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
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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

Page Intentionally Left Blank

Page Intentionally Left Blank

Section 1 :: Xpress
Overview
1. Xpress Overview
2. Xpress Components
3. Flavor System Overview
4. Flavor System Components
T E C H N I C A L S U P P O R T

Section 1: Xpress Overview 3033-001B
1-2 Concordia Xpress Technical Support Manual
2900-300B
Xpress Overview

3033-001B Section 1: Xpress Overview
Concordia Xpress Technical Support Manual 1-3
2900-300B
Xpress Components
Front Panel Touch Pad
The front panel touch pad provides a user interface for selecting and
pouring drinks.
Electrical Enclosure and CPU
The electrical enclosure houses the CPU, AC drawer, and DC board.
Bean Hoppers
Each bean hopper holds whole espresso roast beans and feeds the
beans to the grinders.
Water Pump and Motor
The water pump regulates the water pressure to 135-140psi during the
espresso extraction process. The motor supplies power to the pump.
Hot Water Tank
The hot water tank stores and heats the water used to brew espresso.
Brew Group
The brew group assembly brews espresso and automatically discards
the used coffee into the grounds bin.
Steam Tank
The steam tank provides steam used for steaming the milk.
Grinders and the Grinder Adjustment Assembly
The grinders are calibrated to grind espresso beans according to the
customer’s recipe. The grinder adjustment assembly changes the grind
of espresso beans.
Exhaust Fan
NOT SHOWN
The exhaust fan removes excess heat build-up from the machine interior.
Refrigeration Unit
The refrigeration unit stores the milk used for drinks.
Refrigeration Module Assembly
The refrigeration module assembly regulates the temperature inside the
refrigeration unit.
Milk Pump and Milk Pump Box Assembly
The milk pump assembly draws milk from the milk container.
Syrup Manifold
Xpress 6 only
Flavor is infused into drinks via the syrup manifold.
Product Delivery Bracket
The product delivery bracket holds the milk bowl (not shown) and the
syrup manifold.
Product Delivery Nozzle
The finished drink is poured through the product delivery nozzle and into
the customer’s cup.

Section 1: Xpress Overview 3033-001B
1-4 Concordia Xpress Technical Support Manual
2900-300B
Flavor System Overview
CHOCOLATE HEATER
ASSEMBLY

3033-001B Section 1: Xpress Overview
Concordia Xpress Technical Support Manual 1-5
2900-300B
Flavor System Components
Xpress 6 only
Pump Unit
The pump unit contains the six peristaltic pump assemblies that move
the flavors from the boxes to the syrup manifold, and then to the product
delivery outlet.
Control Unit
The control unit houses the electronic board that controls the syrup
pumps.
Power Supply
The power supply provides 24Vdc power to the control unit.
Chocolate Heater Assembly
The chocolate heater assembly provides heat to the chocolate sauce, to
ensure a minimum temperature of 85°F (29.4°C) is maintained.

Section 1: Xpress Overview 3033-001B
1-6 Concordia Xpress Technical Support Manual
2900-300B
Page Intentionally Left Blank

Section 2 :: Installation
and Removal
1. Technical Specifications and Site
Requirements
2. Machine Dimensions
3. Installation
4. Plumbing
5. Flavor System
6. Additional Tasks Required at Installation
7. Operational Configuration
8. Machine Calibration
9. Customer Training
10. Installation Checklist
11. Removal Procedures
T E C H N I C A L S U P P O R T

Section 2: Installation and Removal 3033-002B
2-2 Concordia Xpress Technical Support Manual
2900-300B
Technical Specifications and Site
Requirements
To ensure the site is ready, the customer is required to complete and
return a pre-installation checklist. The customer is required to have
electrical, water, and a drain located within a specified distance from the
machine.
Technical Specifications
Weight: 300lbs/137kg
Operating Environment: 55°- 85°F (13°-29°C)
Power Consumption: 24 amps @ 208Vac max
8 amps @ 115Vac max
Compliance:
FCC: Part 15B, Class A, Part 68
UL Listed
NSF Certified
Power and Water Requirements
Power
Located within five feet (1.5 meters) of machine
Single Phase:
200-240Vac, 30amp dedicated circuit
NEMA L14-30 Receptacle
High Leg:
200-240Vac, 30amp, high leg dedicated circuit.
International machines are shipped without a power plug. A
plug must be attached at the time of installation and meet
with all local electrical codes.
Flavor Delivery System
Domestic
Chocolate Heater Assembly
115Vac, 15amp
NEMA 5-15P
Control Unit
115Vac, 15amp
NEMA 5-15P
International
Chocolate Heater Assembly
230Vac
Control Unit
90-260Vac
Water
Cold water source with a 1/4” or 3/8” tube fitting with a
shut-off valve, located within five feet (1.5 meters) of
machine
Pressure
Minimum: 30psi; Maximum: 100psi (min: 2 bar, max 7 bar)
25 gallons per hour (95 liters per hour)
A fresh water bypass is required for sites with a reverse
osmosis filter system
Scalex Water Treatment System
Included with the unit: two cartridges (one carbon, one
softener)
25”H x 11”W x 5.25”D
63.5cmHx28cmWx13.34cmD
Location Requirements
Locate indoors only
Overall Space
23.79”W x 26.75”D x 36.13”H
59.64cm x 67.49cm x 91.44cm
Machine Counter Space
36”W x 29”D x 42”H
91.44cm x 73.66cm x 106.68cm
Flavor Delivery System
30”W x 30”D x 27”H
76.2cmWx76.2Dx68.6H
Drain
Connection for ¾”/1.9cm drain dose
Indirect drain required
Located within five feet/1.5 meters of machine