Franke La Marzocco GB5, La Marzocco FB-70, La Marzocco Linea, La Marzocco FB-80 Training Manual

Franke Coffee Systems

North America Inc

5601 1st Ave South

Seattle,WA 98108

Ph 800.310.5710 Fax [phone]

www.franke-cs.com

La Marzocco Training Manual

The La Marzocco is set apart from most other espresso machines due to its two-boiler sys­tem. Having separate coffee and steam boilers allows the machine to achieve and maintain
exceptional thermal balance.

Single boiler espresso machines’ brewing water comes from a heat exchanger located
inside the steam boiler. Brewing water temperature is solely dependent on the pressure of
the water in the boiler used for steaming. As the steam boiler’s pressure rises and falls dur­ing normal operation so does the water temperature in the heat exchanger used for brew­ing.

The LaMarzocco has a separate boiler for each function. A coffee boiler to heat water for
brewing espresso and a steam boiler used to generate steam for preparing milk and hot
water for tea or americanos. This two-boiler system allows for the perfect brewing temp
even if the steam boiler has been under extremely heavy steaming or water usage.

Safety & Tools

Safety Precautions

Before performing maintenance on the steam boiler:
* Turn the machine off.
* Depressurize the steam boiler by opening one or both steam arms.

The only exception would be when rebuilding the steam assemblies, then it will be neces­sary to close the ball valves located on the steam tank.

Before performing maintenance on the coffee boiler:
* Turn the machine off.
* Turn off the incoming water supply.
* Depressurize the coffee boiler by opening the expansion valve.

When performing maintenance on any electrical wiring in the machine, apart from taking
voltage or amp readings ensure the machine is unplugged from the wall outlet.

Tools

Certain maintenance procedures may require one of the following tools, which are unique
to the La Marzocco.

1. Sight Glass Tool

2. Heating Element Wrench

3. Diffuser Tool (only for machines prior to April 2003)

Other tools required are common tools available at most hardware stores:
* Combination metric wrench set ranging from 10mm to 26mm
* Metric Allen wrench set
* Multi-meter
* 3/16 x 4" Standard screwdriver
* 1/4 x 4" Standard screwdriver
* Stubby standard screwdriver
* #2 Phillips screwdriver
* Mini Screwdriver set
* Fuse puller
* Small wire brush
* Wire stripper/crimpers
* Diagonal cutters
* Slip-joint pliers
* Needle-nose pliers
* Snap-ring pliers
* 6, 8 & 10" Adjustable wrenches

* Teon tape

* Food Grade lube gel
* Fuses - (5 x 20mm) 40mAmp, 125mAmp, 1 amp, 10amp and 6.3 amp

Machine Overview, Linea

1

4 3 2

8 7 6 5

10 9

11

12 13

1. Steam Knob, Left 8. Steam Knob, Right

2. Keypad 9. Main Switch

3. Semi-automatic Dispense Switch 10. Portalter

4. Dual-scale Pressure Gauge 11. Group Head

5. Coffee Boiler Heating Element Indicator Light 12. Hot Water Nozzle

6. Hot Water Dispense Switch

13. Sight Glass

14. Steam Wand

Steam Valve Body

Crush Washer

Steam End Gasket

Steam Shaft

Shaft Spring

Shaft O-Rings

Washer

1 & 8 Steam Knobs

The steam knob allows the
barista to open and close the
steam assembly to prepare the
milk used in milk-based drinks.

Washer

Circlip

Swivel
Steam
Wand

Wand

Spring

Wand O-Rings

Steam Wand

Hairpin
Clip

Wand
O-Rings

14

Steam Valve Housing

Mounting Nut

Knob

Washers

Cotter Pin

Bezel

Insert

2. Keypads

BOILER

PRESSURE

DISPENSING

PRESSURE

0,5

1

1,5

2

2,5

3

15

12

9

3

6

The keypads contain up to four seperate product buttons, single ristretto, single shot,
double ristretto, and double shot. Generally, the buttons are programmed to dispense 3/4
oz, 1 oz, 1-1/2 oz, and 2 ounces respectively, but they can be programmed to any desired
volume.

