Concordia Coffee 99420 Service Manual
Integra
Technician’s Manual
Concordia Coffee 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,
Allen Moore, Dana Klatt, Dave Davis
Graphics: Quan Nguyen, Andre Belyea, Daniel Gilbert
Edition: May, 2012
2900-245B
Welcome to Concordia Coffee Systems!
We are very pleased to have you join our team of professionals,
united in the common pursuit of excellence on behalf of our
customers.
Concordia Coffee Systems is a leader in the design,
development and manufacture of fully automated espresso
systems, serving thousands of customers throughout the world.
Our goal is to continuously achieve the highest imaginable
levels of quality, service, and technological performanc e for our
customers. We believe that it is the ability, talent and spirit o f
people like you that will enable Concordia Coffee Systems to
reach this goal.
The basic objectives of Concordia Coffee Systems are:
Deliver quality and value to our customers through
leadership and excellence in everything that we do.
Provide a strong seamless network of service to all
Concordia Coffee Systems customers while, exceeding
their expectations from us.
Build value in our employees and agents through
experience, training and the provision of opportunities
for success.
Build long term value in our Company.
Be strong contributing members of the communities in
which we conduct business.
You are an important part of our team. We want to do our best
to help you find your work with Concordia Coffee Systems
satisfying, rewarding and personally meaningful. The material
in this manual has been designed to be used as a training aid,
reference resource and updated library of Concordia Coffee
Systems Policies and Procedures.
It is important that you keep your manual updated to reflect
our current revisions to ensure we have provided you with the
tools necessary to facilitate YOUR success!
Revision Change Log
Replace
Old
Section
With
New
Section
Brief Description Date
2900-
255
Revision
TableofContents
Section 1 :: Integra Overview...........................................1-1
Integra Overview .................................................................... 1-2
Integra Components................................................................ 1-3
Flavor System Overview........................................................... 1-4
Flavor System Components ...................................................... 1-5
Bin Door Assembly Components – Integra 1 and Integra 4............ 1-6
Bin Door Assembly Components – Integra 0................................ 1-7
Section 2 :: Installation and Removal ................................2-1
Technical Specifications and Site Requirements ........................... 2-2
Plumbing ............................................................................... 2-4
Connecting the External Drain ...................................2-4
Water Supply..........................................................2-4
Problems with Reverse Osmosis Water System ............2-5
Flavor System......................................................................... 2-5
Control Box Installation ............................................2-5
Peristaltic Pump Assembly Installation........................2-5
Chocolate Heater Assembly Installation.......................2-6
Flavor Tubing Installation..........................................2-6
Priming the Flavor System ........................................2-7
Verify Flavor Pour Rate.............................................2-7
Additional Tasks Required at Installation..................................... 2-8
Power Up the Machine..............................................2-8
Bean Hopper...........................................................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 ...............................................................2-10
Section 3 :: Electrical ......................................................3-1
Electrical Block Diagram........................................................... 3-2
Electrical Enclosure.................................................................. 3-3
Electrical Enclosure Fan ............................................3-4
Front Panel Cable ....................................................3-4
AC Fuses................................................................3-4
Expansion Board (Top).............................................3-4
Analog (Middle).......................................................3-4
AC/DC Power Supply................................................3-4
Fuses.....................................................................3-5
AC/DC Power Supply Board....................................................... 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
Transformer Diagram – PN 1320-023 .......................3-11
Transformer Diagram – PN 1320-025 .......................3-11
Machine Operating Voltage......................................3-12
AC Voltage............................................................3-12
DC Voltage ...........................................................3-12
Valves..................................................................3-12
Diodes .................................................................3-12
Flavor System.......................................................3-13
DC Power Supply Board LEDs...................................................3-14
AC Distribution Panel ..............................................................3-16
Jumper Plug Connector Detail ..................................................3-17
Jumper Plug 2.......................................................3-17
Jumper Plug 3, 9, 11..............................................3-18
Jumper Plug 4, 5, 6, 12..........................................3-19
Jumper Plug 7.......................................................3-20
