Astoria Core 600 User manual

AL
AEP
SAE
DISPLAY
EN ESPRESSO COFFEE MACHINE
Use and Maintenance Manual. TECHNICIANS' instructions.

The total or partial reproduction and the dissemination of this document’s contents is forbidden without the Manufacturer’s
prior written authorisation. The Company logo is owned by the Manufacturer of the Machine.
IMPORTANT: Read carefully before use. Store for future reference.

TECHNICIANS' manual 3of 104
I. SAFETY PRECAUTIONS
I.I. LEVEL OF TRAINING AND
KNOWLEDGE REQUIRED OF
THE TECHNICIAN
The Technician is a specialised person that
has been specially trained and authorised to
carry out the following operations in accor-
dance with current regulations: transport and
handling, storage, installation, commissioning,
maintenance, decommissioning, dismantling
and disposal of the machine.
The Technician must be properly trained and
informed regarding any residual risks present
during these operations and while the machine
is operating.
The Technician must be able to apply all the
good practices in compliance with food hy-
giene principles.
Any unauthorised tampering with
any parts of the machine renders
the guarantee null and void and relieves
the manufacturer of any liability should
the machine malfunction or any user acci-
dents occur.
I.II. SAFETY PRECAUTIONS
Even though the machine is provided with all
safety devices required to eliminate possible
risks for the Technician, there are still certain
residual risks.
These so-called residual risks are related to ma-
chine parts that may pose a risk to the Tech-
nician, if used improperly, evaluated or deac-
tivated incorrectly, because the prescriptions
contained in this Manual were circumvented.
The machine is also equipped with appropriate
warnings placed on residual risk areas, which
must be scrupulously observed.
Attention must be paid to the residual risks that
are present during the operations described in
the following paragraphs as they cannot be
eliminated:
Compliance with the installation and ma-
chine’s safety standards is dependent on the
use, installation, maintenance and correct op-
eration of the machine. These factors are the
responsibility of the purchaser, Technician and
Technician’s employer.
The Technician’s employer is responsible for
hiring and training personnel to correctly in-
stall, run and perform maintenance work on the
machine and its protection systems.
I.III. TRANSPORT AND HANDLING
Hand crushing hazard
Handling operations must always and exclu-
sively be performed by the Technician and in
compliance with the current health and safety
regulations.
Before starting the transport and/or handling
manoeuvres, check the route, dimensions
needed, safety distances, places suitable for
placing the load down, and the appropriate
equipment for the operation.
Handling operations must be carried out by at
least 2 people, or with the help of special lifting
equipment.
In view of the substantial weight of the equip-
ment, exercise great caution during the han-
dling operations.
The Manufacturer is not responsible for any
injury or damage caused by clothing, lifting
equipment and personal equipment which was
not suitable for the type of intervention that
the operator had to carry out.
The packaging material must not be left within
the reach of children, since it is a potential
source of danger.

TECHNICIANS' manual4of 104
I.IV.INSTALLATION
Electrical hazard
High temperature hazard
Risk of explosion
It is prohibited to perform mainte-
nance on moving components
Installation operations must always and exclu-
sively be performed by the Technician and in
compliance with the current health and safety
regulations.
The appliance’s water supply must provide wa-
ter which is suitable for human consumption,
and must conform with the regulations in force
in the place of installation.
The Technician must carry out the hydraulic
connections in accordance with the hygiene
and hydraulic safety standards regarding envi-
ronmental protection which are in force in the
place of installation.
To ensure electrical safety, the appliance must
be connected to an effective earthing system,
and the system in which it is installed must be
equipped with a suitable differential circuit
breaker, in compliance with the safety laws and
standards.
The effectiveness of the earthing system and
functionality of the differential circuit breaker
- both of which are fundamental for guarantee-
ing the appliance’s electrical safety - are the
responsibility of the person in charge of the
electrical system on which the equipment is in-
stalled.
The manufacturer cannot be considered re-
sponsible for any damage caused by an inade-
quate electric system.
Make sure that the electric mains power is
enough to supply the energy needed for the
machine to correctly operate.
The appliance installation operations must be
carried out with the electrical mains switched
off. To make the electrical system safe and be
able to carry out operations when the machine
is not powered, the Technician must apply the
rules prescribed by current technical standards
(disconnect the power supply, avoid reclosures,
check that there is no voltage, etc.).
I.V. MAINTENANCE AND CLEANING
Electrical hazard
High temperature hazard
Risk of explosion
The only personnel authorised to ac-
cess the service area are those who
are knowledgeable about and have practical
experience using the appliance, particularly
in regards to safety and hygiene.
Maintenance and cleaning operations must
always and exclusively be performed by the
Technician and in compliance with the current
health and safety regulations.
The maintenance and cleaning operations
must comply with the safety regulations:
• Do not carry out maintenance work when
the machine is in operation.
• Do not immerse the machine in water.
• Do not spill liquids on the machine or use
water jets when cleaning.
• Do not allow maintenance and cleaning
operations to be carried out by children or
incompetent people.
• Do not perform maintenance and clean-
ing operations other than those described
in this manual.
When cleaning, pay attention to the parts of
the machine that can become hot:
• Avoid contact with the dispensing group,
water spouts and steam nozzles;
• Do not place your hands or other body
parts near the steam, hot water or milk