3. Semi-Automatic Dispense Switch

The semi-automatic dispense switch allows you to brew with the machine while by­passing the electronic keypads. Activating the switch sends power directly to the group

valve allowing water to ow through the group head. This switch is generally used when the

fuse in the control box has blown.

4. Dual-Scale Pressure Gauge

The pressure gauge is divided into two sections,
top and bottom. The top portion of the gauge reads
the steam pressure in the rear boiler. The steam
pressure is factory set to 1.2 bar. The bottom
portion of the gauge reads the brewing pressure in
the front boiler. The gauge will read the static water
pressure going to the espresso machine, when the
machine is turned off. When the machine is turned
on, the heating elements will activate, heating the
water in both boilers. As the water heats up in the
front boiler, it expands. The front boiler is a closed,
totally saturated vessel, with no room for the water to
expand into. This causes the pressure to increase,
evidenced by the bottom protion of the gauge
climbing. Once the gauge needle reaches 12 bar,

the expansion valve, located in the drain box,
should unseat and prevent the pressure from climbing higher than 12 bar. If the gauge does
not reach or exceeds 12 bar, adjust the barrel of the expansion valve accordingly.

5. Coffee Boiler Heating Element Indicator Light

This red light illuminates whenever the heating element in the front, or coffee, boiler is
activated. When the water in the coffee boiler reaches the temperature the thermostat has
been set to, the thermostat will cut power to the heating element and the light will go out.
During initial machine start-up, wait for this light to go out before brewing.

6. Hot Water Dispense Switch

Depressing this switch activates the hot water solenoid valve, allowing the valve to open
and water from the steam boiler to exit the hot water nozzle. Steam pressure must be
present in the steam boiler to force water through the valve.

7. Manual Fill Switch

Depressing this switch activates the auto-ll valve, allowing cold water to ow into the

steam boiler. This switch would only be used if the fuse in the control box has blown.

9. Main Switch

The main power switch has three positions: OFF, FILL and RUN (or 0,1,2 on older ma­chines.)

Off - The machine is off
Fill - The electonics are activated, but NOT the heating elements. This allows the machine

to auto-ll prior to the elements heating up.

Run - The electronics as well as the heating elements are activated allowing the machine to
build steam pressure and the coffee boiler to heat up.

10. Portalter

The portalter holds the ground coffee dosed from the grinder. The portalter, dosed and

tamped with coffee is then inserted into the group head to brew espresso.

11. Group Head

The group head is where the brewing water meets with the ground coffee in the portalter

to brew espresso.

The La Marzocco’s group head is called a saturated group. It is either a nickle-plated brass
group, (machines manufactured prior to March 2003) or a stainless steel group, (machines
manufactured from March 2003 to the present).

Brass Group

Group to Boiler
Gasket*

Exit port to Flow­meter

Bleed Screw

Thermal Limiter
Group Cap

O-ring
Banjo Bolt

Fiber Gasket

Banjo Tube

Group Head
O-ring
Diffuser Block

Portalter Gasket

Bayonet Clamp Ring

Stainless Group

The banjo tube has been
redesigned, the banjo bolt is
no longer required.*

Diffuser Screen

Diffuser Screw

Group is welded
to the boiler*

12. Hot Water Nozzle

The hot water nozzle is installed on the outlet of the hot water valve. When the valve is
energized, hot water from the steam boiler is forced, by steam pressure, through the valve
and out of the nozzle.

13. Sight Glass

The sight glass indicates the amount of water in the steam boiler only,as the coffee boiler is
always fully saturated with water. The sight glass should read between 2/3 and 3/4 during
normal operation.

Body

O-ring

Glass

Fiber Gasket

Securing Bezel

Fitting

Washer

Bleed Screw

14. Steam Wand

The steam allows the barista to prepare milk for drinks suchs as lattes, cappuccinnos, and
mochas. The La Marzocco uses stainless steel wands that rotate 360 degrees.

Body Panels

For most repairs, it may be necessary to remove a body panel.