Jumper Plug 8, 10..................................................3-21
Troubleshooting .....................................................................3-22
Section 4 :: Software ......................................................4-1
Software Overview .................................................................. 4-2
Software Menu Informational Screens.........................4-2
Categories..............................................................4-2
Service Switch ........................................................4-3
Service Switch in the RUN position.............................4-3
Service Switch in the SERVICE position.......................4-3
The Service Switch and Cleaning the Machine..............4-3
Navigating the Menu System.....................................4-4
Accessing a Sub-Category.........................................4-4
Exiting the Menu System ..........................................4-4
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 ............................................................................4-11
Pump Pressure......................................................4-12
Espresso ..............................................................4-12
Milk Timings..........................................................4-13
Brewed Coffee (Long Black) ....................................4-14
Flavor Timings.......................................................4-15
CPU Board.............................................................................4-16
Loading New Software to a Machine..........................................4-17
Required Equipment...............................................4-17
Configuring HyperTerminal......................................4-17
Connecting the Laptop to the Machine ......................4-24
Updating Software for Customers with Custom Drink
Recipes ................................................................4-27
Section 5 :: Plumbing......................................................5-1
The Water System................................................................... 5-2
Water Supply.......................................................................... 5-3
Line Pressure ..........................................................5-3
Check Valve............................................................5-3
Water Filtration System............................................5-3
Reverse Osmosis Water System.................................5-3
Expansion Valve...................................................................... 5-4
Water Pump and Motor Assembly .............................................. 5-4
Flowmeter.............................................................................. 5-5
Hot Water Tank....................................................................... 5-6
Pressure Relief Valve................................................5-7
Temperature/Level Probe..........................................5-7
Level Probe............................................................. 5-7
Temperature Probe ..................................................5-8
Drain Valve.............................................................5-8
Water Out ..............................................................5-8
Brew Valve .............................................................5-8
Heating Elements ....................................................5-9
High Temperature Limit Switch – Water......................5-9
Draining the Water Tank...........................................5-9
Valve Tree.............................................................................5-10
Valve Tree Removal ...............................................5-11
Valve Tree Replacement .........................................5-13
The Steam System.................................................................5-14
Steam Tank...........................................................................5-15
Steam Valves........................................................5-16
High Temperature Limit Switch – Steam ...................5-16
Heating Elements ..................................................5-16
Water Level Probes................................................5-17
Pressure Relief Valve..............................................5-17
Safety Probe.........................................................5-18
Vacuum Break Valve ..............................................5-18
Draining the Steam Tank ........................................5-18
Front Panel Assembly..............................................................5-19
Steam Pressure Gauge ...........................................5-19
Water Pressure Gauge............................................5-20
Setting Pump Pressure ...........................................5-20
Check Water Flow Message .....................................5-20
Troubleshooting .....................................................................5-20
Section 6 :: Coffee System...............................................6-1
Coffee System Overview .......................................................... 6-2
Fresh Water Supply..................................................6-3
Water Pump / Motor Assembly...................................6-3
Flowmeter ..............................................................6-3
Hot Water Tank.......................................................6-3
Brew Valve Assembly ...............................................6-3
Brew Group ............................................................6-3
Grounds Chute........................................................6-3
Upper Piston ...........................................................6-4
Lower Piston ...........................................................6-4
Bean Hopper...........................................................6-4
Grinder ..................................................................6-4
