Concordia XPRESS User manual

XPRESS
Technician’s Manual

Concordia Coffee Systems
1287 120th Avenue NE
Bellevue, WA 98005
[phone]
[phone]
[phone] Fax
http://www.concordiacoffee.com/
Technical Writer and Editor: Shana McKibbin
Technical Support: Gary Williams, Gery Jaggars, Chris Collier, Dana
Klatt, Allen Moore, Dave Davis
Graphic Engineers: Dan Gilbert, Quan Nguyen
Edition: December, 2012
2900-300B

Revision Change Log
Replace
Old Section
With New
Section
Brief Description
Date
XXX
Revision

Table of Contents
Section 1 :: Xpress Overview ......................................................................1-1
Xpress Overview.................................................................................................1-2
Xpress Components............................................................................................1-3
Flavor System Overview.....................................................................................1-4
Flavor System Components................................................................................1-5
Section 2 :: Installation and Removal....................................................... 2-1
Technical Specifications and Site Requirements................................................2-2
Machine Dimensions...........................................................................................2-3
Installation...........................................................................................................2-4
Configuring the Machine for Supply Voltage.................................2-4
Espresso Machine Electrical Settings...........................................2-4
Setting the DC Jumper Plug..........................................................2-4
Configuring Transformer Auxiliary Connector #1..........................2-5
Plumbing .............................................................................................................2-6
Connecting the External Drain ......................................................2-6
Water Supply.................................................................................2-6
Problems with Reverse Osmosis Water System...........................2-7
Flavor System .....................................................................................................2-7
Flavor System Installation.............................................................2-7
Prime the Flavor System...............................................................2-7
Chocolate Sauce...........................................................................2-7
Verify Flavor Pour Rate.................................................................2-7
Additional Tasks Required at Installation............................................................2-8
Power Up the Machine..................................................................2-8
Install Bean Hoppers.....................................................................2-8
Install Cup Stand (Optional)..........................................................2-8
Operational Configuration...................................................................................2-8
Placing Milk in the Refrigeration Unit ............................................2-8
Machine Calibration ............................................................................................2-9
Customer Training...............................................................................................2-9
Installation Checklist ...........................................................................................2-9
Removal Procedures...........................................................................................2-9
Section 3 :: Electrical................................................................................. 3-1
Electrical Block Diagram.....................................................................................3-2
Fuses ..................................................................................................................3-3
Backplane ...........................................................................................................3-4
AC Drawer Assembly..........................................................................................3-5
DC Board Assembly............................................................................................3-6
CPU Board..........................................................................................................3-7
J4...................................................................................................3-8
J2...................................................................................................3-8
P3..................................................................................................3-9
P4..................................................................................................3-9
Peripheral Connections Configuration..............................................................3-10
Transformer.......................................................................................................3-11
Power Into the Machine ....................................................................................3-15
DC Power Supply Board LEDs.........................................................................3-18
Heating Element Wiring Diagrams....................................................................3-20
Jumper Plug Connector Detail..........................................................................3-21
Section 4 :: Software.................................................................................. 4-1
Software Overview..............................................................................................4-2

