Synesso Cyncra User manual

Cyncra Technical Manual
2009
Synesso, Inc.
309 S. Cloverdale, C41/ Seattle, WA 98108
tel. [phone] / fax [phone]
www.synesso.com / [email protected]

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Table of Contents
Safety and Tools.............................................Pages 4-5
Installation.......................................................Pages 6-10
Hydraulic System............................................Pages 11-20
Electrical System............................................Pages 21-27
Troubleshooting...............................................Pages 28-32
Periodic Maintenance......................................Pages 33-35
Programming Instructions...............................Pages 36-37

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Tools and recommended Items required to fully diagnose, service and
maintain the Cyncra™
•Multi Meter – reads volts, amps and ohms. The Fluke T5-600 is an excellent tool
•Heat Shrink Gun or Torch
•Vacuum with a Hose
•Compressed Air
•Descaler – Citric Acid
•Flashlight
•Box Knife
•Thread Sealant – Red and Blue Loctite
•Food Grade Grease
•Tube Bender
•Flair Tool - 45°
•Tube Cutter
•Brass Bristle Brush
•Socket Wrench with 1/2” and 9/16” sockets
•Hammer
•Wire Stripper / Crimper
•Small Punch and Chisel
•Small Files – Round and Triangular
•Small Picks – Straight and Curved (great for replacing portafilter gaskets)
SAFETY AND TOOLS
Safety Precautions:
Espresso machines have numerous potential hazards, and it is of paramount importance to
Synesso that people servicing our machines take all necessary precautions to ensure their
personal safety. Please note and follow the safety stickers on the machine.
When working on the machine’s boilers (unless otherwise instructed in the directions):
•Turn the machine off and shut off the incoming water supply.
•Depressurize the boilers (the steam boiler can be depressurized by opening both steam
wands, and the coffee boilers can be depressurized by shutting off the water and heat-
ing element breaker and turning the group top to the pre-infuse position.
When working on any electrical wiring (unless checking voltage or amperage readings or
otherwise instructed in the directions) ensure that the machine is switched off at the electri-
cal box and the machine is unplugged.
SAFETY AND TOOLS

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•Die and Tap, 1/8” NPT and 1/4” NPT
•Tap for Threads, 10 - 32 and 3/8 – 16
•Set of Allen Wrenches – 3/32” is for the brass flow jet, 9/64” for the brew valves, 1/4” for
steam valve seat
•Wrenches: 11/32, 1/4, 5/6, 3/8, 7/16, 1/2, 9/16 , 5/8, 11/16, 3/4, 12mm & 7mm + 1 extra
9/16 and 5/8
•Large, Medium and Small Adjustable Wrenches (Crescent Wrenches)
•Pliers: Channel Lock, Standard and Side Cutters
•Philips Head Screwdrivers: #2 short, #2 long and #1
•Flat Head Screwdrivers: #2 short, #2 medium, #2 long, #1 and large screwdriver to use
as a pry bar
•Pen and paper
•Hand cleaner
•Towels
SAFETY AND TOOLS