1. Top Trim

2. Upper Surround Panel

3. Left Side Panel

4. Right Side Panel

5. Front Panel

1

6

7

4

Steaming

6. Cup Tray

7. Cup Tray Grates

8. Group Cover

2

5

8

9. Drip Tray & Grates

3

9

Installation

Contents

When unpacking the machine, the following items should be included:
* 4 NSF Legs (6 for a 4 group machine)
* Pump & motor assembly

* Portalters

* Drain Hose
* Tamper
* PuroCaff Cleaner
* Owners manual
* Inlet hoses, 24”, 48”, and 84” lengths
* Warranty card with water test strip attached

Water Requirements

A dedicated water line with its own shut-off valve should be placed within four feet of machine instal-

lation location. The shut-off valve should be equipped with a male 3/8 compression tting.

The machine operates best with water between 0-3 grains of hardness. Higher hardness levels may
cause damage due to scale forming inside the machine. If the supply water has a hardness above
3 grains per gallon install the appropriate water softener. ENSURE ALL SOFTENING/FILTERING

CARTRIDGES HAVE BEEN ADEQUATELY FLUSHED BEFORE CONNECTING TO THE MA­CHINE.

ESI recommends our H2O for Espresso system. This cartridge provides both a carbon block to lter
out tastes and odors as well as ion exchange resin for softening of the incoming water. The car­tridge also incorporates a 20% bypass to neutralize the pH allowing for a water “recipe” that pro­vides the best tasting espresso.

In some areas of the country, the use of a Reverse Osmosis system, is necessary. When us­ing an RO system, ensure a small percentage of raw water bypasses the RO system and is then
reintroduced into the RO water fed to the espresso machine. This helps prevent corrosion due to

aggressive water properties. The “postmix” water should then be fed through a carbon block lter to

remove tastes and odors.

Power Requirements

The following voltages and amperage ratings apply.
* 1AV OR EE – 208 - 240v, 20amp
* 2AV OR EE– 208 - 240v, 30amp
* 3AV OR EE– 208 - 240v, 50amp
* 4AV OR EE– 208 - 240v, 50amp
There are two electrical cords attached to the machine. The smaller diameter cord supplies pow-

er to the pump motor assembly and should be connected to the pump motor, NOT plugged
into a wall outlet.

Drainage Requirements

Ensure the drain hose provided with the machine runs downhill to an appropriate oor drain.

First time machine start-up

Once the machine has been properly installed:
* Turn on the water supply.

* The coffee boiler(s) will automatically begin to ll.

* Locate the group caps and loosen the bleed screw 1/4 turn until a water bead is visible.
Once a water bead is visible, re-tighten the bleed screw snugly.
* Once the groups have been bled, turn the main power switch to the FILL position. Within 6

seconds, the rear (steam) boiler will automatically begin to ll .
* Once the rear (steam) boiler has lled, (check the sight glass to ensure the rear boiler has
lled to the appropriate level, between 2/3 - 3/4 full), turn the main power switch to

the RUN position.
* While the boilers are heating, press any dispense switch and ensure the pump pressure
(bottom scale of the gauge) reads 9 bar while dispensing. Adjust if necessary.
* Wait for the boilers to heat fully indicated by the coffee boiler heating light going off and the
top scale of the pressure gauge reaching 1.2 - 1.5 bars.

Pre-infusion

Pre-infusion is the dampening of the coffee grounds allowing them to expand in the portalter prior
to the actual brewing process beginning. This seems to improve the coffee avor of single shots.

To program the machine to pre-infuse, perform the following:
* Turn the main power switch to the OFF position.
* While holding the far left (single ristretto) button on the left most keypad turn the power
switch to FILL.
* The light above the “Swirl” button will illuminate indicating that the control box has received
the pre-infusion command.

To disable pre-infusion, perform the following:
* Turn the main power switch to the OFF position.
* While holding the second button on the left most keypad turn the power switch to the FILL
position.
* The light above the “Swirl” button will illuminate indicating that the control box has received
the pre-infusion command.

Programming

* Using the left most keypad, depress and hold the continuous pour (swirl) button for about 5
seconds.
* Once all of the lights on the keypads begin blinking press the button you wish to program.
* Once the desired volume has been reached, (measure from the bottom of the crema),
push the button again.
* Repeat this procedure for each button.