Grounds Bin............................................................6-4
Espresso Nozzle.......................................................6-4
Bean Grinders......................................................................... 6-5
Calibration: Espresso Grind.......................................6-6
Replacing Bean Grinder Burrs/Blades ..........................6-7
Coffee Powder Channel.............................................6-7
Bean Hoppers......................................................................... 6-8
Inserting the Hopper Stopper ....................................6-8
Brew Group Overview .............................................................. 6-9
Upper Piston .........................................................6-10
Grounds Chute......................................................6-10
Sweep Arm...........................................................6-10
Brew Chamber ......................................................6-10
Thermal Switch .....................................................6-10
Brew Block ...........................................................6-10
Brew Chamber Heater ............................................6-10
Grounds Bin..........................................................6-10
Empty Grounds Bin................................................6-11
Troubleshooting .....................................................................6-11
Section 7 :: Milk System and Refrigeration System..............7-1
Milk Delivery System Overview.................................................. 7-2
Milk Delivery System Components............................................. 7-3
Milk Pump Assembly ................................................7-3
Pick-Up Screen........................................................7-3
Air Check Valve.......................................................7-3
Milk Pick-Up Tube....................................................7-3
Product Delivery Nozzle............................................7-3
Vacuum Break Valve ................................................7-3
The Drink Pour Process ............................................................ 7-4
Latte......................................................................7-4
Cappuccino.............................................................7-4
Milk System Theory of Operation............................................... 7-4
Basic Terminology....................................................7-4
Initial Setup of the Milk System .................................7-5
Milk System Capabilities ...........................................7-6
A Common Milk Timing Mistake..................................7-6
Air Gate Valve Assembly .......................................................... 7-7
Air Gate Valve.........................................................7-7
Air Vent Valves........................................................7-8
Air Vent Needles......................................................7-8
Milk Flow Sensor..................................................................... 7-9
Adjusting the Milk Flow Sensor .................................. 7-9
Cappuccino Temperature Adjustment Valve................................7-11
Mixing TEE............................................................7-11
Refrigeration Unit...................................................................7-12
Placing Milk in the Machine......................................7-12
Checking the Refrigeration Unit Temperature.............7-13
Refrigeration Unit Overview.....................................................7-13
Milk Pump Assembly ..............................................7-13
Refrigeration Cooling Module Assembly.....................7-14
Cold Sink Plenum...................................................7-15
Interior Fan Assembly ............................................7-15
Refrigeration Unit Temperature Probe Assembly.........7-15
Milk Pick-Up Tube..................................................7-15
Exterior Cooling Module Fan Assembly......................7-16
Troubleshooting .....................................................................7-16
Section 8 :: Flavor System...............................................8-1
Flavor System Overview........................................................... 8-2
Chocolate Sauce Delivery Path...................................8-2
Syrup Delivery Path .................................................8-3
Flavor Lines ............................................................8-4
Chocolate Heater Assembly.......................................8-4
Chocolate Sauce......................................................8-5
Flavor Storage Area................................................................. 8-5
Connecting Flavor Tubing..........................................8-6
Changing Flavor Boxes .............................................8-7
Changing the Flavor Pour Rate.................................................. 8-8
Verifying Proper Syrup Flow ....................................8-10
Peristaltic Pumps....................................................................8-10
Syrup Manifold.......................................................................8-11
Replacing the Syrup Manifold ..................................8-12
Cleaning the Flavor System .....................................................8-14
Priming the Flavor System.......................................................8-15
Troubleshooting .....................................................................8-16
Section 9 :: Steam Wand.................................................9-1
Steam Wand Overview............................................................. 9-2
ON/OFF Button........................................................9-2
Installation............................................................................. 9-2
