Schaerer Ambiente 2 User manual

M.Schaerer Ltd. Phone: +41 31 858 51 11 Service manual

Gewerbestrasse 15 Fax: +41 31 858 51 40 SMSO 2 - 02

3302 Moosseedorf E-Mail: [email protected]

Switzerland Internet: www.schaerer.com Order number: 020'731

Herausgeber

M. SCHAERER AG

CH-3302 Moosseedorf

Ausgabe: (Version 2.0)

2. Auflage / Juli 2003

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M. SCHAERER AG

CH-3302 Moosseedorf

Konzept, Text, Illustrationen

R. Krauer, Techn. Grafik

CH-6012 Obernau/Kriens

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CH-3302 Moosseedorf.

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Published by

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Edition: (Version 2.0)

2. edition / July 2003

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CH-3302 Moosseedorf

Designed, Text, Illustrations by

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CH-6012 Obernau/Kriens

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CH-3302 Moosseedorf

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Edition: (Version 2.0)

2. édition / Juillet 2003

Rédaction

M. SCHAERER SA

CH-3302 Moosseedorf

Concept, Text, Illustrations

R. Krauer, Techn. Grafik

CH-6012 Obernau/Kriens

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Copyright by

M. SCHAERER SA

CH-3302 Moosseedorf

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Copyright 15.07.2003

Table of Contents

SMSO-2-02.00- 15.07.03 1

Table of Content

1 Safety Regulations.......................................................................................................... 5

1.1 General .............................................................................................................................................................................5

1.1.1 Hazard labels....................................................................................................................................................................5

1.1.2 Training for operating personnel and service technicians .................................................................................................5

1.1.3 Designated use.................................................................................................................................................................5

1.1.4 Safety equipment..............................................................................................................................................................5

1.1.5 General safety regulations ................................................................................................................................................5

1.2 Electronic regulations........................................................................................................................................................7

1.2.1 General .............................................................................................................................................................................7

1.2.2 Checking electrical circuits................................................................................................................................................7

1.3 Supply / Disposal ..............................................................................................................................................................8

1.3.1 Drinking water connection.................................................................................................................................................8

1.3.2 Waste water connection....................................................................................................................................................8

1.4 Hygiene regulations ..........................................................................................................................................................8

1.4.1 Food regulations (milk) .....................................................................................................................................................8

1.4.2 Using cleaning agents.......................................................................................................................................................8

1.4.3 Using lubricants ................................................................................................................................................................8

1.5 Regulations for components .............................................................................................................................................9

1.5.1 Rotary-vane type pump.....................................................................................................................................................9

1.5.2 Brewing unit ......................................................................................................................................................................9

1.5.3 Grinder..............................................................................................................................................................................9

1.5.4 Valves ...............................................................................................................................................................................9

1.5.5 Unit control system and power PCB .................................................................................................................................9

1.5.6 Safety thermostats............................................................................................................................................................9

1.5.7 Level probe .......................................................................................................................................................................9

1.5.8 Instant heater / steam generator.......................................................................................................................................9

1.6 Refrigerator.....................................................................................................................................................................10

2 General notes for service technicians ........................................................................ 11

2.1 Equipment.......................................................................................................................................................................11

2.1.1 The principles of maintenance ........................................................................................................................................11

2.1.2 Tools and test equipment................................................................................................................................................11

2.1.3 Spare parts .....................................................................................................................................................................11

2.1.4 Hygiene measures..........................................................................................................................................................12

2.1.5 Booster / Hotflush ...........................................................................................................................................................12

2.2 Service instructions.........................................................................................................................................................14

2.2.1 Service intervals for the Ambiente-2 coffee machine (Index e, 30.06.2003) ...................................................................14

2.3 Instructions on check numbers 1-22 ...............................................................................................................................15

2.4 Safety relevant parts A....................................................................................................................................................18

2.5 Conditions for faultless operations..................................................................................................................................18

2.6 Lack of compliance with maintenance rules....................................................................................................................18

2.7 Service instructions - Refrigerator...................................................................................................................................19

2.7.1 Service intervals – Refrigerator / Cappuccinatore appliance (Index e, 30.06.2003) .......................................................19

2.8 Instructions on check numbers 1-16 ...............................................................................................................................20

2.9 Conditions for faultless operation....................................................................................................................................21

2.10 Lack of compliance with maintenance rules....................................................................................................................22

2.11 Notes relating to the dismantling and maintenance instructions .....................................................................................22

2.11.1 Illustrations......................................................................................................................................................................22

2.11.2 Pictograms......................................................................................................................................................................22

2.11.3 Carrying out maintenance work ......................................................................................................................................24

3 Functional descriptions................................................................................................ 29

