Concordia 2500s User manual

Concordia
Model
2500s/i
Super
Automatic
Espresso
Machines
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: Andre Belyea, Gary Williams, Pete Oksendahl, Chris
Collier
Graphic Engineer: Scott Naito
Revision A
September, 2007

Welcome to Concordia Coffee Systems!
We are very pleased to have you join our team of professionals, united
in the common pursuit of excellence on behalf of our customers.
Concordia Coffee Systems is a leader in the design, development and
manufacture of fully automated espresso systems, serving thousands of
customers throughout the world. Our goal is to continuously achieve
the highest imaginable levels of quality, service, and technological
performance for our customers. We believe that it is the ability, talent
and spirit of people like you that will enable Concordia Coffee Systems
to reach this goal.
The basic objectives of Concordia Coffee Systems are:
 Deliver quality and value to our customers through leadership
and excellence in everything that we do.
 Provide a strong seamless network of service to all Concordia
Coffee Systems customers while, exceeding their expectations
from us.
 Build value in our employees and agents through experience,
training and the provision of opportunities for success.
 Build long term value in our Company.
 Be strong contributing members of the communities in which
we conduct business.
You are an important part of our team. We want to do our best to help
you find your work with Concordia Coffee Systems satisfying, rewarding
and personally meaningful. The material in this manual has been
designed to be used as a training aid, reference resource and updated
library of Concordia Coffee Systems Policies and Procedures.
It is important that you keep your manual updated to reflect our
current revisions to ensure we have provided you with the tools
necessary to facilitate YOUR success!
Ray Ross
Vice President of Service and Customer Support
Concordia Coffee Systems

Revision Change Log
Replace Old
Section With New Section Brief Description Date 2900-233 Revision

Table of Contents
Section 1 :: Model 2500s/i Overview.................................................1-1
Model 2500i Overview Diagram........................................................ 1-2
Model 2500s Overview Diagram ....................................................... 1-3
The Model 2500s/i Components....................................................... 1-4
Touch Pad................................................................ 1-4
Electrical Encosure ..................................................... 1-4
Bean Hoppers............................................................ 1-4
Water Pump.............................................................. 1-4
Hot Water Tank ......................................................... 1-4
Brew Group .............................................................. 1-4
Steam Tank .............................................................. 1-4
Refrigeration Unit....................................................... 1-4
Grounds Bin.............................................................. 1-4
Drink Dispensing......................................................... 1-4
Grinders and the Grinder Adjustment Assembly................... 1-4
Refer/Cooling Module Assembly...................................... 1-4
Milk Valve ................................................................ 1-4
Section 2 :: Installation and Removal................................................2-1
Installation Requirements.............................................................. 2-2
Dimensions................................................................................ 2-3
Installation ............................................................................... 2-4
Placing the Unit......................................................... 2-4
Ambient Temperature.................................................. 2-4
Configuring the Machine for Supply Voltage........................ 2-4
Espresso Machine Electrical Settings ................................ 2-4
Setting the DC Jumper Plug........................................... 2-5
Configuring Transformer Auxiliary Connector #1 .................. 2-6
Connecting the Drain................................................... 2-7
Connecting the Water Supply......................................... 2-8
Problems with Reverse Osmosis Water System..................... 2-8
Connecting the Water Treatment System........................... 2-9
Starting the Machine...................................................................2-10
Consumables ............................................................................2-10
Calibration...............................................................................2-10
Customer Training......................................................................2-10
Installation Checklist ..................................................................2-11
Removal Procedures ...................................................................2-12
Cumulative Drink Total ...............................................2-12
Clean Refrigerator.....................................................2-12
Clean Brew Group & Grinders........................................2-12
Run Daily Clean Cycles................................................2-12
Disconnect Water Supply & Drain Tanks ...........................2-12
Preparation for Shipping..............................................2-13
Packaging for Shipment...............................................2-13
Section 3 :: Electrical ..................................................................3-1
Electrical Block Diagram ............................................................... 3-2
Fuses....................................................................................... 3-3
Backplane................................................................................. 3-4
AC Drawer Assembly .................................................................... 3-5
Transformer .............................................................................. 3-6
Transformer Diagrams.................................................. 3-6
Operating Voltage....................................................................... 3-7
AC Voltage ............................................................... 3-7
DC Voltage ............................................................... 3-7