Valves ................................................................................... 9-2
Replacing the Steam Wand Button............................................. 9-3
Replacing a Steam Wand.......................................................... 9-3
Removing a Steam Wand..........................................9-3
Troubleshooting...................................................................... 9-3
Cleaning the Steam Wand ........................................................ 9-4
Section 10 :: Cleaning and Maintenance........................... 10-1
Routine Machine Maintenance ..................................................10-2
Daily Maintenance..................................................10-2
Monthly Maintenance..............................................10-2
Concordia Cleaning Products ...................................10-2
Cleaning Timers.....................................................................10-3
Preventive Maintenance ..........................................................10-3
Section 11 :: Concordia Procedures................................. 11-1
Concordia Coffee Systems Service Call Protocol..........................11-2
Arrival to Site........................................................11-2
Machine Repair......................................................11-2
Hold for Parts Procedures........................................11-2
Departing from Site ...............................................11-2
Required Immediately for Call Closeout.....................11-3
Complete Call Protocol............................................................11-3
Machine Appearance ..............................................11-3
Brew Group ..........................................................11-3
Water Tank...........................................................11-3
Water Pump..........................................................11-3
Steam Tank..........................................................11-3
Refrigeration Unit ..................................................11-3
Espresso Extraction................................................11-3
Milk Pour..............................................................11-3
Service Call Checklist..............................................................11-4
Parts Return Policy for Non-Consignment Agents ........................11-5
Parts Return Policy for Consignment Agents...............................11-5
Return Material Tag ...............................................11-6
Parts Replenishment Form.......................................................11-7
Section 12 :: Customer Service and Training .................... 12-1
Training the Customer ............................................................12-2
Customer Training Includes.....................................12-2
User Guide............................................................12-2
Filling Machine with Beans and Milk..........................12-2
Making a Drink......................................................12-2
Serial Number.......................................................12-2
Accessing the Software Menu ..................................12-2
Cleaning...............................................................12-3
Ordering Cleaning Supplies .....................................12-3
Troubleshooting Tips..............................................12-3
Calling Concordia for Assistance...............................12-3
Concordia Coffee Systems’ Value-Added Service.........................12-4
Value-Added Service..............................................12-4
G.U.E.S.T..............................................................................12-6
Greet the Customer ...............................................12-6
Understand your Customer .....................................12-7
Empathize with the Customer..................................12-8
Solve the Problem..................................................12-9
Train the Customer................................................12-9
Section 13 :: Messages..................................................13-1
Troubleshooting Display Messages............................................13-2
Section 14 :: Troubleshooting......................................... 14-1
Troubleshooting Quick Reference Guide.....................................14-2
Machine Failure .....................................................14-2
Coffee System.......................................................14-3
Flavor System.......................................................14-4
Milk System..........................................................14-4
Troubleshooting Trees.............................................................14-5
Electrical System – CHK ANALOG BOARD..................14-6
Electrical System – CHECK STATS............................14-7
Electrical System – CHECK CLOCK............................14-8
Electrical System – AC Board Failures.......................14-9
Electrical System – Incorrect Software for Touchpad.14-10
Electrical System – Repeated CHECK MILK Error ...... 14-11
Electrical System – NOT CONFIGURED....................14-12
Electrical System – Card Swipe or Tap Not Authorized...14-
13
Electrical System – No Display on Card Reader ........ 14-14
Electrical System – LOAD DISP DATA and LOAD SEQ DATA
.........................................................................14-15
Electrical System – DC Board Failures – PAGE 1....... 14-16
Electrical System – DC Board Failures – PAGE 2....... 14-17
Electrical System – FRONT PANEL FAILED ............... 14-18
Coffee System – Initialize Group............................ 14-19
Coffee System – Extended PLEASE WAIT Message – PAGE
1....................................................................... 14-20
Coffee System – Extended PLEASE WAIT Message – PAGE