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Front of machine
View of top of
1 group machine
Foot diameter
3.1cm / 1.25"
Steam handle
7 cm
3"
59 cm / 23"
30 cm / 12"
15 cm
6"
8.5cm 21cm / 8" (2g= 48 cm / 19",
3g=76cm / 30")
39.5cm / 16" (2g=67cm / 26", 3g=94cm / 37")
14 cm
5.5"
INSTALLATION DIAGRAM
MACHINE FOOTPRINT
4"
Hole for
hoses
6.5cm / 2.5"
Electrical requirements:
1 Group 110v: 110v,60 hz, 20 amp
1 Group 220v: 220v,50/60 hz,16amp
2 Group: 220v, 50/60 hz, 28 amp
3 Group: 220v, 50/60 hz, 36 amp
Hydra Electrical Requirements:
2 Group: 220v, 50/60 hz, 32 amp
3 Group: 220v, 50/60 hz, 42 amp
*Located within 3' of machine
Drainage requirements:
Located within 5 feet of the machine.
Drain hose should run as vertically
away from the machine as possible.
Incoming Water
Filtration System
Drain hose
Treated
water
to pump
Water from
pump to groups
Power
to
pump
Mains
power
Counter requirements
*Easily cleanable
*Sturdy, level and horizontal
*Capable of sustaining weights up
to 300 lbs.
* 2.5" round hole drilled for hoses
(see "Footprint" for hole location)
*Clearance: 1" behind,3" in front
Water requirements
*3/8" cold water supply line
*Properly treated water required for
warranty (see below for details)
* Shut-off valve
* Located within 5' of the machine
*Braided stainless lines provided
Pump and Motor:
Located within 5' of the machine.
Dimensions: H 6.5"x W 5.5"x D 9.5"
Water Requirements
Proper water filtration and regular filter changes are a requirement to keep your factory
warranty valid and your machine functioning properly. It is highly recommended that you
contact a professional water filtration specialist in your area and have your water tested
to determine the proper filtration system.It is important to note that many municipalities
change their water sources throughout the year, so periodic water tests may be necessary.
Water Standards to keep your warranty valid:
Total Dissolved Solids (TDS) 30 to 200 ppm (parts per million)
Total Hardness - in ppm Less than 85 ppm
Total Hardness - in grains 3 to 5 grains (divide ppm by 17.1 to get grains)
pH 6 pH to 8 pH
Chloride 0 ppm - any Chlorides can be corrosive and harmful
Total Alkalinity Less than 100 ppm
Chlorine 0 ppm
Iron 0 ppm
Water to
steam
tank
INSTALLATION

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INSTALLATION
To maintain the warranty, an authorized espresso service representative must per-
form the installation of the Cyncra™ espresso machine.
Site Preparation
The Cyncra must be placed on a level horizontal surface that can be easily cleaned and is
capable of sustaining the weight of the machine, grinders, and associated equipment (see
specifications for acutal weights of machines).
The surface depth should allow for a minimum clearance of 1” behind the Cyncra and 3” in
front.
Make a 2 ½” round hole through the countertop, 4” from the back center of the machine.
This should provide ample room for the hoses and electrical lines.
A 3/8” cold water supply line with a shut off valve is needed within 5’ of the machine, prefer-
ably located directly underneath the Cyncra.
A proper water filtration or softening system must be installed for this espresso machine.
Types and sizes of the water treatment systems will vary. It is important to use a system
designed to match the needs of your specific area. Most water filtration systems require
periodic maintenance, cartridge or filter replacement. This is vital to the proper functioning
of the machine and the quality of the espresso served. Follow the instructions provided by
your water treatment system for proper installation.
Note: Improper water filtration can result in water damage inside the machine causing scale
and corrosion. THIS WILL VOID YOUR WARRANTY.
There must be adequate room underneath the Cyncra to locate the motor and pump. This
should be within 5’ of the cold water supply line. The pump may need periodic adjustment,
so easy access should be available. The pump and motor should have proper ventilation
and a minimum of 3” clearance on all sides.
Dimensions of the pump and motor are:
6 ½” Height x 5 ½” Width x 9 ½” Depth
A floor drain or sink should be readily available. The best location is directly under the
installation site of the machine.
An electrical receptacle and matching plug, rated at the proper voltage and amperage is
required within 3’ of the location of the machine.
INSTALLATION