TECHNICIANS' manual 5of 104
dispensing nozzle tips.
If gas is used (where applicable), take special
care with the following:
• When indoors, always provide air vents.
• Check for any gas leaks.
• Do not under any circumstances attempt
tolightthegaswithoutrstinstallingthe
proper injector.
• Do not start up the gas burners when the
heating unit is empty.
Only perform the maintenance and cleaning
operations indicated in this manual.
If the problem cannot be resolved, switch off
the machine and contact the Manufacturer.
All maintenance operations must be carried
out when the power supply has been turned
off, the water mains has been closed off, and
the machine has completely cooled down.
After maintenance and/or repair work, the com-
ponents that are used must ensure that the
hygiene and safety requirements initially pro-
vided for the appliance are still met. These are
met by only using original spare parts. When
components which come into contact with wa-
ter or food are repaired or replaced, a washing
procedure has to be carried out, as if it were the
rstinstallation.
It is the task of the Technician to in-
form the User about the methods of
periodic testing of pressure equipment and
safety devices in accordance with the legisla-
tion in force in the country of installation.
I.VI.EMERGENCY SITUATIONS
Should an emergency situation occur as a result
of a machine malfunction, adopt the measures
provided for in the emergency plan posted in
the premises and in any case, proceed to imme-
diately carry out the actions based on the type
of problem.
SHORT CIRCUIT FIRE
Intheeventofarecausedbythemachine’s
electrical system malfunctioning, adopt the fol-
lowing behaviours:
• Disconnect the machine from the power
mains via the main switch.
• Callthereandrescueservice.
• Get everyone a safe distance away from
the premises.
• ExtinguishtheamesusingaCO2re
extinguisher.
GAS LEAK
Intheeventofarecausedbythemachine’s
system malfunctioning, adopt the following be-
haviours:
• Shut off the gas supply by closing the
valve upstream of the machine.
• Get everyone a safe distance away from
the premises.
• Ventilate the premises.
• Call the technician that installed the ma-
chine.
• Ifnecessary,callthereandrescueser-
vice.
GAS LEAK FIRE
Intheeventofarecausedbythemachine’s
gas system malfunctioning, adopt the follow-
ing behaviours:
• Shut off the gas supply by closing the
valve upstream of the machine.
• Disconnect the machine from the power
mains via the main switch.
• Callthereandrescueservice.
• Get everyone a safe distance away from
the premises.
• ExtinguishtheamesusingaCO2re
extinguisher.

TECHNICIANS' manual6of 104
General contents
1 INTRODUCTION.................................................................... 7
1.1 Guidelines for reading the Manual....................................7
1.2 Storing the Manual...................................................................7
1.3 Method for updating the Manual......................................7
1.4 Recipients......................................................................................7
1.5 Glossary and Pictograms........................................................8
1.6 Guarantee.....................................................................................9
2 MACHINE IDENTIFICATION............................................ 9
2.1 Make and model designation..............................................9
2.2 General description...................................................................9
2.3 The manufacturer’s customer support service ............9
2.4 Intended use.............................................................................10
2.5 Machine diagram...................................................................10
2.6 Pushbutton panels for the AEP version.........................12
2.7 Pushbutton panels for the SAE version.........................12
2.8 Display.........................................................................................12
2.9 Internal components............................................................13
2.10 Data and marking.................................................................14
3 TRANSPORT AND HANDLING.......................................20
3.1 Safety precautions.................................................................20
3.2 PPE features..............................................................................20
3.3 Dimensions and weight.......................................................20
3.4 Handling the packed machine .........................................20
3.5 Unpacking the machine......................................................20
4 STORAGE.................................................................................21
4.1 Overview.....................................................................................21
4.2 Storing the machine after operation.............................21
5. INSTALLATION.....................................................................21
5.1 Safety precautions.................................................................21
5.2 PPE features..............................................................................21
5.3 Environmental conditions...................................................21
5.4 Installation and operating spaces..................................22
5.5 Support base.............................................................................22
5.6 Drilling the support base.....................................................24
5.7 Hydraulic connection............................................................25
5.8 Gas connection .......................................................................27
6. COMMISSIONING..............................................................30
6.1 Safety precautions.................................................................30
6.2 Preparingthelterholders.................................................30
6.3 Lighting.......................................................................................31
6.4 Turning the machine on and off......................................31
6.5 Water renewal..........................................................................33
6.6 Dispensing coffee...................................................................33
6.7 Dispensing steam...................................................................35
6.8 Dispensing hot water............................................................35
6.9 Automatic steam wand ......................................................36
6.10 Dispensing cappuccinos ....................................................37
6.11 Cup warmer..............................................................................37
6.12 Programming the standby mode ..................................38
7 Programming the DISPLAY parameters.....................38
7.1 Accessing the menu ..............................................................38
7.2 Machine alarms.......................................................................40
7.3 Automatic steam wand temperature............................40
7.4 Cup warmer temperature ...................................................41
7.5 Heating unit pressure...........................................................41
7.6 Energy saving mode..............................................................42
7.7 Work count ................................................................................43
7.8 Work schedule..........................................................................44
7.9 Language...................................................................................45
7.10 Machine standby and programming............................45
7.11 Energy saving mode.............................................................45
7.12 Software information..........................................................46
7.13 Alarm history...........................................................................46
7.14 Programming the parameters ..........................................47
7.15 Tips for a good cup of coffee...........................................60
8 MAINTENANCE AND CLEANING.................................60
8.1 Safety precautions.................................................................60
8.2 PPE features..............................................................................60
8.3 Maintenance ............................................................................60
8.4 Waterltermaintenance....................................................64
8.5 Water softener regeneration.............................................66
8.6 Software update.....................................................................67
8.7 Malfunctions and solutions................................................69
8.8 Cleaning operations..............................................................72
9 DISPLAY WARNINGS.........................................................75
10 SPARE PARTS.........................................................................76
11 DECOMMISSIONING ........................................................76
11.1 Short period of machine inactivity.................................76
11.2 Long period of machine inactivity..................................76
12 DISASSEMBLY.......................................................................76
13 DISPOSAL...............................................................................76
13.1 Disposal information.............................................................76
13.2 Environmental information................................................76
14 WIRING DIAGRAMS..........................................................77
14.1 ELECTRIC MAINS connection .........................................77
14.2 MACHINE power supply.....................................................78
14.3 AL version..................................................................................79
14.4 AEP version...............................................................................80
14.5 AEP connector connection................................................81
14.6 Circuit board diagram .........................................................82
14.7 SAE version connection........................................................83
14.8 DISPLAY version connection..............................................84
14.9 SAE - UL version connection..............................................85
14.10 DISPLAY-UL version connection ......................................86
14.11 DISPLAY Connector Connection.....................................87
14.12 Automatic steam wand connector connection........90
15 HYDRAULIC DIAGRAMS..................................................91
15.1 LEVER GROUP hydraulic diagram..................................91
15.2 AEP hydraulic diagram........................................................92
15.3 SAE hydraulic diagram........................................................93
16 DEBIT-CREDIT SYSTEM....................................................94
16.1 Direct connection to the till..............................................94
16.2 Till connection via the interface ....................................97