Software Menu Informational Screens..........................................4-2
Categories.....................................................................................4-2
Service Switch.....................................................................................................4-3
Navigating the Software Menu......................................................4-4
Accessing a Sub-Category............................................................4-4
Exiting the Menu System...............................................................4-5
Accessing the Grand Total Drink Count........................................4-5
Accessing Total Drink Count Statistics .........................................4-5
Accessing Daily Drink Count Statistics .........................................4-5
Software Quick Reference Table........................................................................4-6
Calibration.........................................................................................................4-13
Calibrating Pump Pressure .........................................................4-14
Calibrating Espresso ...................................................................4-14
Configuring the Bean Hoppers....................................................4-14
Espresso Extraction and Temperature Parameters....................4-15
Drink Temperatures.....................................................................4-15
Verifying Espresso Extraction .....................................................4-15
Calibrating Milk Timings..............................................................4-16
Calibrating Brewed Coffee ..........................................................4-16
Calibrating Flavor Timings...........................................................4-17
Espresso Extraction Pre-Treatment Options ....................................................4-17
Pre-Treatment Options................................................................4-17
CPU Board........................................................................................................4-19
Loading New Software to a Machine................................................................4-20
Required Equipment....................................................................4-20
Configuring HyperTerminal .........................................................4-20
Connecting a Laptop to a Machine .............................................4-27
Updating Software for Customers with Custom Drink Recipes...4-30
Section 5 :: Plumbing ................................................................................ 5-1
The Water System ..............................................................................................5-2
Line Pressure ................................................................................5-3
Check Valve ..................................................................................5-3
Water Filtration System.................................................................5-3
Hot Water Tank...................................................................................................5-4
Temperature/Level Probe..............................................................5-5
Level Probe ...................................................................................5-5
Temperature Probe .......................................................................5-6
Pressure Relief Valve....................................................................5-6
High Temperature Limit Switch.....................................................5-6
Water Inlet.....................................................................................5-6
Flowmeter......................................................................................5-7
Heating Elements..........................................................................5-7
Brew Valve ....................................................................................5-7
Hot Water Valve ............................................................................5-7
Draining the Hot Water Tank.........................................................5-8
Water Pump and Motor.......................................................................................5-8
Water Pressure Gauge..................................................................5-9
Setting Pump Pressure .................................................................5-9
Expansion Valve............................................................................5-9
Check Water Flow Message .........................................................5-9
The Steam System............................................................................................5-10
Steam Tank –Front View............................................................5-10
Steam Tank –Rear View ............................................................5-11
Steam Tank Fill Valve .................................................................5-12
Steam Tank.................................................................................5-12
Water Level Probes.....................................................................5-12

Pressure Gauge ..........................................................................5-13
Heating Elements........................................................................5-13
Pressure Relief Valve..................................................................5-13
High Temperature Limit Switch...................................................5-13
Steam Valves ..............................................................................5-14
Left Steam Valve.........................................................................5-14
Center Steam Valve....................................................................5-15
Right Steam Valve.......................................................................5-15
Air Purge Process .......................................................................5-15
Captive Water Purge System......................................................5-15
Draining the Steam Tank.............................................................5-15
Section 6 :: Coffee System ......................................................................... 6-1
The Coffee System .............................................................................................6-2
Espresso Path...............................................................................6-2
Grinders ..............................................................................................................6-3
Double Grinder Assembly .............................................................6-3
Calibration: Espresso Grind ..........................................................6-4
Grinder Adjustment Panel.............................................................6-4
Grinder Adjustment Diagram.........................................................6-5
Measuring the Coffee Powder Dose .............................................6-5
Coffee Powder Channel................................................................6-6
Removing the Grinder ...................................................................6-6
Replacing the Grinder Burrs/Blades..............................................6-7
Setting the Grinder Adjustment Indicator to Mid-Scale.................6-7
Bean Hoppers .....................................................................................................6-8
Filling a Bean Hopper....................................................................6-8
Inserting the Hopper Stopper........................................................6-8
Removing a Bean Hopper.............................................................6-8
Brew Group.........................................................................................................6-9
Brew Group Initialization .............................................................6-10
Brew Group Components .................................................................................6-10
Hall-Effect Sensors......................................................................6-11
Left Piston....................................................................................6-12
Right Piston.................................................................................6-12
Piston Movement.........................................................................6-12
Viewing the Left Piston Movement..............................................6-13
Removing the Left Piston............................................................6-13
Removing the Right Piston..........................................................6-14
Gearbox Removal and Installation....................................................................6-15
Removing the Gearbox ...............................................................6-15
Installing the Gearbox .................................................................6-16
Section 7 :: Milk System and Refrigeration Unit ...................................... 7-1
The Milk Delivery System ...................................................................................7-2
Milk Delivery System Components .....................................................................7-2
Milk Pump Assembly.....................................................................7-2
Milk Pick-Up Tube.........................................................................7-2
Milk Pump......................................................................................7-2
Milk System Theory of Operation........................................................................7-3
Basic Terminology.........................................................................7-3
Initial Setup of the Milk System.....................................................7-4
Milk System Capabilities ...............................................................7-5
A Common Milk Timing Mistake....................................................7-5
Air Gate Valve Assembly ....................................................................................7-5
Air Gate Valves .............................................................................7-6
Air Purge Valves............................................................................7-6