3.1 Connections (Supply / Disposal).....................................................................................................................................29

3.1.1 General ...........................................................................................................................................................................29

3.1.2 Rating plate.....................................................................................................................................................................29

3.1.3 Drinking water connection...............................................................................................................................................29

3.1.4 Water specifications........................................................................................................................................................29

3.1.5 Water filter / Decalcifier...................................................................................................................................................29

3.1.6 Waste water connection..................................................................................................................................................30

3.1.7 Connection to the power system.....................................................................................................................................30

3.1.8 Calcium (limescale).........................................................................................................................................................31

3.2 Components ...................................................................................................................................................................32

Table of Contents

2 SMSO-2-02.00- 15.07.03

3.2.1 General .......................................................................................................................................................................... 32

3.2.2 Programming.................................................................................................................................................................. 32

3.2.3 ESD protection (electro static discharge) ....................................................................................................................... 32

3.2.4 Lubricant ........................................................................................................................................................................ 32

3.2.5 Grinder ........................................................................................................................................................................... 33

3.2.6 Brewing unit ................................................................................................................................................................... 35

3.2.7 Rotary-vane type pump.................................................................................................................................................. 39

3.2.8 Flow meter ..................................................................................................................................................................... 41

3.2.9 Non-return valve............................................................................................................................................................. 43

3.2.10 Safety valve.................................................................................................................................................................... 44

3.2.11 Solenoid valves Drawing symbol illustration .................................................................................................................. 45

3.2.12 Safety thermostat........................................................................................................................................................... 47

3.2.13 Temperature sensor....................................................................................................................................................... 48

3.2.14 Level probe .................................................................................................................................................................... 49

3.2.15 Screw connections / pipes / hoses ................................................................................................................................. 51

3.2.16 Instant heater ................................................................................................................................................................. 52

3.2.17 Booster........................................................................................................................................................................... 56

3.2.18 Steam generator ............................................................................................................................................................ 58

3.2.19 Unit control system (EHS).............................................................................................................................................. 59

3.2.20 Power PCB..................................................................................................................................................................... 61

3.3 Refrigerator (optional feature) ........................................................................................................................................ 64

3.4 System documentation................................................................................................................................................... 67

3.4.1 General .......................................................................................................................................................................... 67

3.4.2 Brewing system (coffee)................................................................................................................................................. 69

3.4.3 Brewing system (coffee) with booster ............................................................................................................................ 73

3.4.4 Hot water system (tea) ................................................................................................................................................... 75

3.4.5 Hot water system (tea) with booster............................................................................................................................... 77

3.4.6 Steam system (milk drinks) ............................................................................................................................................ 79

3.4.7 Milk drinks ...................................................................................................................................................................... 81

3.4.8 Milk / milk foam (cappuccino or milk coffee)................................................................................................................... 83

3.4.9 Rinsing the milk – milk foam pipes (refrigerator with cold water rinse)........................................................................... 85

3.4.10 Rinsing the milk – milk foam pipes (refrigerator with hot water rinse / HOTFLUSH) ..................................................... 87

4 Fault diagnosis..............................................................................................................89

4.1 General notes................................................................................................................................................................. 89

4.1.1 How this section is structured......................................................................................................................................... 89

4.1.2 Causes of malfunction.................................................................................................................................................... 89

4.1.3 Overview of faults........................................................................................................................................................... 89

4.1.4 Fault lists........................................................................................................................................................................ 90

4.1.5 Grades of fault................................................................................................................................................................ 90

4.1.6 Tips for fault diagnosis ................................................................................................................................................... 91

4.1.7 Frequent causes of faults............................................................................................................................................... 91

4.2 Fault lists for control system / programming system ...................................................................................................... 93

4.2.1 Overview ........................................................................................................................................................................ 93

4.3 Fault lists – Brewing system......................................................................................................................................... 101

4.3.1 Overview ...................................................................................................................................................................... 101

4.4 Fault lists - hot water system........................................................................................................................................ 113

4.4.1 Overview ...................................................................................................................................................................... 113

4.5 Fault lists – steam system............................................................................................................................................ 117

4.5.1 Overview ...................................................................................................................................................................... 117

4.6 Fault lists – Refrigerator (milk / milk foam) ................................................................................................................... 121

4.6.1 Overview ...................................................................................................................................................................... 121

5 Maintenance.................................................................................................................127

5.1 Contents....................................................................................................................................................................... 127

5.2 Contents (SO-2 with Booster) ...................................................................................................................................... 128

5.3 Preparing for maintenance work .................................................................................................................................. 129

5.3.1 Safety Regulations ....................................................................................................................................................... 129

5.3.2 Accessibility of the machine ......................................................................................................................................... 129