TECHNICIANS' manual 7of 104
1. INTRODUCTION
Read this manual carefully. It provides important safety infor-
mation to the Technician regarding the operations indicated
in this document.
Keep this Manual in a safe place. If you lose it, you can ask the
Manufacturer for another copy.
The Manufacturer of the appliance cannot be held responsi-
ble for any damage caused due to the non-observance of the
requirements listed in this manual.
Before carrying out operations on the machine, read
the instructions contained in this publication and fol-
low the guidelines carefully. Keep this manual and all
attached publications in an accessible and secure place.
This document assumes that the machine is installed in a lo-
cation where the current work safety and hygiene standards
are observed.
The instructions, drawings and documentation contained in
thisManualaretechnicalandcondential.Theyarethesole
property of the Manufacturer, and may not be fully or par-
tially reproduced in any way.
The Manufacturer reserves the right to make any improve-
ments and/or modications to the product. We guarantee
thatthisManualreectsthetechnicalstateoftheappliance
at the time it was released to the market.
We encourage the Technicians to make any proposals in re-
gards to improving the product or its Manual.
1.1 Guidelines for reading the Manual
This Manual is divided into separate chapters. The chapter
order is linked to the temporal logic of the life of the machine.
Terms, abbreviations and pictograms are used to facilitate
the immediate understanding of the text.
This Manual consists of cover, index and series of chapters.
Each chapter is sequentially numbered. The page number is
shown in the footer.
Themachineidenticationdataisdisplayedonthemachine’s
nameplate and the EU declaration of Conformity, whilst the
date and revision of the Instruction Manual is provided on
the last page.
Abbreviations
Sec. = Section
Chap. = Chapter
Para. = Paragraph
P. = Page
Fig. = Figure
Tab. = Table
Units of measurement
The units of measurement are those provided by the Interna-
tional System (SI).
1.2 Storing the Manual
The Instruction Manual must be stored carefully. The manual
should be stored, handled with care with clean hands and not
placed on dirty surfaces. The Manual must be stored in an
environment protected from moisture and heat.
Do not remove, tear or arbitrarily modify any of its parts.
On the Technician's request, the manufacturer can provide
additional copies of the machine's Instruction Manual.
1.3 Method for updating the Instruction
Manual
The Manufacturer reserves the right to modify and make im-
provements to the machine without providing notice or up-
dating the Manual that has already been received.
Should the Manual become illegible or otherwise
hard to read, the Technicians must request a new
copy from the Manufacturer before carrying out
any operations on the machine.
It is absolutely forbidden to remove or rewrite parts of the
Manual.
The instructions, drawings and documentation contained
in this manual are condential and the sole property of the
Manufacturer. They may not be reproduced in any way, ei-
ther in full, or in part without prior authorisation.
The Technician is responsible for complying with the instruc-
tions contained in this Manual.
Should any incident occur as a result of these recommenda-
tions being used incorrectly, the Manufacturer declines any
liability.
This manual is also available on the manufacturer’s website
(indicated on the cover of the manual).
1.4 Recipients
This Manual is intended for the Technician who is responsible
for carrying out the following operations on the machine:
• Transport and handling;
• Storage;
• Installation;
• Commissioning;
• Maintenance;
• Cleaning;
• Spare part replacement;
• Emergency operations and faults;
• Decommissioning;
• Disassembly;
• Disposal (refer to the retailer if not directly responsible).
RECIPIENT QUALIFICATIONS
The machine is intended for a professional non-generalised
use, therefore the Technician must:
• Have attended the training courses organised by the Man-
ufacturer relating to the type of machine;