Air Vent Needles ...........................................................................7-6
Connection of Milk Pump Assembly and Air Gate Valve Assembly7-
6
Alt Milk Valve.......................................................................................................7-6
Steam Delivery Components ..............................................................................7-7
Steam Valves ................................................................................7-7
Mixing TEE Assembly ...................................................................7-7
Refrigeration Unit Overview................................................................................7-8
Placing Milk in the Machine...........................................................7-9
Checking the Refrigeration Unit Temperature...............................7-9
Refrigeration Cooling Module Assembly.....................................7-10
Fan Control Board.......................................................................7-11
Cold Sink Deflector......................................................................7-11
Interior Circulation Fan Assembly ...............................................7-12
Exterior Cooling Module Fan Assembly......................................7-12
Temperature Probe Assembly.....................................................7-12
Milk Weight Trays........................................................................7-13
Adjusting a Milk Weight Tray.......................................................7-15
Milk Level Sensors ......................................................................7-16
Auto Milk Select...........................................................................7-16
Section 8 :: Steam Wands .........................................................................8-1
Steam Wand Overview .......................................................................................8-2
Automatic Steam Wand ......................................................................................8-2
Automatic Steam Wand Theory of Operation ...............................8-2
Automatic Steam Wand Selections...............................................8-3
Automatic Steam Wand Programming..........................................8-4
Air Pump........................................................................................8-4
Steam and Vacuum Valve Assembly............................................8-4
Automatic Steam Wand Wiring...........................................................................8-5
Replacing an Automatic Steam Wand................................................................8-5
Manual Steam Wand...........................................................................................8-6
Replacing a Manual Steam Wand ......................................................................8-6
Removing a Steam Wand .............................................................8-8
Installing a Steam Wand.....................................................................................8-8
Cleaning a Steam Wand.....................................................................................8-8
Section 9 :: Flavor System......................................................................... 9-1
The Flavor System..............................................................................................9-2
Chocolate Sauce Delivery Path.....................................................9-2
Syrup Delivery Path.......................................................................9-3
Flavor Tubes..................................................................................9-3
Flavor Storage Area ......................................................................9-4
Chocolate Sauce...........................................................................9-4
Chocolate Heater Assembly..........................................................9-4
Connecting Flavor Tubing.............................................................9-4
Changing the Flavor Pour Rate.....................................................9-5
Verifying Proper Syrup Flow..........................................................9-6
Changing Flavor Boxes.................................................................9-7
Peristaltic Pumps ................................................................................................9-8
Syrup Manifold ....................................................................................................9-8
Chocolate Rinse Purge Valve .......................................................9-9
Milk Bowl .......................................................................................9-9
Removing the Syrup Manifold.......................................................9-9
Replacing the Syrup Manifold .....................................................9-10
Cleaning the Flavor Delivery System................................................................9-10
Priming the Flavor Delivery System..................................................................9-12