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Plumbing Instructions
This equipment is to be installed to comply with the applicable federal, state or local plumb-
ing codes.
Connect the 3/8” compression fitting of the provided stainless steel braided hose to the
connection from the filtered, cold water line.
Fittings on the hoses are 3/8” compression type fittings, thread sealant or Teflon tape is not
necessary. Make connections snug, but do not over tighten.
Turn water ON and check for leaks.
The ¾” inside diameter clear vinyl ribbed hose connects the outlet fitting of the drain box to
the drain (located on the right hand, bottom, rear corner). Run this hose to the floor drain or
floor sink.
NOTE: The Cyncra requires a minimum of 35 PSI of line pressure to have the steam tank
auto-filling system function properly.
Electrical Instructions
After you make sure your receptacle and circuit are for the proper voltage and amperage
rating (see specifications chart on page 9) for your model, install a matching plug on the
power cord provided with the Cyncra.
North American Configuration Outside of North America
Green Ground Green Ground
White 110 V White 220 V
Black 110 V Black Neutral
Make sure that the On/Off electronics switch (red rocker) and the heating element breaker
on the Cyncra are in the OFF (0) position, then plug the power cord into the receptacle.
IMPORTANT - If the voltage on the receptacle used is less than 210 Volts, it may be
necessary to install an inline Buck-Boost transformer to increase this voltage.
•1 and 2 Group 220 Volt Machines require a 1.0 KVA transformer
•3 Group 220 Volt Machines require a 1.5 KVA transformer.
INSTALLATION

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Specifications for the Cyncra Line of Semi Automatic Espresso Machines
Model 1 Group 1 Group 2 Group 3 Group
Voltage 110 220 220 220
Hertz 60 50 / 60 50 / 60 50 / 60
Amps - max draw 20 16 28 36
Brew and Steam Specifications:
Watts per Element, Steam Tank 1000 1000 x 2 2000 x 2 2500 x 2
Total Steam Element Wattage 1000 2000 4000 5000
Steam Tank Capacity (Liters) 3.2 3.2 7.7 12.3
Watts per Element, Brew Tank 700 700 700 x 2 700 x 3
Brew Tank Capacities (Liters) 1.9 1.9 1.9 x 2 1.9 x 3
Machine Dimensions: Inches / mm Inches / mm Inches / mm Inches / mm
Height (Steam Wand 21", Handle 20.5") 18" / 457 18" / 457 18" / 457 18" / 457
Width (Steam Handle to Handle add 3") 18" / 457 18" / 457 29" / 736 40" / 1016
Depth 23" / 584 23" / 584 23" / 584 23" / 584
Weights & Dimensions: Lbs / Kgs Lbs / Kgs Lbs / Kgs Lbs / Kgs
Machine Weight, Empty 106 / 48 106 / 48 154 / 70 190 / 86
Machine Weight, Full of Water 115 / 52 115 / 52 173 / 77 215 / 98
Shipping Weight (approximate) 175 / 80 175 / 80 225 / 103 270 / 123
Boxed Dimensions: L” x W” x H” 20"x30"x31" 20"x30"x31" 41"x32"x31" 49"x32"x31"
Boxed Dimensions: L x W x H m/m 508x762x787 508x762x787 1042x762x787 1245x813x787
Plumbing (Compression) 3/8" OD 3/8" OD 3/8" OD 3/8" OD
· Certified by ETL for Sanitation to NSF / ANSI Standard 4
· Certified by ETL for Electrical Safety to ANSI / UL Standard 197
· Certified by ETL for Electrical Safety to CSA Standard C22.2 No. 109
· CE Compliant (By request)
· C-Tick Compliant (By request)
INSTALLATION