TECHNICIANS' manual8of 104
• be aged 18 and over;
• bephysicallyandmentallyttousethemachine;
• be able to understand and interpret the Instruction Man-
ual and the safety requirements;
• know the safety procedures and how they are imple-
mented;
• be able to use the machine;
• haveunderstoodtheproceduresofuseasdenedbythe
machine's manufacturer.
1.5 Glossary and Pictograms
This paragraph lists uncommon terms or terms whose mean-
ings are different than those most commonly used.
Abbreviations are explained below, as well as the meaning
ofpictogramsdescribingtheoperator'squalicationandthe
machine status; they are used to quickly and uniquely pro-
vide the information needed to correctly and safely use the
machine.
1.5.1 Glossary
User
The person in charge of operating the machine and perform-
ing the routine cleaning operations indicated in this manual.
Technician
A specialised person who has been specially trained and au-
thorised to carry out the following operations in accordance
with current regulations: transport and handling, storage, in-
stallation, commissioning, maintenance, decommissioning,
dismantling and disposal of the machine.
Danger
A potential source of injury or damage to health.
Dangerous area
Any area in the vicinity of the machine where the presence
of a person constitutes a risk to the safety and health of that
person.
Risk
Combination of the probability and severity of an injury or
damage to health that can arise in a hazardous situation.
Guard
Machine component used specically to provide protection
by means of a physical barrier.
Personal protective equipment (PPE)
Clothing or equipment worn by someone to protect their
health or safety.
Intended use
The use of the machine in accordance with the information
provided in the instructions for use.
Machine status
The machine status includes the mode of operation and the
condition of the machine's safety devices.
Residual risk
Risks that remain despite adopting the protective measures
integrated into the machine's design and despite the guards
and complementary protective measures that have been
adopted.
Safety component:
• Designed to perform a safety function.
• whose failure and/or malfunction endangers the safety of
persons.
1.5.2 Pictograms
Descriptions preceded by these symbols contain very im-
portant information/requirements, particularly in regards to
safety. Failure to comply with these may result in:
• A safety risk for those operating the machine.
• User injury, including serious injury (in some cases even
death).
• The guarantee being rendered null and void.
• The Manufacturer waiving liability.
GENERAL DANGER symbol used when there is a
risk of permanent serious injury that would require
hospitalisation, or in extreme cases, even cause
death.
ELECTRICAL HAZARD symbol used when there is a
risk of permanent serious injury that would require
hospitalisation, or in extreme cases, even cause
death.
HIGH TEMPERATURE HAZARD symbol used when
there is a risk of permanent serious injury that
would require hospitalisation, or in extreme cases,
even cause death.
HAND CRUSHING RISK symbol used when there is
a risk of permanent serious injury that would re-
quire hospitalisation, or in extreme cases, even
cause death.
EXPLOSION RISK symbol used when there is a risk
of permanent serious injury that would require
hospitalisation, or in extreme cases, even cause
death.
CAUTION symbol used when there is a risk of mi-
nor injury that could require medical attention.
WARNING symbol used when there is a risk of mi-
nor injury that could be treated with rst-aid or
similar measures.
NOTE symbol used to provide important informa-
tion about the topic.

TECHNICIANS' manual 9of 104
It is prohibited to perform maintenance on moving
components as there is a risk of permanent serious
injury that could require hospitalisation.
Mandatory symbol indicating that safety gloves
must be worn; used when there is a risk of perma-
nent serious injury that would require hospitalisa-
tion.
Mandatory symbol indicating that eye protection
must be used when there is a risk of permanent
serious injury that would require hospitalisation.
Mandatory symbol indicating that safety shoes
must be used when there is a risk of permanent
serious injury that would require hospitalisation.
Mandatory symbol indicating that the documen-
tation must be read; used to make the Technician
aware of the importance of this action for their
safety.
1.6 Guarantee
All of the machine's components are covered by a 12-month
guarantee, except for electrical and electronic components
and parts prone to wear and tear.
If any work is carried out on the machine electronics when
the machine is still live, any guarantee will automatically be
invalidated.
2. MACHINE IDENTIFICATION
2.1 Make and model designation
The machine and model ID information is found on the ma-
chine's NAMEPLATE and in the provided EU DECLARATION
OF CONFORMITY.
2.2 General description
The machine described in this Manual consists of mechani-
cal, electrical, and electronic components which, when used
together, produce milk, coffee and water-based beverages.
This product is manufactured in compliance with the EU Di-
rectives, Regulations and Standards indicated in the EU DEC-
LARATION OF CONFORMITY provided with the machine.
2.3 The manufacturer’s customer sup-
port service
ASTORIA MACCHINE PER CAFFÈ S.R.L.
Via Condotti Bardini, 1
31058 SUSEGANA (TV) - ITALY
Tel. [phone] - Fax [phone]
E-mail: [email protected]
Web-site: www.astoria.com