Section 10 :: Vending............................................................................... 10-1
Vending Overview.............................................................................................10-2
Vending Backpack.......................................................................10-2
Replacing a Card Reader .................................................................................10-2
Installing a Vending Unit ...................................................................................10-3
Removing a Vending Unit.................................................................................10-3
Troubleshooting ................................................................................................10-3
Section 11 :: Cleaning and Maintenance ..................................................11-1
Daily Maintenance.............................................................................................11-2
Concordia Cleaning Products......................................................11-2
Cleaning Timers................................................................................................11-3
Preventive Maintenance ...................................................................................11-3
Section 12 :: Concordia Procedures ........................................................ 12-1
Service Call Process.........................................................................................12-2
Arrival to Site...............................................................................12-2
Machine Repair ...........................................................................12-2
Hold for Parts Procedures...........................................................12-2
Departing from Site .....................................................................12-2
Required Immediately for Call Closeout......................................12-3
Complete Call Protocol .....................................................................................12-3
Machine Appearance ..................................................................12-3
Milk System.................................................................................12-3
Brew Group .................................................................................12-3
Water Tank..................................................................................12-3
Water Pump.................................................................................12-3
Steam Tank.................................................................................12-3
Refrigeration Unit ........................................................................12-4
Espresso Extraction ....................................................................12-4
Milk Pour......................................................................................12-4
Service Call Checklist .......................................................................................12-5
Parts Return Policy ...........................................................................................12-6
Non-Consignment Agents...........................................................12-6
Consignment Agents...................................................................12-6
Return Material Tag.....................................................................12-7
Parts Replenishment Form ...............................................................................12-8
Section 13 :: Customer Service and Training.......................................... 13-1
Training the Customer.......................................................................................13-2
User Guide ..................................................................................13-2
Starting and Resetting the Machine............................................13-2
Filling Machine with Beans and Milk ...........................................13-2
Pouring Drinks and Cancelling Drinks.........................................13-2
Restocking and Changing Flavor Boxes.....................................13-2
Cleaning ......................................................................................13-3
Serial Number .............................................................................13-3
Accessing Software Menu...........................................................13-3
Troubleshooting Tips...................................................................13-3
Contacting Concordia for Assistance..........................................13-4
Concordia Beverage Systems’ Value-Added Service.......................................13-5
Value-Added Service...................................................................13-6
G.U.E.S.T..........................................................................................................13-7
Greet the Customer.....................................................................13-7
Understand your Customer.........................................................13-8
Empathize with Your Customer...................................................13-9
Solve the Problem.....................................................................13-10
Train the Customer....................................................................13-10

Section 14 :: Messages ............................................................................. 14-1
Troubleshooting Display Messages..................................................................14-2
Section 15 :: Troubleshooting...................................................................15-1
Troubleshooting Quick Reference Guide..........................................................15-2
Machine Failure...........................................................................15-2
Coffee System.............................................................................15-3
Flavor System .............................................................................15-3
Milk System.................................................................................15-4
Troubleshooting Trees......................................................................................15-5
Brew System: Right Drive Timeout .............................................15-6
Brew System: Invalid Stop L .......................................................15-7
Brew System: Invalid Stop R.......................................................15-9
Brew System: Left Drive Timeout..............................................15-11
Grinder System: Out of Beans ..................................................15-13
Milk System: Overpouring Milk..................................................15-15
Milk System: Cold Milk Pour......................................................15-17
Milk System: No Milk Pour ........................................................15-19
Milk System: Short Milk Pour ....................................................15-21
Refrigeration System: Temperature Above 40˚F ......................15-23
Steam System: Steam Temperature High ................................15-25
Steam System: Check Sensor Voltage.....................................15-26
Steam System: Check Steam Probes.......................................15-27
Steam System: Check Steam Tank ..........................................15-28
Steam System: Steam Temperature Low .................................15-29
Water System: Water Temperature Too High...........................15-30
Water System: Water Temperature Too Low............................15-31
Water System: Check Water Supply.........................................15-33
Water System: Water Tank Limit Switch Open.........................15-35
Flavor System: Cross-Contamination of Syrup Lines...............15-37
Flavor System: Too Much Flavor in Drink.................................15-38
Flavor System: Not Enough Flavor in Drink..............................15-39
Flavor System: No Flavor in Drink ............................................15-41
Electrical System: Check Analog Board....................................15-43
Electrical System: Incorrect Software for Touchpad.................15-44
Electrical System: Milk Pump Running Continuously ...............15-45
Electrical System: Front Panel Failed .......................................15-46
Electrical System: Check Clock.................................................15-47
Electrical System: Check Stats .................................................15-48
Electrical System: CPU Load Disp and Seq Error ....................15-49
Electrical System: AC Voltage Error .........................................15-51
Electrical System: DC Voltage Failure ......................................15-53
Vending System: Card Swipe or Tap Not Authorized...............15-55
Vending System: Not Configured..............................................15-56
Vending System: No Display on Card Reader..........................15-57
Section 16 :: Parts Lists & Diagrams ....................................................... 16-1
Recommended Tools List .................................................................................16-2
Standard Tools............................................................................16-2
Concordia Stocked Tools............................................................16-2
Consumables ..............................................................................16-2
Parts Lists and Diagrams..................................................................................16-3
Diagram 1: Machine Overview....................................................16-4
Diagram 1, Parts List: Machine Overview...................................16-5
Diagram 2: Grounds Bin Door, Refrigerator Door with Hot Water
Button Assembly .........................................................................16-6