Valves..................................................................... 3-7
Diodes..................................................................... 3-7
Electrical Enclosure Fan ............................................... 3-8
Power Into the Machine ................................................................ 3-9
Power into DC Power Supply Board .................................. 3-9
Power into AC Components ..........................................3-10
Setting the DC Jumper Plug (J1) ....................................3-10
Set Transformer Auxiliary Connector #1 ...........................3-11
DC Power Supply Board LEDs .........................................................3-12
Solid State Relays......................................................3-13
Jumper Plug Connector Detail........................................................3-14
Jumper Plug 1 ..........................................................3-14
Jumper Plug 2 ..........................................................3-15
Jumper Plug 3 ..........................................................3-15
Jumper Plug 6 ..........................................................3-16
Jumper Plug 7 ..........................................................3-16
Jumper Plug 8 ..........................................................3-17
Jumper Plug 10.........................................................3-17
Jumper Plug 9 ..........................................................3-18
Heater Element Wiring Diagrams ....................................................3-19
Section 4 :: Software...................................................................4-1
Software Overview...................................................................... 4-2
Main Menu Categories.................................................. 4-2
The Service Switch...................................................... 4-3
Navigating the Menu System .......................................... 4-3
Accessing the Main Menu .............................................. 4-4
Accessing a Submenu................................................... 4-4
Exiting the Menu System............................................... 4-4
Modifying a Value....................................................... 4-4
Accessing Cumulative Drink Statistics ............................... 4-5
Software Quick Reference Table...................................................... 4-6
CPU Board ...............................................................................4-11
CPU and LEDs...........................................................4-11
Calibration Overview ..................................................................4-13
Espresso Extraction....................................................4-13
The Extraction Goal ...................................................4-13
Espresso Extraction & Temperature Parameters..................4-13
Espresso Extraction Time.............................................4-13
Temperatures...........................................................4-13
How to Calibrate Espresso ............................................................4-14
Step 1: Verify Factory Settings ......................................4-14
Step 2: Use Fresh Espresso Roast Coffee Beans...................4-14
Step 3: Adjust the Coffee Grind Texture...........................4-15
Step 4: Ask Customer to Approve Extraction......................4-16
Step 5: Coffee Powder Dose and Water Volume are adjustable per
customer request ......................................................4-16
Espresso Extraction Pre-Treatment Options .......................................4-17
Pre-Treatment Options ...............................................4-17
Setting Milk and Water Timings ......................................................4-19
Latte Milk Timing ......................................................4-19
Double/Triple Latte Milk Timing ....................................4-19
Cappuccino Foamed Milk Timing ....................................4-19
Cappuccino Boost Delay ..............................................4-19
Cappuccino Coffee Delay.............................................4-19
Section 5 :: Plumbing...................................................................5-1