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Start-Up Instructions
1. To fill the coffee brew tanks, turn the water ON.
2. Switch the electronics On/Off switch to ON. This activates the machine’s water auto-
fill feature for the steam tank and the electronics, but NOT the heating elements.
3. The water level sight glass for the steam tank is located
on the right side of the machine. As the tank fills, the
water level will rise in the sight glass and will automati-
cally stop when the preset level is reached.
4. Turn the brew group to the BREW position, (see sketch
on the right) allow the air to escape and return the brew
group to the OFF position.
5. Make sure the water level in the sight glass reads at
least ½ full and then turn the heating element breaker to
the ON or (1) position.
6. To adjust the pump pressure, activate the pump infusion
by turning the brew group to the BREW position.
7. Locate and read the pump pressure / brew gauge.
8. Set the pump pressure to 9 Bar. To do this, locate the
pump adjusting screw on the right side of the brass
pump housing. Loosen the lock nut and turn screw with a screwdriver.
•Clockwise to INCREASE pressure
•Counterclockwise to DECREASE pressure
9. Please allow at least ½ hour of “warm up” time before using your Cyncra espresso
machine to brew shots or steam milk. The steam gauge should read a minimum of
1.1 Bar.
Unplugging EMC Compliant Machines
(C-Tick for Australia and NZ, CE for Europe)
To comply with EMC (Electromagnetic Compatibility) regulations, Synesso is required to
install a capacitor in the electronics box across the main power IN. To avoid an electric
shock from the charge held in the capacitor, leave the electronics ON/OFF red rocker
switch in the ON position when unplugging the machine. When the electronics “go
dark” or OFF, the charge has dissipated.
INSTALLATION
BREW PRE OFF

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Hydraulic System
HYDRAULIC SYSTEM
Overview
The hydraulic system in the Synesso is comprised of all parts through which water flows
starting with where it enters the machine from the water treatment/filtration system. This
chapter will detail the flow of water and some of the associated electrical componentry.
Water requirements:
Proper water filtration and regular filter changes are a requirement to keep your
factory warranty valid and your machine functioning properly. It is highly recom-
mended that you contact a professional water filtration specialist in your area and have your
water tested to determine the proper filtration system. Good water treatment systems will
remove tastes and odors as well as particulate matter that can block valves and cause
issues with the machine. Hard water will cause scale to develop inside the machine which
adversely affect the water flow and heating processes, so it is vital to have water hardness
in the recommended range. It is important to note that many municipalities change their
water sources throughout the year, so additional water tests may become necessary.
Water Standards to keep your warranty valid:
Total Dissolved Solids (TDS) 30 to 200 ppm (parts per million)
Total Hardness -(in ppm) Less than 85 ppm
Total Hardness – (in grains per gallon) 3 to 5 grains (divide ppm by 17.1 to get gpg)
pH 6 pH to 8 pH – above 8 is very harmful
Chloride 0 ppm – any Chlorides can be corrosive and harmful
Total Alkalinity Less than 100 ppm
Chlorine 0 ppm
Iron 0 ppm
Synessos utilize 3/8” braided stainless hoses (supplied with machine) to connect to the
water treatment system. Once the machine is set up and the water quality is checked, the
machine is ready to be connected to the water treatment system. The water then passes to
the pump and motor.
On single inlet machines, the water then travels through one hose to the machine and
supplies both the coffee boiler system and the steam boiler.
On dual inlet machines, the water splits off at the pump: the water for the coffee boiler goes
through the pump and the water for the steam boiler splits off and goes through a separate
line to fill the steam boiler. The next 3 pages show the dual, single, and Hydra inlet water
paths.

