Concordia Integra User manual

Integra
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,
Allen Moore, Dana Klatt, Dave Davis
Graphics: Quan Nguyen, Andre Belyea, Daniel Gilbert
Edition: May, 2012
2900-255B

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!

Revision Change Log
Replace
Old
Section
With
New
Section
Brief Description
Date
2900-
255
Revision

Table of Contents
Section 1 :: Integra Overview........................................... 1-1
Integra Overview ......................................................................1-2
Integra Components ..................................................................1-3
Flavor System Overview.............................................................1-4
Flavor System Components ........................................................1-5
Bin Door Assembly Components –Integra 1 and Integra 4 .............1-6
Bin Door Assembly Components –Integra 0 .................................1-7
Section 2 :: Installation and Removal ................................ 2-1
Technical Specifications and Site Requirements.............................2-2
Plumbing..................................................................................2-4
Connecting the External Drain....................................2-4
Water Supply ...........................................................2-4
Problems with Reverse Osmosis Water System.............2-5
Flavor System...........................................................................2-5
Control Box Installation .............................................2-5
Peristaltic Pump Assembly Installation.........................2-5
Chocolate Heater Assembly Installation .......................2-6
Flavor Tubing Installation ..........................................2-6
Priming the Flavor System .........................................2-7
Verify Flavor Pour Rate..............................................2-7
Additional Tasks Required at Installation ......................................2-8
Power Up the Machine...............................................2-8
Bean Hopper ............................................................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 ................................................................ 2-10
Section 3 :: Electrical ...................................................... 3-1
Electrical Block Diagram.............................................................3-2
Electrical Enclosure....................................................................3-3
Electrical Enclosure Fan .............................................3-4
Front Panel Cable .....................................................3-4
AC Fuses .................................................................3-4
Expansion Board (Top) ..............................................3-4
Analog (Middle) ........................................................3-4
AC/DC Power Supply.................................................3-4
Fuses ......................................................................3-5
AC/DC Power Supply Board ........................................................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
Transformer Diagram –PN 1320-023........................3-11
Transformer Diagram –PN 1320-025........................3-11

Machine Operating Voltage ...................................... 3-12
AC Voltage.............................................................3-12
DC Voltage ............................................................ 3-12
Valves...................................................................3-12
Diodes ..................................................................3-12
Flavor System ........................................................ 3-13
DC Power Supply Board LEDs ................................................... 3-14
AC Distribution Panel ............................................................... 3-16
Jumper Plug Connector Detail ................................................... 3-17
Jumper Plug 2 ........................................................ 3-17
Jumper Plug 3, 9, 11...............................................3-18
Jumper Plug 4, 5, 6, 12 ...........................................3-19
Jumper Plug 7 ........................................................3-20
Jumper Plug 8, 10 ..................................................3-21
Troubleshooting ...................................................................... 3-22
Section 4 :: Software....................................................... 4-1
Software Overview ....................................................................4-2
Software Menu Informational Screens .........................4-2
Categories ...............................................................4-2
Service Switch .........................................................4-3
Service Switch in the RUN position..............................4-3
Service Switch in the SERVICE position .......................4-3
The Service Switch and Cleaning the Machine ..............4-3
Navigating the Menu System......................................4-4
Accessing a Sub-Category .........................................4-4
Exiting the Menu System ...........................................4-4
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 ............................................................................. 4-11
Pump Pressure ....................................................... 4-12
Espresso ............................................................... 4-12
Milk Timings ..........................................................4-13
Brewed Coffee (Long Black) .....................................4-14
Flavor Timings .......................................................4-15
CPU Board.............................................................................. 4-16
Loading New Software to a Machine .......................................... 4-17
Required Equipment................................................ 4-17
Configuring HyperTerminal ...................................... 4-17
Connecting the Laptop to the Machine.......................4-24
Updating Software for Customers with Custom Drink
Recipes .................................................................4-27
Section 5 :: Plumbing ...................................................... 5-1
The Water System.....................................................................5-2
Water Supply............................................................................5-3
Line Pressure ...........................................................5-3
Check Valve .............................................................5-3
Water Filtration System.............................................5-3
Reverse Osmosis Water System .................................5-3
Expansion Valve........................................................................5-4
Water Pump and Motor Assembly ................................................5-4