TECHNICIANS' manual10 of 104
2.4 Intended use
The espresso coffee machine has been designed to profes-
sionally prepare hot beverages such as tea, cappuccinos and
weak, strong and espresso coffee, etc. The appliance is not
intended for domestic use, it is intended for professional pur-
poses only.
The machine can be used under all the conditions set forth,
contained or described in this document; any other condi-
tions must be considered dangerous. The machine must be
installedinaplacewhereitsaccessisrestrictedtoqualied
personnel only who have received suitable training (coffee
shops, restaurants, etc.).
Permitted uses
All uses compatible with the technical features, operations
and applications described in this document, in addition to
those that do not endanger the safety of users or cause dam-
age to the machine or its surrounding environment.
All uses not specically mentioned in this Manual
are prohibited and must be expressly authorised
by the Manufacturer.
Intended uses
The machine has been designed exclusively for professional
use.Theuseofproducts/materialsotherthanthosespecied
by the Manufacturer, which can cause damage to the ma-
chine and be dangerous for the operator and/or those in close
proximity to the Machine, is considered incorrect or improper.
Contraindications of use
The machine must not be used:
• for uses other than those indicated in this paragraph or for
uses that differ from or are not mentioned in this Manual.
• with materials other than those listed in this Manual.
• with safety devices that have been disabled or are not
working.
Incorrect use of the machine
The type of application and performance that this machine
has been designed for, requires a number of operations and
procedures that cannot be changed, unless previously agreed
with the Manufacturer. All permitted behaviours are indicated
in this document; any operation not listed and described
herein is to be considered improper and therefore, hazardous.
Improper use
The only permitted uses are described in the Manual; any
other use is considered improper and therefore, hazardous.
General safety features
The Technician must be aware of accident risks, safety devices
and the general safety rules set forth in EU directives and by
the legislation of the country where the machine is installed.
The Technician must know how all the machine's devices
work. They must also have fully read and understood this
Manual. Maintenance work must be performed by the Techni-
cian after the machine has been properly prepared. The tam-
pering or unauthorised replacement of one or more machine
components, the use of accessories which modify its use and
the use of materials other than those recommended in this
Manual, can cause accidents.
2.5 Machine diagram
1. Steam knob
2. Cup warmer shelf
3. Hot water knob
4. Group lever
5. Heating unit water level window
6. Scald protection
7. Steam nozzle
8. Filter holder
9. Adjustable foot
10. Pressure gauge
11. Gas burner inspection window (*)
12. Gas safety (*)
13. Gas ignition button (*)
14. Cup holder grille
15. Hot water nozzle
16. Power switch
17. Manual dispensing button
18. Pushbutton panel
19. Display
20. USB socket (for software updates only)
21. ON-OFF warning light/ heating unit/ cup warmer
22. Raised cup grille
23. ON switch
24. Automatic steam wand nozzle (*)
25. Blindlter
26. Tamper
27. Cleaning brush
(*) Optional device
The only stick that can be used in the USB port (20)
is the USB stick provided exclusively to the Mainte-
nance Technician. Do not connect external devices
(iPhones, iPads, PCs, etc.) to the USB port because it could
create serious machine software problems.
171 2 1819 17
1
6
7
20
8
23 24 15 1014 922
21 3 4
1
6
7
8
131516 14 10 912 11
4 5
171 2 18 17
1
6
7
8
151621 14 1022 9
21 1 2 24
1
6
7
8
22
1516 14 10 911
AL version
SAE - DISPLAY versionSAE version
AEP version
27 2928

TECHNICIANS' manual 11 of 104
cian after the machine has been properly prepared. The tam-
pering or unauthorised replacement of one or more machine
components, the use of accessories which modify its use and
the use of materials other than those recommended in this
Manual, can cause accidents.
2.5 Machine diagram
1. Steam knob
2. Cup warmer shelf
3. Hot water knob
4. Group lever
5. Heating unit water level window
6. Scald protection
7. Steam nozzle
8. Filter holder
9. Adjustable foot
10. Pressure gauge
11. Gas burner inspection window (*)
12. Gas safety (*)
13. Gas ignition button (*)
14. Cup holder grille
15. Hot water nozzle
16. Power switch
17. Manual dispensing button
18. Pushbutton panel
19. Display
20. USB socket (for software updates only)
21. ON-OFF warning light/ heating unit/ cup warmer
22. Raised cup grille
23. ON switch
24. Automatic steam wand nozzle (*)
25. Blindlter
26. Tamper
27. Cleaning brush
(*) Optional device
The only stick that can be used in the USB port (20)
is the USB stick provided exclusively to the Mainte-
nance Technician. Do not connect external devices
(iPhones, iPads, PCs, etc.) to the USB port because it could
create serious machine software problems.
171 2 1819 17
1
6
7
20
8
23 24 15 1014 922
21 3 4
1
6
7
8
131516 14 10 912 11
4 5
171 2 18 17
1
6
7
8
151621 14 1022 9
21 1 2 24
1
6
7
8
22
1516 14 10 911
AL version
SAE - DISPLAY versionSAE version
AEP version
27 2928