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HYDRAULIC SYSTEM
SYNESSO
INC.
PUMP
PRESSURE
ADJUSTMENT
HEAT
EXCHANGER
WATER P
P
ATH L
L
AYOUT-
DUAL I
I
NLET C
C
ONFIGURATION
DESCRIPTION
REVISIONDATE:
BY
ALL
DIMENSIONS
IN
MILLIMETERS
DRAWN
BY:
MB 10/31/08
DATE:
DWG.
NO.
NOT
SCALE
1.22X
STEAM T
T
ANK
STEAM T
T
ANK
1.313
1.313
1.313
1.225 1.225 1.225
1.451
1.452
1.453
1.320
1.321
1.322
PUMP
100-240
VAC
PUMP
MOTOR
130PSI
SEATTLE,
WA
98108
(206)
764-0600
309
SOUTH
CLOVERDALE,
SUITE
C41
BE
USED,
COPIED
OR
REPRODUCED
SYNESSO
INCORPORATED
WITHOUT
THE
WRITTEN
CONSENT
OF
SYNESSO
INCORPORATED
AND
IS
NOT
THIS
DRAWING
IS
THE
PROPERTY
OF
PROPRIETARY
INFORMATION
WATER
LINE
CHECK
VALVE MAX
100
PSI
SOLENOID
VALVE
CHECK
VALVE
TANK
PENETRATION
SOLENOID
VALVE
TANK
PENETRATION
CHECK
VALVE
SOLENOID
VALVE
NEEDLE
VALVE
WATER
SPOUT
EXPANSION
VALVE
BREW
PRESSURE
GAUGE
DRAIN
VALVE
DRAIN
VALVE
DRAIN
VALVE
SIGHT
GLASS
TANK
PENETRATION
TANK
PENETRATION
TO
DRAIN
COLD
WATER
MIX
STEAM
PRESSURE
GAUGE
SET
AT
11
TO12
BAR
BREW
WATER
OUT
WATER
INLET
WATER
DRAIN
SOLENOID
VALVE
WATER FLOW THROUGH BREW GROUP
BREW T
T
ANK #
#
1
BREW T
T
ANK #
#
3
BREW T
T
ANK #2
1.509
HYDRAULIC SCHEMATIC--DUAL INLET

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HYDRAULIC SYSTEM
SYNESSO INC.
SYNESSO INC.
PUMP PRESSURE ADJUSTMENT
HEAT EXCHANGER
BREW WATER OUT
WATER INLET
WATER DRAIN
SOLENOID VALVE
WATER FLOW THROUGH BREW GROUP
WATER PATH LAYOUT-
WATER PATH LAYOUT-
SINGLE INLET SCHEMATIC
SINGLE INLET SCHEMATIC
DESCRIPTION
REVISION DATE: BY
ALL DIMENSIONS IN MILLIMETERS
DRAWN BY:
MB
MB
10-31-08
10-31-08
DATE: DWG. NO.
NOT
NOT
SCALE
1.22X
1.22X
STEAM TANK
STEAM TANK
STEAM TANK
STEAM TANK
1.313
1.313
1.313
1.313
1.313
1.313
1.225
1.225
1.225
1.225
1.225
1.225
1.451
1.451
1.452
1.452
1.453
1.453
1.320
1.320
1.321
1.321
1.322
1.322
PUMP
100-240 VAC
PUMP MOTOR
130PSI
SEATTLE, WA 98108 [phone] 309 SOUTH CLOVERDALE, SUITE C41
BE USED, COPIED OR REPRODUCED
SYNESSO INCORPORATED WITHOUT THE WRITTEN CONSENT OF SYNESSO INCORPORATED AND IS NOT THIS DRAWING IS THE PROPERTY OF
PROPRIETARY INFORMATION
WATER LINE
CHECK VALVE MAX 100 PSI
SOLENOID VALVE
CHECK VALVE
TANK PENETRATION
SOLENOID VALVE
TANKPENETRATION
CHECK VALVE
SOLENOID VALVE NEEDLE VALVE
WATER SPOUT
EXPANSION VALVE
BREW PRESSURE GAUGE
BREW TANK #1
DRAIN VALVE
DRAIN VALVE
BREW TANK #3
DRAIN VALVE
BREW TANK #2
SIGHT GLASS
TANK PENETRATION
TANK PENETRATION
TO DRAIN
COLD WATER MIX
STEAM PRESSURE GAUGE
SET AT 11 TO12 BAR
1.509
HYDRAULIC SCHEMATIC--SINGLE INLET