Diagram 2, Parts List: Refrigerator Door with Hot Water Button
Assembly.....................................................................................16-7
Diagram 3: Refrigerator Door with Steam Wand Assembly........16-8
Diagram 3, Parts List: Refrigerator Door with Steam Wand
Assembly.....................................................................................16-9
Diagram 4: Front Panel.............................................................16-10
Diagram 4, Parts List: Front Panel............................................16-11
Diagram 5: Top Panel ...............................................................16-12
Diagram 5, Parts List: Top Panel ..............................................16-13
Diagram 6: Grinder Assembly...................................................16-14
Diagram 6, Parts List: Grinder Assembly..................................16-15
Diagram 7: Grinder Adjustment Assembly................................16-16
Diagram 7, Parts List: Grinder Adjustment Assembly...............16-17
Diagram 8: Group Upper and Lower Piston Assembly.............16-18
Diagram 8, Parts List: Group Upper and Lower Piston Assembly16-
19
Diagram 9: Group Drive System ...............................................16-20
Diagram 9, Parts List: Group Drive System ..............................16-21
Diagram 10: Milk Pump Assembly ............................................16-22
Diagram 10: Parts List, Milk Pump Assembly...........................16-23
Diagram 11: Product Delivery Assembly, Xpress 6 ..................16-24
Diagram 11, Parts List: Product Delivery Assembly, Xpress 6 .16-25
Diagram 12: Product Delivery Assembly, Xpress 0 ..................16-26
Diagram 12, Parts List: Product Delivery Assembly, Xpress ....16-27
Diagram 13: Refrigeration Unit Assembly.................................16-28
Diagram 13, Parts List: Refrigeration Unit Assembly................16-29
Diagram 14: Chocolate Sauce Delivery System.......................16-30
Diagram 14, Parts List: Chocolate Sauce Delivery System......16-31
Diagram 15: Syrup Delivery System .........................................16-32
Diagram 15, Parts List: Syrup Delivery System ........................16-33
Diagram 16: Refrigeration Unit Cooling Assembly....................16-34
Diagram 16, Parts List: Refrigeration Unit Cooling Assembly...16-35
Diagram 17: Steam Tank, Front................................................16-36
Diagram 17, Parts List: Steam Tank, Front...............................16-37
Diagram 18: Steam Tank, Rear ................................................16-38
Diagram 18, Parts List: Steam Tank, Rear ...............................16-39
Diagram 19: Water Pump and Motor ........................................16-40
Diagram 19, Parts List: Water Pump and Motor .......................16-41
Diagram 20: Hot Water Tank.....................................................16-42
Diagram 20, Parts List: Hot Water Tank ...................................16-43
Diagram 21: Water/Steam Gauge/ Air Valve Assembly............16-44
Diagram 21: Parts List: Water/Steam Gauge/Air Valve Assembly16-
45
Diagram 22, Parts List: Drain Valve Bridge Web Assembly .....16-46
Diagram 22, Parts List: Drain Valve Bridge Web Assembly .....16-47
Section 17 :: Index ....................................................................................17-1