Flowmeter ................................................................................5-5
Hot Water Tank.........................................................................5-6
Pressure Relief Valve.................................................5-7
Temperature/Level Probe ..........................................5-7
Level Probe..............................................................5-7
Temperature Probe ...................................................5-8
Drain Valve..............................................................5-8
Water Out ...............................................................5-8
Brew Valve ..............................................................5-8
Heating Elements .....................................................5-9
High Temperature Limit Switch –Water ......................5-9
Draining the Water Tank............................................5-9
Valve Tree.............................................................................. 5-10
Valve Tree Removal ................................................ 5-11
Valve Tree Replacement ..........................................5-13
The Steam System .................................................................. 5-14
Steam Tank............................................................................ 5-15
Steam Valves.........................................................5-16
High Temperature Limit Switch –Steam.................... 5-16
Heating Elements ...................................................5-16
Water Level Probes ................................................. 5-17
Pressure Relief Valve...............................................5-17
Safety Probe ..........................................................5-18
Vacuum Break Valve ...............................................5-18
Draining the Steam Tank ......................................... 5-18
Front Panel Assembly .............................................................. 5-19
Steam Pressure Gauge ............................................ 5-19
Water Pressure Gauge............................................. 5-20
Setting Pump Pressure ............................................5-20
Check Water Flow Message ...................................... 5-20
Troubleshooting ...................................................................... 5-20
Section 6 :: Coffee System............................................... 6-1
Coffee System Overview ............................................................6-2
Fresh Water Supply ..................................................6-3
Water Pump / Motor Assembly ...................................6-3
Flowmeter ...............................................................6-3
Hot Water Tank ........................................................6-3
Brew Valve Assembly ................................................6-3
Brew Group .............................................................6-3
Grounds Chute .........................................................6-3
Upper Piston ............................................................6-4
Lower Piston ............................................................6-4
Bean Hopper ............................................................6-4
Grinder ...................................................................6-4
Grounds Bin.............................................................6-4
Espresso Nozzle .......................................................6-4
Bean Grinders...........................................................................6-5
Calibration: Espresso Grind........................................6-6
Replacing Bean Grinder Burrs/Blades ..........................6-7
Coffee Powder Channel..............................................6-7
Bean Hoppers ...........................................................................6-8
Inserting the Hopper Stopper .....................................6-8
Brew Group Overview ................................................................6-9

Upper Piston .......................................................... 6-10
Grounds Chute ....................................................... 6-10
Sweep Arm ............................................................6-10
Brew Chamber ....................................................... 6-10
Thermal Switch ......................................................6-10
Brew Block ............................................................6-10
Brew Chamber Heater .............................................6-10
Grounds Bin...........................................................6-10
Empty Grounds Bin .................................................6-11
Troubleshooting ...................................................................... 6-11
Section 7 :: Milk System and Refrigeration System ............. 7-1
Milk Delivery System Overview ...................................................7-2
Milk Delivery System Components...............................................7-3
Milk Pump Assembly .................................................7-3
Pick-Up Screen.........................................................7-3
Air Check Valve ........................................................7-3
Milk Pick-Up Tube .....................................................7-3
Product Delivery Nozzle.............................................7-3
Vacuum Break Valve .................................................7-3
The Drink Pour Process ..............................................................7-4
Latte.......................................................................7-4
Cappuccino ..............................................................7-4
Milk System Theory of Operation.................................................7-4
Basic Terminology ....................................................7-4
Initial Setup of the Milk System ..................................7-5
Milk System Capabilities ............................................7-6
A Common Milk Timing Mistake ..................................7-6
Air Gate Valve Assembly ............................................................7-7
Air Gate Valve ..........................................................7-7
Air Vent Valves.........................................................7-8
Air Vent Needles.......................................................7-8
Milk Flow Sensor .......................................................................7-9
Adjusting the Milk Flow Sensor ...................................7-9
Cappuccino Temperature Adjustment Valve ................................ 7-11
Mixing TEE.............................................................7-11
Refrigeration Unit .................................................................... 7-12
Placing Milk in the Machine ......................................7-12
Checking the Refrigeration Unit Temperature .............7-13
Refrigeration Unit Overview ...................................................... 7-13
Milk Pump Assembly ...............................................7-13
Refrigeration Cooling Module Assembly .....................7-14
Cold Sink Plenum ...................................................7-15
Interior Fan Assembly .............................................7-15
Refrigeration Unit Temperature Probe Assembly .........7-15
Milk Pick-Up Tube ................................................... 7-15
Exterior Cooling Module Fan Assembly ......................7-16
Troubleshooting ...................................................................... 7-16
Section 8 :: Flavor System ............................................... 8-1
Flavor System Overview.............................................................8-2
Chocolate Sauce Delivery Path ...................................8-2
Syrup Delivery Path ..................................................8-3
Flavor Lines .............................................................8-4