*Any programming performed on the left group will carry over to all of the groups to the
right. After programming the left group, verify that groups to the right are dispens

-ing the proper volume. You can also individually program the right groups without
affecting the others.

Temperature and Pressure Adjustments

Machines ship from ESI with the coffee boiler thermostat adjusted to heat and brew water for
espresso at 197 degrees Fahrenheit or 92 degrees Celsius. If you prefer to adjust the tempera-

ture to t your coffee roast perform the following:

* Make certain that the machine is at operating temperature and that the coffee boiler

heating indicator light is off.
* Remove the top cover from the machine and locate the thermostat between the groups.
* Turn the main switch to the OFF position.
* Using a long insulated screwdriver adjust the thermostat clockwise to increase tempera
ture and counter-clockwise to lower temperature.

* This adjustment is very sensitive and only slight adjustments should be made. Each 1/4
turn represents a 3 degree Fahrenheit temperature change.
*Turn the main switch back to the RUN position.

If your steam pressure gauge does not read 1.2 bar, adjust the pressure switch as follows:

*Turn the main switch to the OFF position.
* Remove the top panel of the machine.
* Locate the pressure switch in the back, top, left-hand corner of the machine.

* For machines equipped with Sirai pressure switches (Rectangular switch approximately
2” x 4”), remove the screw and lift cover from pressure switch to access the adjust
ment screw. There will be arrows pointing towards - and +. Turn towards - to lower
the steam pressure and turn towards + to raise steam pressure.
* For machines equipped with Giemme pressure switches (Round switch approximately

1-1/4 in diameter), locate the samll adjustment screw in the center of the switch
and adjust very delicately towards - to decrease the presure and + to increase the
presure.
*Turn the main switch back to the RUN position.

Section 1 Questionnaire

1. What’s unique about the La Marzocco espresso machine compared to other traditional machines
on the market?

2. Why are two boilers in an espresso machine better than having only one?
A. The heat exchangers require less maintenance.
B. More stable brewing temperature.
C. The machine uses less electricity.
D. You can operate the machine at a higher steam pressure.

3. What safety precautions must be carried out before performing maintenance on the coffee boiler?

A.

B.

C.

4. What are the three special La Marzocco tools?

A.

B.

C.

5. There are two electical cords coming out of the machine. What are each of them for?

6. What must you do to the coffee boiler after initial installation before you operate the machine?

7. Explain why the bottom portion of the pressure gauge travels up and down between 3 bar and 12
bar during normal operation?

8. What design change allows for a more stable and effecient brew temperature on machines
manufactured after March 2003?

9. How should the water supplying the machine be treated to ensure its quality?

10. What are the proper steps to take when programming the machine?

A. Turn the machine offand hold down the continuous pour button while turning the machine
on.
B. Press and hold the continuous pour button until the LED above the button illuminates.
Then press the button you wish to program.
C. Press the continuous pour and the button you wish to program at the same time. When
the lights blink, press the button you wish to program again.

11. Which keypad do you program to facilitate programming of the entire machine?

12. Why don’t we generally recommend using water treated by reverse osmosis, except in extenu­ating circumstances?

A. It’s more expensive and complicated to use than lter/softening cartridges.

B. It can cause the water to become very agressive, causing corrosion.

C. It can remove too much of the TDS in the water, causing the auto-ll system to not func-

tion properly.
D. The coffee usually doesn’t taste as good.

13. If circumstances require you to use RO water, what step should you take to alleviate the neg­ative side effects of RO water in espresso machines?

14. Explain the three positions of the main power switch.

A. Off -

B. Fill -

C. Run -

15. What does the red light on the machines control panel indicate when illuminated?

16. How do you initiate the pre-infusion feature of the La Marzocco?

4. Hydraulic System

Tubing and ttings

* Virtually all of the ttings on the LaMarzocco are of the compression or are type. Most are made

from brass, which will strip or crack if over-tightened.
* It is important when working with tubing not to bend or twist the sections you are working with, as

this will restrict the water ow or cause fatigue or leaks in the tubing.