5.3.3 Notes on the maintenance instructions ........................................................................................................................ 129

5.3.4 Assembling / installing the components ....................................................................................................................... 129

5.4 Dismantling / installing ................................................................................................................................................. 130

5.4.1 Disconnect supply connections.................................................................................................................................... 130

5.4.2 Bean container ............................................................................................................................................................. 131

5.4.3 Cup plate...................................................................................................................................................................... 132

5.4.4 Casings / front covers .................................................................................................................................................. 133

5.4.5 Grinder ......................................................................................................................................................................... 135

5.4.6 Booster......................................................................................................................................................................... 137

Table of Contents

SMSO-2-02.00- 15.07.03 3

5.4.7 Brewing unit ..................................................................................................................................................................138

5.4.8 Brewing unit piston motor .............................................................................................................................................141

5.4.9 Rotary-vane type pump.................................................................................................................................................143

5.4.10 Distributor cabinet .........................................................................................................................................................145

5.4.11 Flowmeter .....................................................................................................................................................................147

5.4.12 Instant heater coffee .....................................................................................................................................................148

5.4.13 Instant heater coffee (Booster) .....................................................................................................................................150

5.4.14 Instant heater tea..........................................................................................................................................................152

5.4.15 Instant heater tea (Booster) ..........................................................................................................................................154

5.4.16 Steam generator ...........................................................................................................................................................156

5.4.17 Valve battery.................................................................................................................................................................158

5.4.18 Dispenser carriage........................................................................................................................................................159

5.4.19 Power PCB ...................................................................................................................................................................161

5.4.20 Unit control system .......................................................................................................................................................162

5.5 Service..........................................................................................................................................................................163

5.5.1 Replace heating foil ......................................................................................................................................................163

5.5.2 Grinder..........................................................................................................................................................................164

5.5.3 Brewing unit ..................................................................................................................................................................167

5.5.4 Rotary-vane type pump.................................................................................................................................................171

5.5.5 Clean flowmeter / replace O-ring ..................................................................................................................................174

5.5.6 Replace safety thermostat ............................................................................................................................................175

5.5.7 Repair valve battery......................................................................................................................................................176

5.5.8 Replace Flash-ROM, EEPROM ....................................................................................................................................177

5.5.9 Replace, install microswitch..........................................................................................................................................178

6 Control system diagram............................................................................................. 179

6.1 Safety regulations .........................................................................................................................................................179

6.2 Control system diagram ................................................................................................................................................179

6.3 Technical diagram.........................................................................................................................................................179

6.4 Trouble-shooting electrical circuits................................................................................................................................179

6.4.1 Voltage data..................................................................................................................................................................179

6.4.2 System test / initial test .................................................................................................................................................180

6.4.3 Selecting the test locations ...........................................................................................................................................180

6.4.4 Conventions of presentation .........................................................................................................................................180

6.4.5 Colour coding for cables ...............................................................................................................................................180

6.4.6 Electrical circuits / conductor designations ...................................................................................................................180

6.5 Trouble-shooting electrical circuits................................................................................................................................181

6.5.1 Power supply line..........................................................................................................................................................181

6.5.2 Power PCB, control voltage ..........................................................................................................................................183

6.5.3 Power PCB, stabiliser, control voltage..........................................................................................................................185

6.5.4 Cup plate heating..........................................................................................................................................................186

6.5.5 Ventilators.....................................................................................................................................................................187

6.5.6 Ventilators (from SW NT2v1.07) ...................................................................................................................................188

6.5.7 Panel switch..................................................................................................................................................................189

6.5.8 Drawer for coffee grounds – limit switch .......................................................................................................................190

6.5.9 Grinder motor “left hand side ........................................................................................................................................191

6.5.10 Grinder motor “right hand side”....................................................................................................................................192

6.5.11 Piston motor..................................................................................................................................................................193

6.5.12 Limit switch for brewing unit start position.....................................................................................................................194

6.5.13 Instant heater – “coffee”, 3kW heater............................................................................................................................197

6.5.14 Temperature sensor “coffee” ........................................................................................................................................198

6.5.15 Flow meter ....................................................................................................................................................................199

6.5.16 Brewing valve ...............................................................................................................................................................200

6.5.17 Brewing valve (Booster)................................................................................................................................................201

6.5.18 Flush valve....................................................................................................................................................................202

6.5.19 Valve for additional water (optional features)................................................................................................................203

6.5.20 Booster .........................................................................................................................................................................204

6.5.21 Rotary-vane type pump, motor .....................................................................................................................................207

6.5.22 Instant heater – tea, 3kW heater...................................................................................................................................209

6.5.23 Temperature sensor – “tea” ..........................................................................................................................................210