TECHNICIANS' manual12 of 104
2.6 Pushbutton panels for the AEP ver-
sion
2.7 Pushbutton panels for the SAE
version
2.8 Display
2
1
1 GR ver.
COMPACT ver.
1 espresso
2 espressos
2 medium coees
2 long coees
1 - Work surface lighting
2 - Cup warmer lighting
Hot water
Cup warmer
Automatic steam wand (optional)
Stop / Programming
Continuous dispensing
1 medium coee
1 long coee
Automatic steam
wand temperature
Cup warmer
Automatic
steam wand
Display
page
Heating unit
water level
Water
mains pres-
sure
Time and
date
Heating unit
pressure
45°C

TECHNICIANS' manual 13 of 104
2.9 Internal components
1. Cup warmer heating element
2. Dispensing group
3. Electronic control unit
4. Side LED power supply
5. Side LEDs
6. Electronic control unit
7. Work surface LED
8. Motor pump
9. Drain tray
10. Gas system
11. Static relay
12. Fuses
13. Remote switch
14. Work surface LED power supply
15. Pressure switch
1
15
4
12
14
13
12
32 4 5 2
5
7
8
6
9 7101071011

TECHNICIANS' manual14 of 104
2.10 Data and marking
The machine’s general technical data is provided in the fol-
lowing table:
TECHNICAL DATA TABLE 1GR COMPR. 2GR 3GR 4GR
120 V
Power
2200 W 2900 W 3100 W --- ---
220-240 V
2700-3100 W 2900-3100 W 3100-4900 W 5100-6850 W 5800-6900 W
380-415 V
Frequency 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz
Heating unit 5.2-6 L 7 L 9-10.6 L 14.7-17.2 L 20.4-23.8 L
Safety valve calibration 0.19 MPa (1.9 bar) +/- 0.015 MPa
Heating unit operating pressure 0.08 - 0.14 MPa (0.8 - 1.4 bar)
Mains water pressure 0.15 - 0.6 MPa max. (1.5 - 6 bar max.)
Coffee dispensing pressure 0.8 - 0.9 MPa (8 - 9 bar)
Working environment temperature 5 - 35°C 95° MAX. R.H.
Sound pressure level < 70 dB
Conforming to directive 2006/42/CE, the machine is marked
with the CE code with which the manufacturer states under
his responsibility that the machine is safe for persons and
things.
Alternativemarkingscanbeafxedaccordingtothetarget
markets, provided they comply with current product regula-
tions.
The nameplate which provides the appropriate markings,
identicationdataandspecictechnicaldata,isafxedun-
der the drain tray.
An example of a nameplate is provided below.
The nameplate is afxed
under the drain tray
When contacting the Manufacturer, always provide the fol-
lowing information:
• S/N - machine serial number.
• Mod. - machine model
• Y - year of manufacture.
The appliance data can also be found on the label located on
the machine's packaging.
It is forbidden to remove or modify the nameplate.
Should it deteriorate or become illegible, contact
the Manufacturer.
To correctly connect the machine to the electric
mains, refer to Chap. "14. WIRING DIAGRAMS" on
page 77.
Via C. Bardini
,
1 SUSEGANA
(
TV
)
- ITALY
Tel. [phone] Fax [phone]
MADE IN ITALY
W
S/N: Mod.
Hz
Y
V
ASTORIA MACCHINE PER CAFFÈ S.r.l.
MARCHIO COMMERCIALE

TECHNICIANS' manual 15 of 104
2.10.1 Heating unit
The heating unit is made of copper sheet metal (1). The heat
exchangers are assembled onto this unit and are in turn con-
nected to the dispensing group. The water used for dispensing
coffee is taken directly from the heat exchanger. During the
dispensing process, cold water is sent inside the exchanger
by means of the motor pump. Cold water and the pre-exist-
ing hot water are mixed together inside the heat exchanger,
in order to obtain the optimal water temperature for coffee
infusion.
2
1
Electric heating
The heating unit is electrically heated by an electric heating
element immersed in the water (2).
Gas heating
Gasheatingisobtainedbyfeedingtheburneramewhichis
located under the heating unit.
Electric + gas heating
In machines equipped with both systems, it is possible to
combine the two heating types.
2.10.2 Overow device
The cover installed on the pressure relief valve makes it possi-
ble to collect any water and steam which may leak from the
heating unit due to a malfunction and channel it to the drain
tray, via a special hose.
2.10.3 Pressure relief safety valve
The pressure relief safety valve has a calibration
of 0.19 MPa (1.9 bar) +/- 0.015 MPa in order to
ensure that the pressure in the steam heating unit
does not exceed 0.21 MPa (2.1 bar). Should a fault
occur, the capacity of the valve is such as to be able
to eliminate all the excess pressure in the heating
unit.
The safety valve should be checked regularly as in-
dicated in Chap. "8. MAINTENANCE AND CLEAN-
ING" on page 60.
Two safety valves are installed on all machines
with 4 groups.
2.10.4 Expansion valve + check valve
This is a valve consisting of an expansion valve and a check
valve.
• Expansion valve (A): the cold water sent from the pump
to the heat exchangers is heated. This heating causes an
increase in the volume of water. To limit pressure increases
in the hydraulic circuit, the valve limits the maximum in-
ternal pressure of the circuit to 1.2 MPa (12 bar).
• Check valve (B): its function is to prevent the water
back-owingintothehydrauliccircuitexchangers.
2.10.5 Negative pressure valve
The purpose of the negative pressure valve is to pre-
vent liquids from back-owing through the steam
nozzle when they are being heated. Furthermore, the
excess air inside the heating unit is removed during
the machine's heating phase.
2.10.6 Pressure switch
The pressure switch makes it possible
to control the heating unit pressure by
activating or bypassing the heating
element in the heating unit. Any pres-
sure switch calibration can be carried
out with the machine in operation by
turning the screw (6) located on the
body of the component.
6