Boilers & Groups

The La Marzocco uses hollow plated brass group castings attached to a stainless steel boiler on
machines manufactured prior to March 2003, and stailess steel groups welded to the boiler on ma­chines manufactured beginning March 2003.

*In auto-volumetric models, the water from the group exits through a small tube on the left side of

the group and ows to the owmeter, which meters the volume of the water. From the
owmeter the water passes through to the group valve. From the group valve, the water
then ows back into a small tube inside of the group head and then to the diffuser block, the
diffuser screw, diffuser screen and nally to the ground coffee in the portalter

Below is a cutaway of a grouphead. Below the photo is the sequence of water ow through the
group to the portalter.

2

1

6

7

3

8

4

5

1. Water exits the group head and travels through a tube to the owmeter.

2. Water enters the owmeter and rotates the impellor.

3. Water exits the owmeter and travels through a tube to the group valve.

4. Water passes through the group valve...

5. And travels through a tube to the banjo tube inlet.

6. Water enters the banjo tube and ows to the banjo bolt.

7. Water passes through the banjo bolt and down towards the diffuser block.

8. Water passes through the diffuser block and enters the diffuser screw and screen where it

then meets with the tamped coffee in the portalter.

Group Valves

Each group has a three-way solenoid valve mounted underneath each head to allow for water

ow through the group.

* Each valve consist of valve body, valve stem, spring-loaded
piston and a coil.
* The valve is mechanically closed by spring pressure.
* The coil receives electrical power when the brew switch or
keypad is depressed.

* When energized, the coil creates a magnetic eld which opens
the piston, allowing water to ow through the valve body.

* When the valve closes, pressurized water from the valve outlet to

Valve Piston

Valve Body

Solenoid Coil

Brass Washer

Fitting for tube from
Flowmeter

Valve Shaft

the diffuser block discharges through the bottom of the
valve stem to the drain box.

Flowmeters

Ground Wire

The owmeters measure the volume of water passing through to the

groups.

* The Flowmeter is made up of an electromagnetic eld, an impeller

and a body.
* As water enters the Flowmeter body it causes the impeller to
rotate. The impeller has two small magnets imbedded in it.

As the impeller spins, the magnets pass the magnetic eld,

causing a switch to close, which sends a pulse signal to the
microprocessor.

Flowmeter Field

Magnets

Impellor

O-ring

Flowmeter Body

Autoll System

The autoll system maintains the water level in the steam boiler.
* The autoll system consists of an autoll circuit on the control box, an auto-ll probe and an
autoll valve.
* The autoll probe is a metal probe, which sticks down into the boiler. An electrical lead is at

tached to the top of the probe, approximately 1-2 vac travels through this probe from the
control box.
* As the water rises in the boiler, and reaches the probe, the 1-2 vac travels through the water
and grounds itself against the sidewall of the boiler. When this ground signal travels back

to the control box, it signals the auto-ll circuit to switch off the auto-ll valve.

* As water is depleted from the boiler it lowers below the probe causing the signal to be inter-

rupted. When the auto-ll circuit can no longer read a ground signal, it activates the
autoll valve allowing water to enter the boiler.
* The autoll valve consist of an electromagnetic coil and a valve.

* The valve is mechanically closed by spring tension. When the coil is energized it creates a

magnetic eld, which pulls the valve piston open, allowing water to pass through it.

Vacuum Breaker

The vacuum breaker is a mechanical valve located on the steam boiler.
As pressure builds in the boiler, steam pressure lifts a plunger, sealing
the boiler, allowing steam pressure to increase above atmospheric
pressure.

Expansion Valve

The expansion valve relieves front boiler pressure at 12 bar.
* The expansion valve is located in the drain box, which is
underneath the drip tray.
*It consists of a valve body, a valve seal and spring, which
are enclosed by an adjustable brass barrel.
*The expansion valve is adjusted by adding or relieving
tension on the spring by turning the adjusting barrel.

Washer

Body

Valve

Seal

Top Cap

Gasket

Teon Cone

Body

Brass Washer

Spring

Barrel

Safety Relief Valve

The pressure relief valve relieves boiler pressure at 1.8 bar
preventing the boiler from over-pressurizing. It is factory
adjusted and sealed and cannot be adjusted.

