Azkoyen Zensia Manual

Technical Information
ZENSIA
Avda. San Silvestre, s/n
31350 Peralta (Navarra) Spain
Tel.: [phone]
www.sat.azkoyen.com

2ª 10028 –E 03 - 2016
2
I N D E X
1. INTRODUCTION
1.1. DEFINITIONS
1.2. PRINCIPLE TECHNICAL CHARACTERISTICS
2. DESCRIPTION OF COMPONENTS
3. INSTALLATION AND START UP
3.1. UNPACKING
3.2. START UP
4. ERRORS
4.1. ERROR MESSAGES SHOWN ON THE DISPLAY
4.2 CONTROL POINTS
5. CLEANING AND MAINTENANCE
6. WORKING CONDITIONS AND NORMS
7. DIMENSIONS

2ª 10028 –E 03 - 2016
3
1. INTRODUCTION
The automatic vending machines in the Zensia range are designed to elaborate and vend
espresso coffee and instant drink powder mixed with hot water. The final product is served to
the customer in a plastic cup.
In the rest of this document, the names of the following components
indicated below will be abbreviated as shown below:
The machines in the Zensia range, as “machine or machines”.
The coffee infusion group, as “group”. The electro-valves, as “EV”.
1.1. DEFINITIONS
Espresso coffee: infusion of coffee elaborated according to the following conditions:
-7 g of ground coffee.
-The temperature of the water the infusion is between 92º C and 96º C.
-The pressure of the infusion water is at 9 kg/cm².
-The time of infusion of the coffee is between 15 and 20 seconds.
-The volume of water in the infusion is 40 ml.
Volume dosage: this dosage system measures the volume of water that is used in the
infusion.
Water pump: an electro-mechanical system used to pump the infusion water and to apply the
necessary water pressure.
Infusion: In coffee terms it means to pass hot water through the ground coffee to extract its
oils and essences.
Volumetric infusion: during the infusion process the volume of water used is always
constant.
Tablet: in coffee terms it means the pressed coffee residue that remains in the group after the
infusion.
Programming status: when the machine is ready to be programmed.
Working mode: when the machine is in ready for the user to request any of services that the
machine offers.

2ª 10028 –E 03 - 2016
4
MODELS
The Zensia series is comprised of the models LE and LI.
The LE model elaborates espresso coffee and instant products.
The LI only elaborates instant products.
1.2. PRINCIPLE TECHNICAL CHARACTERISTICS
On automatic: the press of the finger is enough to elaborate any service; espresso
or instant.
It grinds the coffee in the time of the infusion.
Products available in each model of machine:
Model
Coffee
beans
Sugar
Instant
Coffee
Instant
Decaf.
Milk
Chocolate
Tea
Soup
Zensia ESP+4
Yes
Yes
No
Yes
Yes
Yes
Yes
No
Zensia ESP+5
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Zensia INST 5
No
Yes
Yes
Yes
Yes
Yes
No
No
Zensia INST 6
No
Yes
Yes
Yes
Yes
Yes
Yes
No
The temperature of the water is programmable.
Dosage of ground coffee is programmable up to a maximum of 8g.
Electrical connection and disconnection of the machine is automatic and
programmable.
Water pump for the water pressure incorporated in the machine.
Volume of water dosage is programmable in the different services of espresso
coffee.
Painted in black - RAL 9005 “textured”
Electrical characteristics:
ZENSIA instant
Voltage
Power
Length
Mains voltage of red
230 Vac / 50 Hz
Heating element
230 Vac / 50 Hz
2000 W
Mains cable
3,400 mm
ZENSIA espresso
Voltage
Power
Length
Mains voltage of red
230 Vac / 50 Hz
Heating element
230 Vac / 50 Hz
1100 W
Mains cable
3,400 mm

2ª 10028 –E 03 - 2016
5
2. DESCRIPTION OF COMPONENTS
PRINCIPLE COMPONENTS
A1. Mains switch.
Allows the mains power to be disconnected from all the components in the machine
A2. Waste liquids bucket.
It collects all the waste liquids that the machine generates. It has a capacity of 8 litres. When
it reaches a determined level, a device is activated that puts the machine in “out of order”
status.
A3. Coffee residue bucket.
It collects all the waste coffee grinds that are generated in the machine. It has a capacity for
7500 grams of ground coffee.