2....................................................................... 14-21
Coffee System – CHECK WTR FLOW – PAGE 1..........14-22
Coffee System – CHECK WTR FLOW PAGE 2 ............ 14-23
Coffee System – OUT OF BEANS / NO GROUNDS......14-24
Coffee System – Slow Espresso Pour ......................14-25
Coffee System – Upper Piston Stuck in Up/Chamber
Position – PAGE 1 ................................................14-26
Coffee System – Upper Piston Stuck in Up/Chamber
Position – PAGE 2 ................................................14-27
Milk System – Cold Milk Pour – PAGE 1................... 14-28
Milk System – Cold Milk Pour – PAGE 2................... 14-29
Milk System – Milk Overpour – PAGE 1 ..................14-30
Milk System – Milk Overpour PAGE 2......................14-31
Milk System – No Milk Pour – PAGE 1 ..................... 14-32
Milk System – No Milk Pour – PAGE 2 ..................... 14-33
Milk System – Short Pour Milk – PAGE 1..................14-34
Milk System – Short Pour Milk – PAGE 2..................14-35
Refrigeration System – REFR TEMP HI – PAGE 1.......14-36
Refrigeration System – REFR TEMP HI – PAGE 2.......14-37
Refrigeration System – REFR TEMP LO.................... 14-38
Refrigeration System – REFR DOOR OPEN...............14-39
Steam System – CHK SENSOR VOLTAGE.................14-40
Steam System – CHK STEAM PROBES .................... 14-41
Steam System – Steam High Limit.........................14-42
Steam System – STEAM TEMP HI........................... 14-43
Steam System – STEAM TEMP LO – PAGE 1............. 14-44
Steam System – STEAM TEMP LO – PAGE 2............. 14-45
Steam System – No Steam During Milk Pour – PAGE 1..14-
46
Steam System – No Steam During Milk Pour – PAGE 2..14-
47
Steam System – No Steam During Milk Pour – PAGE 3..14-
48
Steam System – CHECK STEAM TANK .................... 14-49
Flavor System – Cross-Contamination of Flavors......14-50
Flavor System – Not Enough Flavor........................ 14-51
Flavor System – No Flavor in Drink – PAGE 1........... 14-52
Flavor System – No Flavor in Drink– PAGE 2............ 14-53
Flavor System – Too Much Flavor in Drink............... 14-54
Water System – CHK WATER SUPPLY – PAGE 1........ 14-55
Water System – CHK WATER SUPPLY – PAGE 2........ 14-56
Water System – Water Tank Limit Switch Open – PAGE 1
.........................................................................14-57
Water System – Water Tank Limit Switch Open – PAGE 2
.........................................................................14-58
Water System – WATER TEMP HI...........................14-59
Water System – WATER TEMP LO........................... 14-60
Section 15 :: Parts List & Diagrams ................................. 15-1
Recommended Tools List.........................................................15-2
Standard Tools......................................................15-2
Concordia Stocked Tools.........................................15-2
Consumables ........................................................15-2
Parts List and Diagrams ..........................................................15-3
Diagram 1: Machine Overview.................................15-4
Diagram 1, Parts List: Machine Overview ..................15-5
Diagram 2: Bin Door Assembly................................15-6
Diagram 2, Parts List: Bin Door Assembly .................15-7
Diagram 3: Refrigeration Unit Door ..........................15-8
Diagram 3, Parts List: Refrigeration Unit Door............15-9
Diagram 4: Front Panel ........................................ 15-10
Diagram 4, Parts List: Front Panel..........................15-11
Diagram 5: Grinder Assembly................................15-12
Diagram 5, Parts List: Grinder Assembly.................15-13
Diagram 6: Brew Group Assembly..........................15-14
Diagram 6, Parts List: Brew Group Assembly...........15-15
Diagram 7: Milk Delivery System...........................15-16
Diagram 7, Parts List: Milk Delivery System.............15-17
Diagram 8: Refrigeration Unit Module Assembly....... 15-18
Diagram 8, Parts List: Refrigeration Unit Module Assembly
.........................................................................15-19
Diagram 9: Steam Tank Assembly..........................15-20
Diagram 9, Parts List: Steam Tank Assembly...........15-21
Diagram 10: Water Tank ...................................... 15-22
Diagram 10, Parts List: Water Tank Assembly .......... 15-23
Diagram 11: Electrical Enclosure............................ 15-24
Diagram 11, Parts List: Electrical Enclosure.............15-25
Diagram 12: Sauce Delivery System.......................15-26
Diagram 12, Parts List: Sauce Delivery System........ 15-27
Diagram 13: Milk Pump Assembly..........................15-28
Diagram 13, Parts List: Milk Pump Assembly............15-29
Diagram 14: Flowmeter........................................ 15-30
Diagram 14, Parts List: Flowmeter ......................... 15-31
Diagram 15: Water Pump Assembly .......................15-32
Diagram 15, Parts List: Water Pump Assembly......... 15-33
Section 16 :: Index....................................................... 16-1
Section 17 :: Service Bulletins........................................ 17-1
Service Bulletins ....................................................................17-3
Section 1 :: Integra Overview
1. Integra Overview
2. Integra Components
3. Flavor System Overview
4. Flavor System Components
5. Bin Door Assembly – Integra 1 and 4
6. Bin Door Assembly Components – Integra 1
and 4
7. Bin Door Assembly – Integra 0
8. Bin Door Assembly Components – Integra 0
TECHNICAL SUPPORT
Section 1: Integra Overview 3029-001x
Integra Overview
1-2 Concordia Integra Technical Support Manual
2900-245B
3029-001x Section 1: Integra Overview
Integra Components
Air Gate Valve Assembly
The air gate valve assembly allows a regulated supply of air to
mix with the milk inside the milk pump assembly.