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HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC--HYDRA
SYNESSO
INC.
BREW
WATER
OUT
WATER
INLET
WATER
DRAIN
WATER P
P
ATH L
L
AYOUT-
HYDRA C
C
ONFIGURATION
DESCRIPTION
REVISION DATE:
BY
ALL
DIMENSIONS
IN
MILLIMETERS
DRAWN
BY:
MB 10/31/08
DATE:
DWG.
NO.
NOT
SCALE
1.22X
STEAM TANK
STEAM T
T
ANK
1.313
1.313
1.313
1.313
1.313
1.225 1.225 1.225 1.451
1.452
1.453
1.320
1.321
1.321
1.322
SEATTLE,
WA
98108
(206)
764-0600
309
SOUTH
CLOVERDALE,
SUITE
C41
BE
USED,
COPIED
OR
REPRODUCED
SYNESSO
INCORPORATED
WITHOUT
THE
WRITTEN
CONSENT
OF
SYNESSO
INCORPORATED
AND
IS
NOT
THIS
DRAWING
IS
THE
PROPERTY
OF
PROPRIETARY
INFORMATION
SOLENOID
VALVE
CHECK
VALVE
TANK
PENETRATION
SOLENOID
VALVE
TANK
PENETRATION
SOLENOID
VALVE
NEEDLE
VALVE
WATER
SPOUT
DRAIN
VALVE
DRAIN
VALVEDRAIN
VALVE
BREW
TANK
#3BREW
TANK
#3
DRAIN
VALVE
BREW
TANK
#2
SOLENOID
VALVE
SIGHT
GLASS
TANK
PENETRATION
TANK
PENETRATION
COLD
WATER
MIX
STEAM
PRESSURE
GAUGE
WATER FLOW THROUGH BREW TANK
PUMP
PRESSURE
ADJUSTMENT
PUMP
100-240
VAC
PUMP
MOTOR
130PSI
CHECK
VALVE
1.509
PUMP
PRESSURE
ADJUSTMENT
PUMP
100-240
VAC
PUMP
MOTOR
130PSI
iNCOMING
WATER
LINE
CHECK
VALVE
MAX
100
PSI
1.509
PUMP PRESSURE
ADJUSTMENT
PUMP
100-240 VAC
PUMPMOTOR
130PSI
CHECKVALVE
1.509
BREW
GAUGE
#1
EXPANSION
VALVE
SET
AT
11
TO
12
BAR
TO
DRAIN
PUMP MOTOR #3
PUMP MOTOR #2
BREW
GAUGE
#3
BREW
GAUGE
#3
EXPANSION
VALVE
SET
AT
11
TO
12
BAR
TO
DRAIN
BREW
GAUGE
#2
EXPANSION
VALVE
SET
AT
11
TO
12
BAR
TO
DRAIN
PUMP
MOTOR
#1
HEAT
EXCHANGER
CHECK VALVE
BREW
TANK
#1

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Pump and Motor:
Synesso uses a Fluid-o-tec rotary vane
pump which boosts incoming water pres-
sure to 9 bar when the motor is activated.
Pressure can be adjusted by loosening the
nut on the right side fitting and then turning
the adjustment screw clockwise (increasing
pressure) or counter-clockwise (decreasing
pressure).
Water in
Water to
steam tank
Water to
coffee
tanks
Pump configurations:
Until serial number 356, Synessos had a
single inlet configuration as the standard.
After 356, the dual inlet configuration is the
standard. Hydras have a separate pump
and motor per group, therefore all Hydras
come equipped with single inlet style
pumps.
Water Inlet control valves:
Serial numbers 1-340 feature the Skinner-
style valves shown in the upper part of the
picture on the left. These were replaced on
serial number 341 onwards with the Parker
ZB09 for ease of repair or replacement.
Both valve styles feature electronic coils
which, when energized, move a piston
which allows water flow through the valve.
When deactivated, the piston’s presence in
the valve stops the flow of water.
The picture on the right shows the steam
tank autofill configuration.All 3 of the water
control valves are now Parker ZB09. Up-
grade kits are available through Synesso.
HYDRAULIC SYSTEM