2ª 10028 –E 03 - 2016
6
A4. Group and piston. These are made of plastic resins and are the elements where the
machine makes the infusion with the dosage of ground coffee.
The group has moving parts activated by 24 Vdc motor that rotates the flywheel that moves
the coffee holder from the dosage device to the piston. It also moves a lever that acts on a
micro switch, which indicates the position that the group is located to the electronic board.
At rest position, the group cannot be removed. Before removing, and with the machine
switched on, activate the black button on the device. On pressing button, the group situates
itself in the load coffee position. Now the levers that hold it in place can be turned to free it
from the support and it can be removed.
Pull on the clip
Remove the piston
B1. Lower Group
B2. Loading funnel
B3. Piston
To replace the group in the machine, it can be in any position and it does not matter if it has
been turned while it was out of the machine. It is only necessary to fit it and fasten the holding
levers; the motor of the group will automatically position it correctly.

2ª 10028 –E 03 - 2016
7
C1. Piston
C2. Group
C3. Filter
C4. Holding lever
C5. Extraction button
C6. Position Microswitch
C7. Lever for moving the group
C8. Group motor
The piston has a spring and two spacers that,
depending on where they are placed, adjust the
pressure of the piston for the quantity of ground
coffee in the dosage.
The position of the spacers will depend on the
quantity of coffee configured in the dosage
mechanism; the positions are indicated in the following table:
Dosage
Position of spacers
Position of dosage
5 g
Inferior
Inferior
1
5.5 g
Inferior
Inferior
2
6 g
Inferior
Superior
3
6.5 g
Inferior
Superior
4
7 g
Inferior
Superior
5
7.5 g
Superior
Superior
6
8 g
Superior
Superior
7

2ª 10028 –E 03 - 2016
8
A5. Beaters
This mechanism mixes the product with the hot water from the boiler.
D1. Beater motor
D2. Beater fins
D3. Beater assembly
D4. Vapour extractor
D5. Holding screw
D6. Beater holding pivots
D7. Motor holding tabs
The movement of the beater is carried out by a motor of the following technical characteristics:
Supply voltage
34 Vdc.
Speed
15,000 rpm
The beater assembly can be removed from the machine by turning it to free it from the holding
pivots. To remove the motor, remove the holding screw and twist the motor to the right to free
it from the holding tabs.
WARNING! When mounting the wiper motor (04101650) and wiper base
assembly (11037941 Beige / Grey 11037931 / Green 41221621) the grey
part which is inside the base must be pushed toward the beater motor.
The contact between this grey part and the wiper base assembly must be avoided. If these two
bodies remain in contact or very close to each other, when the motor runs, friction between
the two parts causes them to fuse together, leaving the beater unusable. For this task,
Azkoyen has available in its catalogue, the appropriate tool which is part number 10040130.

2ª 10028 –E 03 - 2016
9
During the beating process, the EVs of the instant products is very important; they allow the
hot water from the boiler into the beaters to elaborate the instant products. These are housed
on a brass support that is at a constant temperature, because it is fixed to the hot water
boiler. This way the water for elaborating the instant products does not suffer temperature
losses and reaches the beaters at an adequate temperature.

2ª 10028 –E 03 - 2016
10
A6. Soluble product hoppers
The capacity in volume of the hoppers of instant product is of 6 litres.
The approximate weight of the product is:
Capacity in grams
Product
Zensia ESP
Zensia INS
Instant coffee
1,500
1,500
Decaffeinated
1,500
1,500
Milk
2,200
2,200
Chocolate
3,100
3,100
Tea
3,900
3,900
Soup
6,000
6,000
Sugar
5,300
5,300
A7. Coffee bean hopper
The coffee bean hopper is only fitted to the espresso machines, its capacity is 4.2 Kg.
A8. Programming handset
This device is used to programme the machine.
A9. Cup, sugar and stirrer extraction systems
The three systems are together in the one module which is loacted in the door.
The standard instant models do not have a holder for the stirrers
To remove there extractors from the machine, follow the instructions below:
1º Disconnect the power from the board of the cup extractor.