Milk Pump Assembly
The milk pump assembly draws milk from the milk container.
Bean Hopper
Each bean hopper holds whole espresso roast beans and feeds
the beans to the grinders.
Refrigeration Module Assembly
The refrigeration module assembly regulates the temperature
inside the refrigeration unit.
CPU Assembly
The CPU assembly controls all machine functions.
AC/DC Power Supply
The AC/DC power supply board provides the voltage for the
machine.
Syrup Manifold
Syrup is infused into drinks via the syrup manifold.
Brew Group
The brew group assembly brews espresso and automatically
discards the used coffee into the grounds bin.
Water Pump
The water pump regulates the water pressure to 140psi during
the espresso extraction process.
Grinders (Left and Right)
The grinders are calibrated to grind espresso beans according
to the customer’s recipe.
Valve Tree Assembly
The valve tree assembly houses the hot water valve, steam fill
valve, chocolate purge valve, and steam tank purge valve.
Hot Water Tank
The hot water tank stores and heats the water used to brew
espresso.
Steam Tank
The steam tank provides steam used for steaming the milk.
Concordia Integra Technical Support Manual 1-3
2900-245B
Section 1: Integra Overview 3029-001x
Flavor System Overview
DRAIN
115 VAC
208 VAC
POWER
SUPPLY
WATER
FILTER
10'
CONTROL
UNIT
WATER
SUPPLY
INPUT
FLAVOR
BOXES
PUMP UNIT
19"W x 13"D x 9"H
4'
SYRUP RACK
WITH WARMING MAT
12"
115 VAC
16"
9.5"
12" / 305 mm
32" / 82 cm
FLAVOR BOX
DIMENSIONS
6.25"
15.5"
1-4 Concordia Integra Technical Support Manual
2900-245B
3029-001x Section 1: Integra Overview
Flavor System Components
Integra 1 and Integra 4 only
Pump Unit
The pump unit is the assembly of peristaltic pumps that moves
the product from the box to the syrup manifold.
Control Unit
The control unit houses the electronic board, which controls the
syrup pumps.
Power Supply
The power supply provides power to the control unit.
Chocolate Heater Assembly
The chocolate heater assembly provides heat to the flavor tray
used for chocolate sauce, to ensure a minimum temperature of
85°F/29°C is maintained.
Syrup Rack
The flavor boxes are placed on syrup racks, in the designated
flavor storage area.
Concordia Integra Technical Support Manual 1-5
2900-245B
Section 1: Integra Overview 3029-001x
7 4
5
3
Bin Door Assembly Components – Integra 1 and Integra 4
2
1
6
1. Syrup Manifold – Steam, air, milk, and syrup are
mixed in the syrup manifold.
2. Milk Input Tube – The milk input tube introduces milk
to the syrup manifold.
3. Flavor Tubes – INTEGRA 4 ONLY
The syrup tubes transfer syrup from the flavor boxes to
the syrup manifold. The flavor lines utilize the same
color coding that is present on the flavor boxes.
4. Chocolate Sauce Tube – The chocolate sauce tube
transfers chocolate sauce from the chocolate sauce box
to the syrup manifold. The chocolate sauce tube utilizes
the same color coding that is present on the chocolate
sauce box.
5. Milk Output Tube – Once milk and any flavor have
been mixed on the syrup manifold, the milk output tube
transfers the milk mixture to the product delivery output
and into the customer’s cup.
6. Product Delivery Outlet – The product delivery outlet
dispenses drinks and hot water.
7. Display Board – The display board provides power to
the menu board on the front of the machine.
1-6 Concordia Integra Technical Support Manual
2900-245B
3029-001x Section 1: Integra Overview
3
1
Bin Door Assembly Components – Integra 0
2
1. Milk Input Tube – The milk input tube introduces milk
to the syrup manifold.