TECHNICIANS' manual16 of 104
2.10.7 LEVER group
The group lever uses the heating unit pressure and water. This
system does not require heat exchangers.
When the lever (1) is lowered, the spring (2) inside the group
is compressed: the piston (3) raises, allowing the water to en-
ter the pre-infusion jacket.
When the lever is released, the piston compresses the water
at 8-10 bar, allowing the espresso coffee to be dispensed.
The check ball valve (4)preventsthewaterfromowingback
into the heating unit (5).
1
45
2
3
PHASE 1
Lowering the
lever
PHASE 2
Pre-infusion for
3-5 seconds
PHASE 3
The lever releases
and coee is dis-
pensed.
2.10.8 CTS group (with a thermosiphonic
circuit)
In this system, the dispensing group (1) is heated by a ther-
mosiphonic circuit (2) connected to the heat exchanger (3).
The same water is used when dispensing coffee, thus ensur-
ing that all coffees are the same temperature:
• The solenoid valve and the pump are activated in order
to send cold water into the exchanger (3) through the in-
jector (4).
• The heating unit water is carried from the exchanger (3)
to the group (4) for dispensing.
• Thepump allows the waterow pressure toincrease to
8-9 bar for dispensing.
The injector (4)andtheowreducer(5) are important com-
ponents for the dispensing group’s operation. To increase the
coffeeextractiontemperature,removetheowreducer(5) or
replace it with one that has a bigger diameter. To decrease
the temperature, replace it with one that has a smaller di-
ameter. If necessary, the exchangers can be replaced by re-
moving the ange and disconnecting the relative hydraulic
circuit pipes. These operations should be carried out when the
machine has been switched off and has cooled down: always
replace the seals.
3
Water inlet
Coee
dispensing
5
34
DISPENSING IN PROGRESS
2
3
1
IDLE

TECHNICIANS' manual 17 of 104
2.10.9 Safety thermostat
The thermostat prevents any damage occurring to the elec-
trical heating element if there is no water in the heating unit.
The thermostat bulb (7) is located inside a sheath (8) in the
middle of the heating elements. The thermostat contacts (9)
are connected to the electric heating element (10). If the
electricheatingelementisexposedduetoafailuretollthe
heating unit with water, the temperature of the heating el-
ement increases dramatically. At this point, the thermostat
cuts the power supply to the heating element in order to pre-
vent damage occurring.
10
911
7
8
To reset the thermostat, press the centre button
(11). However, before starting the machine up
again, identify what prevented the water from be-
ing fed into the heating unit.
2.10.10 Motor pump
This component feeds the machine
by increasing the water pressure to
0.8-0.9 MPa (8-9 bar) in order to dis-
pense coffee and automatically ll
the heating unit.
2.10.11 Electronic control unit
The electronic control unit is installed on the SAE versions.
Its purpose is to electronically control the cof-
fee dose via the water owing through the
dosing device and to check that the heating
unitisbeinglledwithwater.
Some versions of the control unit are set up
to be connected to the dispensing account-
ingsystemsbymeansofaspecicinterface
device.
2.10.12 Automatic Water Entry
The Automatic Water Entry system is designed to check the
water level in the heating unit. It consists of:
• A probe inserted into the heating unit (1) consisting of a
stainless steel rod.
• The standard control unit (2) on SAE versions and the elec-
tronic level regulator on the other versions (3).
• A hydraulic circuit with a solenoid valve controlled by the
regulator.
The electronic control unit controls the level of water in the
heating unit. When the level of water in the heating unit
drops, the contact with the probe is interrupted. The control
unit sends an impulse to the inlet solenoid valve and the mo-
tor pump, which are then activated until the normal level of
water in the heating unit has been restored.
To avoid any ooding caused by machine malfunctions or
water leaks in the circuit, the electronic control unit has a
“Timeout”featurewhichcutsofftheautomaticwaterlling
function after a certain time (2 minutes). The LED (4) located
on the front of the machine body comes on to indicate acti-
vation of this system. When installing machines with three
orfourgroups,theinitialwaterllingtimemayexceedthe
established timeout limit. Should this occur, simply turn the
machine off and then back on to restore normal operating
conditions.
1
2
4
3