2ª 10028 –E 03 - 2016
11
2º Remove the screws and the holding plate as indicated in the photograph.
3º Pull upwards on the extractor to free the holding tabs from the support.

2ª 10028 –E 03 - 2016
12
The sugar and stirrer extractor can be separated from the cup extractor. First disconnect the
power loom by removing the cover that protects the cup extractor, then free the clip and pull
upwards as indicated the figure.

2ª 10028 –E 03 - 2016
13
H1. Clip
H2. Sugar and stirrer motor extractor
H3. Cup motor extractor
H4. Cup holder motor
H5. Cup support arm
H6. Cup support motor
H7. Electronic circuit board
H8. Cup extractor switch
H9. Cup detection photo-cells
H10. Hopper position microswitch
H11. Connector for the sugar and stirrer
cable
Characteristics of the cup extractor:
Range - ESP and INS
Units
700
Ø of the cups
From 70 to 71 mm.
Motor voltage
24 Vdc.
There is an extractor available for cups with a diameter of 73 mm.
The cup hopper is divided into 5 separate columns. When one of the columns is
empty, the motor spins the hopper so that another column of cups is situated over
the extractor. If, after 65 seconds of the motor running, the photo cells do not
detect a new column with cups, the machine goes to "out of order" status and the
display shows the message of "Out of order, no cups".
The cup hopper has a switch that can be pressed to manually extract a cup.
The electrical connexions of the terminals of the infrared photocells that are used to
detect the presence of the cups are:

2ª 10028 –E 03 - 2016
14
Characteristics of the stirrer extractor:
Range ESP and INS
Units
500
Standard measurements of the
Stirrer
90x9x1.3 mm.
Voltage of the motor
24 Vdc.
There is an extractor available for stirrers of 105 x 9 x 1.5 mm
Characteristics of the sugar extractor of:
Range ESP and INS
Capacity of the sugar hopper
6,100
Voltage of the motor
24 Vdc.
A10. Coin System
The models of the Zensia range can work with coin changers that have executive or MDB
protocol.
On the left of door there is a space with 3 screws to hang the coin changer. The connectors for
the coin changer are on the top of the changer. On connecting it to the machine, the MDB or
Executive protocol is automatically recognised.
I1. Connexions of the Executive protocol
I2. Connexions of the MDB protocol

2ª 10028 –E 03 - 2016
15
A11. Waste liquid tray
It collects the possible drops of water or any other liquid after making a vend. It channels
them to the waste liquid bucket.
To remove it, unscrew the white screw and pull on the tray to release it from its mounting.
A12. Product extractors
Their function is to extract the instant products from the corresponding hoppers and take them
to the beaters.
Manufacturer: Mabuchi
Voltage: 24 Vdc.
Speed: 40 rpm
A13. Coffee grinder
Model ELDOM L60
Voltage:
Current:
200-230 Vac.
0.8A

2ª 10028 –E 03 - 2016
16
Moving the lever in an anticlockwise direction will obtain a coarser grind and a higher quantity
of coffee, and moving the lever in a clockwise direction will obtain a finer grind and therefore
less quantity of ground coffee.
This grinding system has a level detector that indicates when the coffee bean hopper is empty.
It also has a detection system to stop it working when there is a jam in the grinder.
A14. Selection panel
In the Zensia models, the product selection buttons are touch sensitive; to select a product it
is not necessary to press a button, just put one’s finger near the product required and the
machine detects its presence, which activates the service of the product requested.
Behind the glass of the machine, there is an electronic board with detectors for 20 products or
pre-selections. Each one of the product selections is lit with a LED; when a selection is
requested from the machine, all the rest of the selections are switched off, only leaving the
requested product lit up.
Access to the product and pre-selection pictures and the electronic board with the detectors:

2ª 10028 –E 03 - 2016
17
A15. Water inlet Electro-valve
This allows water from the mains to enter the cold water
deposit. It works on 230 Vac.
It has a security mechanism for cases where solids, such as
scale or any other solids, or the EV does not close properly and
does not cut the entry of water into the machine. This
mechanism is activated when the level of water in the waste
water bucket reaches its maximum.
To reset the EV, just reduce the mains water pressure. If this is
not possible, a light tap with a rounded object, like an Allen key, inside the hole (as shown in
the figure) in the upper part of the EV will suffice.
It is also possible to reset it by giving the EV a sharp knock with the handle of a screw driver.

2ª 10028 –E 03 - 2016
18
A16. Volume meter
This meter measures the quantity of water that the pump sends
for the elaboration of coffee espresso.
Inside there is a flow meter with two small electro-magnets that
spin with the flow of water. As it spins, 5 Vdc electrical pulses are
sent to the infusion board. With these pulses, the board is capable
of calculating the quantity of water that has entered for the
elaboration of the deferent products.
It has three electrical connections: positive, negative and the terminal that sends the electrical
pulses.
A17. Water pump
The water pump uses the cold water from the water deposit and pumps it into the boiler, which
makes the hot water go out through the EV to the instant drinks or the espresso coffee drinks.
When the product to be elaborated is espresso coffee, the water pressure needed to force the
water through the ground coffee that has been compressed by the piston in the infusion group
is very high. This increases the pressure of the water going into in the boiler, and also the
pressure of the water that leaves the boiler to elaborate the coffee, up to a pressure of 9
Kg/cm². At this pressure the by-pass (2) on the pump opens, allowing a little water to return
back to the boiler; sufficient to avoid the pressure going above 9 Kg/cm².
The by-pass is a small opening that is closed with a small ball bearing, held in place with a
spring. This spring will hold the ball bearing in place up to a pressure of 9 Kg/cm²; above this
pressure the spring is compressed, which allows the water to go past the ball bearing through
to the by-pass. A pressure of 9 Kg/cm² is considered to be the most adequate for the
elaboration of espresso coffee.

2ª 10028 –E 03 - 2016
19
K1. By-pass
K2. Anti-return
valve
When the product to be elaborated is an instant product, there is no resistance for the water to
go from the boiler to the beater, so that when instant products are elaborated, the pump
operates at a lower pressure than when an espresso coffee is elaborated.
The pump has an anti-return valve that prevents the water returning to the boiler.
Technical characteristics:
Voltage
Pulsing at 110 V
Nominal power
70 w
Working pressure
9 Kg/cm²
A18. Cold water deposit
Made with polypropylene, it has a capacity of 500 cc.
It works at atmospheric temperature and pressure.
The water for elaborating the instant and espresso
coffee products is taken from this deposit.
The water level is controlled with a magnetic switch
activated by a float.

2ª 10028 –E 03 - 2016
20
A19. Hot water boiler for espresso machines
The boiler works under pressure. Its capacity is 320cc of water. It heats the water for both
products, espresso coffee and instant products.
L1. Temperature sensor (PTC)
L2. Security thermostat: switches off at 120º C
L3. Heating element 1100 W
L4. Electro-valves
L5. Upper part
L6. Lower part
L7. Water inlet
It is made from brass and does not need any device to control its water level, as the boiler is
automatically filled when the machine is switched on. Whenever a service is made, the amount
of water that is needed enters the boiler. Unless there are any problems, the boiler will always
be full.
In the models that elaborate espresso coffee, the electro-valve has 3 ways. This EV has an
outlet of water from the boiler, another to the group, and a third that, at rest position, allows
the group to be at atmospheric pressure.
When the machine making an espresso coffee the third way is closed while the outlet to the
boiler and the entry to the group are interconnected.
M1. Coil
M2. Valve
M3. 3-way valve
L1
L2
L3
L4
L5
L6
L7