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HYDRAULIC SYSTEM
Mix valve
adjuster Cold water
valve
Expansion
valve Drain hose
Coffee
inlet hose
Steam
tank fill
hose
Brew Tanks
Check valve
Drain box
Steam inlet
check valve
Steam tank
water inlet
valve
Heat Exchanger
Tubes
Pressure Relief
Valve (under hose)
Vacuum breaker
Sight Glass
Hot water
valve
Drain tube
from brew
tanks
Water Inlet Components:
Brew Gauge: The brew gauge reflects the pressure in the brewing system. On a
standard Cyncra, there is one gauge for the entire brewing system; on
a Hydra, each brew tank has its own brew gauge. The gauge normally
moves between 3-5 bar (resting pressure) to 9 bar (brewing pressure)
and up to 12 bar (expansion pressure) at which point the expansion
valve opens and releases the excess pressure.
Brew Tanks Check valves prevent water going the wrong way in the hydraulic
Check Valve: system. Water flow should only go one direction and the check valve
ensures that pressurized water from inside the tanks cannot over-
whelmthe incoming water pressure and go backwards.
Coffee Inlet (Single inlet machines would have this line only ) Supplies the brew
Fill Line: tanks with water, passing first through the heat exchangers.
Major Components of the Water Inlet System
Brew gauge

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Water Inlet Components (cont.):
Cold Water Valve: Synesso has 2 valves which provide water to theAmericano (tea)
spout: the hot water valve and this cold water valve. The cold water
input allows the user to moderate the temperature at the spout to
make drinks appropriate temperatures for their customers.
Drain box: Water flows into this box prior to going through the drain hose to the
floor drain. It is important to periodically pour small quantities of hot
water down this drain box to clear any build up of coffee oils inside the
box.
Drain Hose: Waste water and some grounds go down this tube to the drain. It’s
important to keep this free of clogs and should run in a steeply vertical
path to the floor drain.
Drain tube This copper manifold allows water from the brew valves to discharge
from brew tanks: safely down the drain after shots are completed. It also is directly
connected to the drain system on the left hand group, allowing the
user to drain the left tank easily after depressurizing the system.
Expansion valve: The brew tanks are completely saturated with water, and when they
are heating, the pressure increases as the water expands. The expan-
sion valve allows this pressurizing water to release safely into the drain
box. The release point is 12 bar and is adjustable by turning the end of
the valve with a wrench clockwise (increase) or counter clockwise to
decrease.
Heat Exchanger In order to maintain extremely stable brewing temperatures, Synesso
tubes: incorporates heat exchanger tubes which run from the water inlet side
through the steam tank and then go to each separate coffee boiler.
The internal diameter of the heat exchangers are precisely designed
and aid in the energy efficiency and thermal stability of the Synesso.
Hot Water Valve: This valve supplies hot water from the steam tank (which is mixed with
cold water from the cold water valve) to the Americano (tea) spout.
Mix Valve Adjuster: This butterfly valve allows the user to increase or decrease the amount
of cold water (from the cw valve above) going to the Americano (tea)
spout. Turning this valve completely clockwise shuts the cold water off
completely, and turning it ccw allows more cold water in. Synesso sets
our machines to have a steady flow of water at approximately 200° F
at bench test.
HYDRAULIC SYSTEM