TECHNICIANS' manual18 of 104
2.10.13 Volumetric dosing
The volumetric dosing device that is installed on the SAE ver-
sions, measures the quantity of water sent to the group in
order to dispense coffee.
The dispenser generates electrical im-
pulses which are sent to the electronic
control unit.
These impulses are read by the control
unit and counted while the dose is be-
ing programmed.
TheashingLEDlight(4) indicates that the electrical impulse
has been sent from the dosing device to the control unit.
2.10.14 Electronic pushbutton panels
The electronic pushbutton panels on the SAE versions allow
the coffee doses to be selected and programmed. They are
connected to the electronic control unit.
To use and programme these, please consult the user manual.
2.10.15 Cup warmer
The cup warmer device (5) warms the cups before they are
used.
In some versions it is possible to adjust the temperature by
following the instructions on the user manual.
5
2.10.16 Hot water spout
The hot water nozzle is connected to a heating unit suction
hose. Depending on the model, hot water can be dispensed
in two ways:
• Manually: by turning the adjustment knob on the front of
the machine.
• Automatically: by selecting a button connected to a sole-
noid valve.
2.10.17 Steam nozzle
The steam nozzle is connected to the top of the heating unit.
Adjust the dispensing setting by turning the knob on the front
of the machine.
2.10.18 Cappuccino maker (optional)
The cappuccino maker is installed on a steam
nozzle. This device can both heat and froth the
milk.
To adjust and clean the cappuccino maker, follow the instruc-
tions in the user manual.
4
2.10.19 Water lter
In the mains water, non-soluble salts are
present which cause limestone to form in
the heating unit and other parts of the
machine.
Drinking water can also contain heavy
metals and substances, such as chlorine
which are harmful to health.
The lter makes it possible to eliminate
or substantially reduce the presence of
these mineral salts.
Thecartridgecontainedinthewaterlter
must be replaced at the frequency speci-
edbythemanufacturer.
To use and maintain the water lter, follow the in-
structions provided in para. "8.4 Water Filter Main-
tenance" on page 64.
2.10.20 Water softener
The resin softener can be used as an alternative to the water
lter.
This component has the property of retaining the calcium
contained in the water. For this reason, the
resins become saturated after a certain pe-
riod and must be regenerated with coarse
kitchen salt (NaCl, sodium chloride) or spe-
cial water softening salt. It is very important
to regenerate the softener within the estab-
lished times. However, in locations where
the water is very hard, it will be need to be
regenerated more frequently. The same rule
can be applied to locations where there is
a large consumption of hot water (for tea,
etc.).
To use and regenerate the water softener, follow
the instructions provided in para. "8.5 Softener re-
generation" on page 66.

TECHNICIANS' manual 19 of 104
2.10.21 Automatic steam wand (optional)
The “Automatic steam wand” system - tted on some ver-
sions with a display - enables milk to be automatically frothed
at the programmed temperature. The operating principle of
the automatic steam wand is listed below:
• Pressthespecicbutton(1).
• The solenoid valve opens (2) which consequently allows
thesteamtoowfromtheheatingunittotheautomatic
steam wand nozzle.
• The system simultaneously activates the air suction pump
(6) which is controlled by the control unit (3)and powered
by the transformer (8). The milk froth can be adjusted
by changing the amount of air intake when opening the
valve (5).
• After the air has passed through the non-return valve (4),
it mixes with the steam in the mixing interface (11).
• Steam comes out of the nozzle (9).
• The probe (10) that is connected to the machine’s elec-
tronic control unit, detects the temperature of the milk
while it is being heated.
• Once the set milk temperature has been reached, the elec-
tronic system stops the air and steam from being dis-
pensed.
45°C
1
2
910
3
11
42
6
8
7
To adjust the milk temperature, see para. 7.3.

TECHNICIANS' manual20 of 104
3. TRANSPORT AND HANDLING
3.1 Safety precautions
Carefully read the instructions provided in chapter
"I. SAFETY PRECAUTIONS" on page 3.
3.2 PPE features
When transporting the machine, the following PPE is required:
The use of protective gloves is mandatory.
The use of safety shoes is mandatory.
3.3 Dimensions and weight
Model 1GR COMPR. 2GR 3GR 4GR
Maximum gross
weight 77 kg 100 kg 104 kg 113 kg 130 kg
3.4 Handling the packed machine
Upon arrival, the machine must be unloaded and handled
with care, carefully following the instructions on the packag-
ing, or those contained in this Manual.
It is very important to check that the maximum
load capacity of each piece of lifting equipment, is
at least equal to the weight of the loads to be
lifted plus the safety margins which are required by current
standards.
3.5 Unpacking the machine
Only remove the machine from its packaging when it is ready
to be installed, in order to prevent accidental collisions which
could damage it:
• Open the packaging, taking care not to damage the ma-
chine.
• Remove and take out the machine guards and equipment
inside the packaging.
• Remove the machine.
• Dispose of the packaging in compliance with the current
waste regulations.
After unpacking the machine, check that there are
no damaged parts due to transport or missing
parts. Should there be any, immediately inform (no
later than 7 days after delivery) both the CARRIER and the
MANUFACTURER, by indicating the machine data and pro-
viding photographic evidence.
We recommend that you keep the packaging until the guar-
antee has expired.
Wood, nails, staples, cardboard: non-polluting material
which must be recycled properly.
Plastic: polluting material that must not be burned (danger
of toxic fumes), nor disposed of as normal waste; to be dis-
posed of according to current regulations.