External Boost Pump

The boost pump increases existing water
pressure to 135 psi or 9 bar, which is
required to properly brew espresso.
* The pump pressure can be adjusted by
adjusting the screw on the side of
the pump.
* Rotating the screw clockwise will
increase pump pressure, while
rotating counter-clockwise will
decrease pump pressure.
*Ensure your waterline is stable, as

uctuations in line pressure will

affect output pressure.

Motor

Relief Valve

Brass Washer

Outlet
Fitting

Check Valve

Inlet Fitting

Adjustment Screw

Pump

Clamp

* Note - The boilers shown are from an EE, semi-automatic machine, an AV model would have

owmeters.

1. Circulation of water within the boiler and group head.

2. Water ow during the brew cycle.

3. Discharge of water after completion of brewing cycle.

1 2 3 4 5 6

97 10

8

12 13 14 18

1511 16 17 19

2420 25 26 2821 22 23 27 29

Hydraulic Lines and Components

1. Inlet water tube to the coffee boiler.

2. Inlet water line feeding the inlet manifold.

3. Inlet water tube to the steam boiler.

4. Expansion valve.

5. Discharge tting.

6. Discharge from the 3-way group valve.

7. Group valve.

8. Tube feeding water from the group valve to the banjo tube.

9. Tube feeding water from the owmeter to the group valve.

10. Check valve for the coffee boiler.

11. (Same tube as #8).

12. Flowmeter.

13. Banjo tube (located inside of the group head).

14. Tube feeding water from the group to the owmeter.

15. Tube feeding water from the owmeter to the group valve.

16. Tube feeding water from the coffee boiler check valve to the “X” tting.

17. Tube feeding water into the coffee boiler.

18. Tube feeding water to the gauge.

19. Tube feeding water to the expansion valve.

20. Tube feeding steam to the right steam assembly.

21. Tube feeding the top of the sight glass.

22. Tube feeding water to the hot water valve.

23. Tube feeding water to the steam boiler.

24. Auto-ll probe.

25. Pressure relief valve.

26. Vacuum breaker

27. Tube feeding steam to the pressure gauge.

28. Tube feeding steam to the pressure switch.

29. Tube feeding steam to the left steam assembly.

1

19

10

8

7

6

5

4

3

2

18

17

16

15

14

13

11

12

1111

1818

Brass Fitting/Tubing

Cold Water

Hot Water

1. Water Inlet

2. Auto-fill Valve

3. Inlet Check Valve

4. Left Steam Assy. Valve

5. Vacuum Breaker

6. Safety Valve

7. Auto-fill Probe

8. Right Steam Assy. Valve

9. Pressure Switch

10. Left Steam Assembly

11. Flowmeter

12. Dual Scale Gauge

13. Hot Water Valve

14. Sight Glass

15. Right Steam Assembly

16. Expansion Valve

17. Group Valve Drain Tube

18. Group Valve

19. Drain Box

20. Check Valve

21. Banjo Bolt

Solenoid Coil

Steam

20

21 2121

LaMarzocco Hydraulic Schematic

9

Section 2 Questionnaire

1. What material are the machines tubes made from? What precaution should you take in working
with them?

2. What is the order of water ow while brewing in an AV machine?

A. Banjo tube, group, owmeter, group valve, diffuser block.

B. Group, owmeter, group valve, banjo tube, diffuser block.

C. Flowmeter, banjo tube, group, group valve, diffuser block.

D. Diffuser block, banjo tube, group valve, owmeter, group.

3. Explain how the machine maintains the water level in the steam boiler.

4. What does the vacuum breaker do?

5. Why must the group valve be a 3-way valve?

6. What problem can cause damage to the machine’s entire hydraulic system?

7. What products are dispensed from the steam boiler?

8. When backushing the machine, what specic areas of the hydraulic system are being cleaned?

9. Describe what kind of water should be fed to the espresso machine.

A B

10. Identify the hydraulic compents in the above picture.

A.

B.

C.

D.

E.

F.

G.

H.

I.

C D

E F G H I J K

J.

K.