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Pressure Relief The PRV is a safety release for the steam boiler which opens and
Valve: releases pressure if the boiler goes above 3.5 bar (50 psi). The PRV is
housed inside the yellow tubing which would direct any releases to the
drain box, minimizing spray on the electronic valves.
Sight Glass: Connected by two stainless tubes to the steam tank, the sight glass
provides a visual representation of the level of water in the steam tank.
It should be about 1/2 to 2/3 full during normal operation. This is a
safety feature which enables the user to ensure that they have
sufficient water levels in their steam system.
Steam Inlet See Brew tanks check valve description.
Check Valve:
Steam Inlet Water When the upper level probe detects an absence of water, it sends a
Control Valve: signal to the CPU to open this valve and allow water into the steam
tank. The water then fills the tank until the probe grounds out on the
water, and the valve is then closed.
Steam Tank (Dual inlet machines only) This is the incoming 3/8” steel braided
Inlet Fill Line: line which supplies the steam tank with water.
Vacuum breaker: Allows steam pressure to build above atmospheric pressure. As the
element heats the water in the steam tank, the pressure from the
steam pushes an internal rod and o-ring up, sealing the steam inside
the tank. Pressure continues to build until the temperature probes
sense the temperatures are to the set points and then keep this pres-
sure inside for use in heating milk, maintaining a hot water supply, and
pre-heating the brew water in the heat exchanger tubes.
HYDRAULIC SYSTEM
Water Inlet Components (cont.):

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HYDRAULIC SYSTEM
Major Components of the Water Outlet Side
Steam
actuator
rod
1st position brew
tank fill tube
Brew tank
drain tube
Brew tank
Steam shut off valve
Steam
gauge
Steam tank
thermal overload
switches
Upper Level
probe
Heating
element
Low level probe
Steam gauge
tube
Temperature probes
2nd position
brew tank fill
tube
1st and 2nd position After travelling through the steam boiler, the heat exchangers
brew tank fill tubes: exit on the left side of the machine and copper tube (these
were stainless steel until serial number 352) deliver the pre-
heated water to the brew tanks.
Brew tank: Synesso’s brew tanks are solid stainless steel, welded internally
and externally in order to be leak-proof and thermally stable.
Each brew tank has its own isolated system, from the water
inlet on, and this allows the user to set different temperatures
on each group, as well as function without a group in the sys -
tem if something has gone wrong with the group. There is a 3-
way brew valve which controls the flow of water to the group
head.
Brew tank drain tube: Each group head is fitted with a drain tube and ball valve to
easily drain the tank. The 1st position (left-most) brew tank’s
drain valve is directly hooked up to the drain manifold. The
center and right brew tanks will need to have a suitable 3/8”
rubber line hooked up and extended to the drain prior to
opening the valve.

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HYDRAULIC SYSTEM
Water Outlet Components (cont.):
Heating element: A 2-leg incoloy and stainless steel heating element which
provides the heat for the steam boiler. It is controlled by the 2
thermal probes and will be shut off in the case of over-heating
or low water levels.
Low level probe: This probe detects when the water level has dropped below the
height of the probe in the tank. It sends signal to the CPU
which immediately cuts power to the heating element, starts an
“alarm” light flashing on the display and begins an audible alarm
to alert the operator to the problem.
Steam actuator rod: This is pushed in when the steam handle is activated. The rod
opens the seal, releasing steam through the valve.
Steam gauge: Displays the amount of steam pressure in the steam tank. The
gauge reads between 0 and 4 bar (0-60psi) and normal
operating pressure is 1.5 bar. The pressure is set to 1.3 in test.
Steam shut-off valve: Safety device for service agents: turning this ball valve shuts off
steam to the valve for protection during repairs.
Steam tube: Delivers steam from the upper part of the steam tank to the
steam valve to heat and foam milk.
Steam tank thermal Cuts power to the element if the temperature exceeds 280° F.
overload switch:
Thermal probes: 2K ohm probes have been part of the Synesso machines since
serial number 229 (prior to this, 100 ohm probes were standard).
These probes are highly sensitive and send thermal data to the
PID controller to control the temperature within the steam tank.
Since the steam tank has two independently controlled legs on
the element, there are two thermal probes on the steam tank.
Upper level probe: Detects whether the desired water level has been reached. A
small amount of VAC travels through this probe in an open
circuit. When water touches the probe, the circuit is closed
(grounded) and the steam inlet water control valve closes. Both
probes are adjustable by turning the entire probe clockwise to
increase or ccw to decrease the water level. The bend in the
probe is identical inside the tank, so the level of the water inside
is where the probe connects to the wire on the outside.