met:
Drain accommodating a 3/4” (1.9cm) ID drain hose
Drain must be located within five feet (1.5 meters) of machine
The minimum rate of fall required is one inch (2.54cm) per foot, and the
drain hose must have a continuous rate of fall. Ensure the drain hose is
connected to the machine drain port.
If the drain has any low spots or any horizontal runs as it travels from the
machine to the drain, water and other waste from the machine will back
up and cause the drain hose and/or the drain tray to clog.
NOTE: When water and drain lines are connected, check for leaks.
Water Supply
To ensure proper operation of the machine, the following requirements
must be met:
Cold water source with a shut-off valve and 1/4" or 3/8” tube
fitting
Water pressure: minimum 30psi; maximum 100psi
Water source must be located within five feet (1.5 meters) of
machine
All machines ship with a Scalex water treatment system
Prior to connecting the water filter to the machine, flush the water
filtration system with 2 gallons (8 liters) of water.
2-6 Concordia Xpress Technical Support Manual
2900-300B
3033-002B Section 2: Installation and Removal
Problems with Reverse Osmosis Water System
A fresh water bypass is required for sites with a reverse osmosis filter
system. The machine water level sensors are inoperative when used
with this system.
Flavor System
Flavor System Installation
The flavor boxes and the flavor tubes are color-coded. It is important to
verify the colors are correctly matched, to ensure customers receive the
desired drink and that cross-contamination of flavors does not occur.
Flavor boxes containing one gallon of syrup can be stacked. Boxes of
chocolate sauce should not be stacked, as the chocolate sauce box must
be on the chocolate heater assembly to ensure it maintains the correct
temperature.
Prime the Flavor System
Once the flavor boxes are positioned and connected, the flavor system
must be primed. Please see the Priming the Flavor Delivery Tubes topic
in Section 9: Flavor System.
WARNING: The machine MUST be fully warmed up before priming
the flavor system, or a false head of steam may occur in the steam tank.
Chocolate Sauce
It is necessary to pre-warm the chocolate sauce to 85°F (29.4°C) before
use; otherwise, it will not flow properly.
WARNING: If chocolate sauce is not heated to the required
temperature, there is a high risk of the chocolate sauce flavor tubing
exploding. This is due to the viscosity of cold chocolate sauce.
NOTE: Installation cannot be completed until the chocolate sauce is at
the proper temperature.
Verify Flavor Pour Rate
It is important to verify flavor volume and ensure it meets the
requirements and preferences of the customer.
Please see the Changing the Flavor Pour Rate topic in Section 9: Flavor
System, for information and directions for adjusting the time and volume
of flavor pours.
Concordia Xpress Technical Support Manual 2-7
2900-300B
Section 2: Installation and Removal 3033-002B
Additional Tasks Required at Installation
Power Up the Machine
1. Close both tank drain valves
2. Ensure the electrical cord is plugged in and twist-locked
3. Ensure water is supplied to unit
4. Ensure a drain is connected to the unit
5. Start the unit by turning on the main power switch located behind
the grounds bin door
6. Warm-up will take 10-15 minutes
NOTE: The grounds bin must be in place and all doors must be
closed.
Install Bean Hoppers
1. Install the bean hoppers.
2. Fill the bean hoppers with fresh, whole, espresso roast beans.
For information on the bean hoppers, please see Section 6:
Coffee System.
IMPORTANT: Ensure the hopper stoppers are removed, so that the
beans can be delivered to the grinder.
Install Cup Stand (Optional)
Install the cup stand beneath the product outlet.
Operational Configuration
The Xpress is configured with a default recipe. However, it may still be
necessary to make minor adjustments to the grinder settings or milk
levels, depending on an existing customer recipe or customer
preference. For instructions on calibrating the grinder, please see
Section 6: Coffee System, and for instructions on adjusting the milk
levels, please see the Calibration topic in Section 4: Software. For
instructions on adjusting flavor timings, please see Section 9: Flavor
System.
At this time, set the time and date, using the software menu in the
machine. Please see Section 4: Software for detailed instructions on
accessing and using the TIME & DATE menu.
Placing Milk in the Refrigeration Unit
Place two gallons of milk in the upper refrigeration unit. Non-fat milk is
placed in the rear position and regular milk (whole or 2%) in the front.
2-8 Concordia Xpress Technical Support Manual
2900-300B
3033-002B Section 2: Installation and Removal
Machine Calibration
The calibration process is the same regardless if the setup includes the
default recipe, or if it includes a customer-specific recipe.