2. Product Delivery Outlet – The product delivery outlet
is where drinks and hot water are dispensed.
3. Display Board – The display board provides power to
the menu board on the front of the machine.
Concordia Integra Technical Support Manual 1-7
2900-245B
Section 1: Integra Overview 3029-001x
Page Intentionally Left Blank
1-8 Concordia Integra Technical Support Manual
2900-245B
Section 2 :: Installation and
Removal
1. Technical Specifications and Site
Requirements
2. Machine Dimensions
3. Plumbing
4. Flavor System
5. Additional Tasks Required at Installation
6. Operational Configuration
7. Machine Calibration
8. Customer Training
9. Installation Checklist
10. Removal Procedures
TECHNICAL SUPPORT
Section 2: Installation and Removal 3029-002x
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.
Technical Specifications
Weight:
Operating Environment:
Maximum ambient temp: 85°F /29°C
Power Consumption:
Compliance:
FCC:
UL Listed
NSF Listed
CE Compliant
Location Requirements
Locate indoors only
Overall Space
20” W x 28” D x 28” H
49cm W x 71cm D x 71cm H
Flavor System
30” W x 30” D x 27” H
76cm W x 76cm D x 69cm H
Drain
Connection for ¾”/1.9cm drain dose
Indirect drain required
Located within five feet/1.5 meters of machine
200lbs/137kg
55°- 85°F (13°-29°C)
19 amps @ 208vac max
4 amps @ 115vac max
Part 15B, Class A, Part 68
Power and Water Requirements
Power
Located within five feet/1.5 meters of machine
Single Phase:
200-240vac, 30amp dedicated circuit
NEMA L6-30P Receptacle
High Leg:
200-240vac, 30amp, high leg dedicated circuit.
International machines are shipped withou t a power plug.
A plug must be attached at the time of installation and
meet with all local electrical co des.
Flavor System
Chocolate Heater Assembly
115vac, 15amp
NEMA 5-15P
Flavor Control Box
115vac, 15amp
NEMA 5-15P
Water
Cold water source with a ¼” or 3/8” tube 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)
20.5”H x 11.5”W x 5”D
52cm Hx29cm Wx13cm D
2-2 Concordia Integra Technical Support Manual
2900-245B
3029-002x Section 2: Installation and Removal
Machine Dimensions
Concordia Integra Technical Support Manual 2-3
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Section 2: Installation and Removal 3029-002x
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 ¾”/1.9cm ID drain hose
Drain must be located within 5 feet/1.5 meters of
machine
DRAIN HOSE
FROM MACHINE
INDIRECT
DRAIN
The minimum rate of fall required is 1 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 create clogs in either the
drain hose and/or the drain tray.
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 female ¼”
or 3/8” tube fitting.
• Minimum Pressure: 30psi; Maximum 100psi.
• Water source must be located within 5 feet/1.5 meters
of machine.
• All machines ship with a Scalex® Water Treatment
System.
DRAIN HOSE
FROM MACHINE
FLOOR SINK
DRAIN
Prior to connecting the water filter to the machine, flush the
water filtration system with 2 gallons/8 liters of water.
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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. Using a reverse
osmosis water system will negatively affect the flavor of
espresso drinks.
Flavor System
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 cross-contamination
of flavors does not occur.
Prior to installing the flavor system, ensure that the designated
location for the flavor system has adequate space for the
chocolate heater assembly, the peristaltic pump assembly,
flavor tubing, and control box.
Control Box Installation
The control box is responsible for supplying power to the
peristaltic pump assemblies.
1. Mount/position the control box within the designated
flavor location.
2. Connect the two cables from the machine.
3. Connect the control cable from the peristaltic pump
assembly.
4. Connect the power supply cable.
NOTE: The power supply cable must be plugged into a
power source appropriate for the location (this varies by
country).
Peristaltic Pump Assembly Installation
Each peristaltic pump assembly houses two pumps. All tubing
should already be connected and installed in the peristaltic
pump(s).
1. Place the peristaltic pump assembly in the designated
location for the flavor system.