Water System ............................................................................ 5-2
2500s & 2500i Hydraulics Diagram ................................... 5-2
Water Supply............................................................................. 5-3
Water Filtering .......................................................... 5-3
Water Pump and Motor................................................................. 5-4
Water Pressure Gauge.................................................. 5-4
Changing Pump Pressure............................................... 5-5
Expansion Valve......................................................... 5-5
Flowmeter................................................................................ 5-5
Check Water Flow Message............................................ 5-6
Water Tank............................................................................... 5-6
Temperature/Level Probe............................................. 5-6
Level Probe .............................................................. 5-6
Temperature Probe..................................................... 5-7
Heating Elements ....................................................... 5-7
High Temperature Limit Switch ...................................... 5-7
Pressure Relief Valve................................................... 5-7
Drain Valve............................................................... 5-8
Valves ..................................................................................... 5-8
Brew Valve............................................................... 5-8
Hot Water Valve......................................................... 5-8
Water Level Sensors..................................................................... 5-9
The Steam System....................................................................... 5-9
Steam Tank Fill Valve .................................................5-10
Steam Tank .............................................................5-10
Water Level Probes....................................................5-10
Pressure Gauge.........................................................5-11
Heating Elements ......................................................5-11
Pressure Relief Valve..................................................5-11
High Temperature Limit Switch .....................................5-11
Steam Valves............................................................................5-12
Latte Steam Valve .....................................................5-12
Cappuccino Steam Valve..............................................5-12
Steam Wand Valve (if present) ......................................5-12
Captive Water Purge System.........................................5-13
Post Steam Valve.......................................................5-13
Air Purge Process ......................................................5-13
Section 6 :: The Coffee System.......................................................6-1
Coffee System Overview ............................................................... 6-2
The Espresso Path....................................................... 6-2
Grinders................................................................................... 6-3
Double Grinder Assembly.............................................. 6-3
Grinder Calibration..................................................... 6-3
Grinder Adjustment Panel............................................. 6-4
Coffee Powder Channel................................................ 6-5
Removing a Grinder .................................................... 6-5
Replacing Grinder Burrs/Blades ...................................... 6-5
Setting Grinder Adjustment Indicator to Mid-Scale ............... 6-6
Bean Hoppers ............................................................................ 6-7
Directions for Filling Bean Hopper ................................... 6-7
Inserting the Hopper Stopper ......................................... 6-7
Section 7 :: Milk System and Refrigeration Unit ...................................7-1
Milk System Overview................................................................... 7-2
Milk Delivery System Overview........................................................ 7-2
The Milk Delivery System Components............................................... 7-3

Milk Valve Assembly .................................................... 7-3
Milk Valve Solenoid and Plunger...................................... 7-3
Nozzle and Anti-Splatter Shield ...................................... 7-4
Air-Gate Valve Assembly ............................................................... 7-4
Air-Gate Valve........................................................... 7-4
Air Vent Needle ......................................................... 7-4
Connection of Milk Valve Assembly and Air-Gate Valve .......... 7-4
Alt Milk Valve ............................................................................ 7-4
The Latte Pour Process ................................................ 7-5
The Cappuccino Pour Process......................................... 7-5
Understanding the Relationship between Steam Temperature and Milk
Temperature ............................................................................. 7-5
Troubleshooting and Repair........................................... 7-6
The Milk Delivery System............................................................... 7-7
Placing Milk in the Machine ........................................... 7-7
Checking the Refrigeration Unit Temperature..................... 7-7
The Refrigeration Unit.................................................................. 7-8
Refrigeration Cooling Module Assembly.............................................. 7-9
Cold Sink Deflector ....................................................7-10
Fans.......................................................................................7-11
Interior Circulation Fan Assembly...................................7-11
Temperature Probe Assembly........................................7-11
Exterior Cooling Module Fan Assembly .............................7-12
Milk Weight Trays.......................................................................7-13
Adjusting the Milk Weight Tray......................................7-14
Milk Level Sensors......................................................7-15
Auto Milk Select........................................................7-15
Troubleshooting and Repair...........................................................7-16
Section 8:: Brew Group ................................................................8-1
The Brew Group ......................................................................... 8-2
Hall-Effect Sensors...................................................................... 8-3
Piston Movement ........................................................................ 8-4
Group Initialization ..................................................................... 8-5
Measuring Coffee Powder Dose........................................................ 8-5
Motors..................................................................................... 8-6
Right Motor .............................................................. 8-6
Left Motor................................................................ 8-6
Pistons..................................................................................... 8-7
Left Piston ............................................................... 8-7
Right Piston.............................................................. 8-8
Piston Removal Procedures ............................................................ 8-9
Left Piston Removal Procedure....................................... 8-9
Right Piston Removal Procedure...................................... 8-9
Gearbox Removal and Installation...................................................8-10
Gearbox Removal ......................................................8-10
Gearbox Installation...................................................8-10
Section 9 :: Cleaning and Maintenance..............................................9-1
Daily Maintenance of the Concordia Espresso Machine............................ 9-2
Importance of Cleaning................................................ 9-2
Concordia Cleaning Products.......................................... 9-2
Performing Daily Cleaning............................................. 9-2
Auto-Rinse ............................................................... 9-3
Preventive Maintenance................................................................ 9-3
PM Kits.................................................................... 9-3
Preventive Maintenance Checklist ................................... 9-4