To ensure the machine is properly calibrated, verify the following:
1. Water Pump Pressure
2. Espresso Extraction Times
3. Drink Temperatures
4. Drink Levels
5. Syrup Volumes
6. Taste Profile
If necessary, adjust the bean grind to achieve the appropriate extraction
times.
Customer Training
Complete customer training is required at the time of installation. Refer to
Section 12: Concordia Procedures, for complete instructions.
Customer Training Includes:
How to turn machine on/off
How to refill milk supply, bean hoppers, consumables
How to select drinks and drink options
Show location of serial number
How to clean the machine (including cleaning cards)
How to change flavor boxes
How to empty the grounds bin
Installation Checklist
The installation checklist (PN 6000-075) must be completed and faxed to
Concordia within 24 hours of installation.
Removal Procedures
Prepare and package machine and components following the procedure
described in the Concordia Shipping Kit (PN 2900-142).
1. Record the drink GRAND TOTAL on the service invoice.
2. Record the machine serial number.
3. Clean the grinders.
4. Clean the brew group.
5. Run the daily clean cycle (brew group and milk system clean
processes).
6. Clean the refrigeration unit.
7. Clean the flavor delivery system.
Concordia Xpress Technical Support Manual 2-9
2900-300B
Section 2: Installation and Removal 3033-002B
8. Clean all interior and exterior surfaces (drain tray and grate,
grounds bin, cup holder).
9. Drain and disconnect the water supply, and drain the water and
steam tanks.
10. Prepare the machine and components for shipping.
11. If Demo Machine: remove, clean, and pack water filtration
system.
12. Ensure the User Guide and cleaning cards are included with the
unit.
13. Coil the power cord, water supply line, and drain hose and
secure with a Ty-Wrap®.
2-10 Concordia Xpress Technical Support Manual
2900-300B
T E C H N I C A L S U P P O R T
Section 3 :: Electrical
1. Electrical Block Diagram
2. Fuses
3. Backplane
4. AC Drawer Assembly
5. DC Power Supply Board
6. CPU Board
7. Peripheral Connections Configuration
8. Transformer
9. Power Into the Machine
10. DC Power Supply Board LEDs
11. Heater Element Wiring Diagrams
12. Jumper Plug Connector Detail
Section 3: Electrical 3033-003B
Power In
Fuses
Power Switch
Main Power
Relay/Contactor
Relay for Water
Tank Heating
Elements
Relay for Steam
Tank Heating
Elements
Water Pump
Transformer
DC Power Supply
Display
Heating Elements
Heating Elements
Rear Grinder
Front Grinder
Backplane
Left
Piston
Hall
Right
Piston
Hall
Flow
meter
Coffee
Piston
Left-Motor
Hall
Brew
Piston
Right-
Motor Hall
Transducer
Refer
Temp
Steam
Level
Grounds Bin
Mag Switch
Grounds Bin
Door Mag Switch
JP8
Front Panel
Mag Switch
Milk
Level
Sensor
Water
Temp
Water
Tank
Level
Post
Steam
Capp
Purge
Valve
Latte
Steam
Fill
Alt
Milk
optional
Switched
Fans
Un-
Switched
Fans
Water
Element
Cutoff
Steam
Element
Cutoff
Refer
Chip #2
Refer
Chip #1
Refer
Chip #1
Refer
Chip #3
Right
Group
Motor
Right
Group
Motor
JP2
JP7
JP3
Brew
Water
Hot
Water
CPU
Board
P1
AC Drawer
J1
JP9
J2
Fuses
Ground
L1
L2
Neutral
JP5
DC Voltage
AC Voltage
JP10 Control Voltage
F19F19
F18
F18
F18
F18
F18 F18
F18
F18
F18
F18
F16
F15
F16
F16 F17
F16F16F16
Fuse # on DC Board
F18
J3
KEY
F18
F18
J3
Jumper Plug on Back
Plane
JP
Fuse
J1 Adjustable
Jumper Plug
CPU/DC
Controlled Triac
CPU/DC
Controlled Triac
CPU/DC
Controlled Triac
JP3
Air
Vent
Valve
P4
Steam
Level
Safety
Syrup
Control Box
Milk
Pump
Latte
Air Valve
Capp Air
Valve
F18
Mini Backplane
Speed Cntrl
Expansion PCA
Electrical Block Diagram
3-2 Concordia Xpress Technical Support Manual
2900-300B
Loading...