2. Attach the tubing that connects the peristaltic pump
assembly to the machine – this is the tubing connected
to the output side of the peristaltic pump assembly.
3. Attach the tubing that connects the peristaltic pump
assembly to the flavor boxes – this is the tubing
connected to the “input” side of the peristaltic pump
assembly.
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Section 2: Installation and Removal 3029-002x
When positioning the peristaltic pump assembly, it is important
to position it in such a way that the tubing will comfortably
reach both the machine and flavor boxes, and that the tubing
will not be damaged, twisted, bent, or kinked. The assembly
needs to be within 10 feet of the machine, and within four feet
of the flavor boxes.
Chocolate Heater Assembly Installation
Plug the power cord for the chocolate heater assembly into a
wall plug outlet (115vac domestic, 230vac international). The
chocolate heater assembly can reach full operating temperature
within 15 minutes.
NOTE: It can take more than 24 hours for a box of chocolate
sauce to warm up to the proper temperature, depending on the
temperature of the chocolate sauce at the time it is put on the
chocolate flavor rack. For this reason, it is strongly
recommended to always have to an extra box of chocolate
sauce on the chocolate heater assembly, to ensure an
uninterrupted supply of chocolate sauce is available.
Once the chocolate heater assembly is situated, place the
chocolate sauce boxes on it, and then place the remaining
flavor boxes next to them. Ensure all tubing is free from kinks
or bends.
NOTE: The chocolate heater assembly can only be used for
chocolate sauce. Placing a non-chocolate flavor box on the
chocolate heater assembly will degrade the quality of the flavor
syrup.
Flavor Tubing Installation
1. Connect the tubing from the peristaltic pump(s) to the
flavor box(es).
2. Connect tubing from the machine to the peristaltic pump
assembly.
NOTE: Re-inserting a dry o-ring may result in leaks. See the
Connecting Flavor Tubing topic in Section 8: Flavor System.
The Integra 1 and Integra 4 are shipped with the flavor tubing
pre-installed.
When attaching and arranging the tubing in the flavor area,
ensure all tubing will not be damaged, twisted, bent, or kinked.
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3029-002x Section 2: Installation and Removal
Priming the Flavor System
The flavor system must be primed under the following
circumstances:
• Initial setup of flavor system
• Changing a flavor (e.g. replacing caramel with almond)
NOTE: The affected flavor tube MUST be cleaned
before the new flavor is introduced.
• Purging an air bubble from a tube
• Replacing flavor tubing
• Replacing the syrup manifold
Please see the Priming the Flavor System topic in Section 8:
Flavor System.
Verify Flavor Pour Rate
It is important to verify flavor volume and ensure the volume of
flavor meets the requirements and preferences of the
customer.
Please see the Changing the Flavor Pour Rate topic in Section
8: Flavor System, for information about adjusting the time and
volume of flavor pours.
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Section 2: Installation and Removal 3029-002x
Additional Tasks Required at Installation
Power Up the Machine
1. Close the steam and hot water tank drain valves.
2. Ensure the electrical cord is plugged in and twist-locked.
3. Ensure water is supplied to unit and the valves are open.
4. Ensure the unit is connected to a drain.
5. Start the unit by turning on the main power switch
located behind the refrigerator door.
6. Warm-up will take 10-15 minutes.
NOTE: The grounds bin must be in place and all doors
must be closed.
Bean Hopper
1. Install the bean hopper.
2. Fill each bean hopper compartment with fresh, whole,
espresso roast beans. For information on the bean
hopper, please see Section 6: Coffee System.
IMPORTANT: Ensure the hopper stoppers are
removed, so that beans are delivered to the grinders.
Operational Configuration
The Integra may be configured with a default recipe, depending
on customer requirements. If a customer-specific recipe exists,
it may be pre-programmed into the machine prior to delivery at
the customer site. 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.
At this time, navigate to TIME & DATE and set the time and
date. Please see Section 4: Software for detailed instructions on
accessing and using this menu.
Placing Milk in the Refrigeration Unit
Place a one-gallon/four-liter container of milk in the
refrigeration unit and insert the milk pick-up tu be into the milk
container.
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