6.5.24 Discharge valve – “tea” .................................................................................................................................................211

6.5.25 Steam generator heating, 3kW .....................................................................................................................................213

6.5.26 Temperature sensor - “steam” ......................................................................................................................................214

6.5.27 Level probe – “steam” ...................................................................................................................................................215

6.5.28 Feed valve – “steam” ....................................................................................................................................................216

6.5.29 Discharge valve – “steam” ............................................................................................................................................217

6.5.30 Discharge valve – “steam, milk”....................................................................................................................................218

6.5.31 Discharge valve – “steam, milk foam”...........................................................................................................................219

6.5.32 Refrigerator, cover switch .............................................................................................................................................220

Table of Contents

4 SMSO-2-02.00- 15.07.03

6.5.33 Refrigerator, cooling unit motor.................................................................................................................................... 221

6.5.34 Refrigerator, foamer head limit switch.......................................................................................................................... 222

6.5.35 Refrigerator, solenoid valve for squeeze cylinder......................................................................................................... 223

6.5.36 Refrigerator, solenoid valve for squeeze cylinder (Hotflush) ........................................................................................ 224

6.5.37 Refrigerator, ventilation valve....................................................................................................................................... 225

6.5.38 Refrigerator, rinsing valve – “milk”................................................................................................................................ 226

6.5.39 Refrigerator, rinsing valve – “milk foam”....................................................................................................................... 227

6.5.40 Refrigerator, rinsing valve – “hotflush” ......................................................................................................................... 228

6.5.41 Refrigerator, level sensor ............................................................................................................................................. 229

6.5.42 Refrigerator, level sensor (Hotflush)............................................................................................................................. 230

6.5.43 Cup sensor................................................................................................................................................................... 231

7 Technical data..............................................................................................................233

7.1 Standard settings (NT2000 software / V1.05-SO-2).................................................................................................... 233

Chapter 1 Safety regulations

SMSO-2-02.01- 15.07.03 5

1 Safety Regulations

1.1 General

1.1.1 Hazard labels

In this manual, hazard notes are labelled

with the hazard symbol shown alongside.

Depending on the type of hazard these are:

 DANGER TO LIFE (i.e. from the pressure container or

by electric shock.

 DANGER OF INJURY (by scalding, cutting, or other

mechanical injury)

 MATERIAL DAMAGE caused by discharged products,

machine parts falling down or away etc.).

These hazards can also result in loss of guarantee or third-

party liability claims. Deficiencies in the functional safety of

individual components can cause serious accidents.

1.1.2 Training for operating personnel and service

technicians

Operating personnel

 The Machine Owner is responsible for training the operat-

ing personnel. This includes in particular instructions in

handling foodstuffs, hygiene measures and the safety de-

vices on the machine. The safety regulations also include

local safety and accident prevention regulations.

 People who are not familiar with the user manual, chil-

dren and people under the influence of alcohol, drugs or

medication must not operate the machine.

 At self-service units, danger zones such as the steam

pipe and the hot water outlet must be clearly labelled in

such a manner that the warning is visible to the user.

Maintenance personnel

 Those persons involved with carrying out maintenance

work on the machine must have attended the relevant

training course provided by the manufacturer of the ma-

chine or by the manufacturer’s designated and authorised

representatives.

 In particular they must be familiar with the safety regula-

tions relevant to all maintenance work.

 They must have available the necessary tools and origi-

nal spare parts.

Service instructions

 All maintenance work must be carried out in accordance

with the current service instructions issued by the manu-

facturer.

 All persons involved in maintenance work must have up-

to-date knowledge of the current status of these service

instructions.

1.1.3 Designated use

Proper use of the machine and its associated accessories and

optional features are subject to the contractually agreed use,

any other existing additional agreements and the general

terms and conditions of M. Schaefer AG. The user manual is

an integral part of the above agreement of use. Any usage

other than within the limits specified herein shall be regarded

as not in accordance with the designated use. The manufac-

turer shall not be liable for any resulting damage.

1.1.4 Safety equipment

The coffee machine is equipped with all the necessary safety

equipment that is required for the machine to operate correctly

as intended.

1.1.5 General safety regulations

Safety regulations must be observed in line

with the work procedure or the maintenance

work concerned. In principle those safety

instructions that ensure maximum protec-

tion from bodily injury and material damage

must be applied. This applies in particular

where tests and measurements need to be

made on a machine operating without its

protective casing. Work carried out on live

electrical components or on pressurised

hydraulic systems should be carried out

only by trained personnel.

Only start maintenance work once all the safety precautions

have been taken.

Scalds and burns

Hydraulic systems inside drinks machines can contain hot

liquids (water, milk etc.) Some of the components and a pro-

portion of the products served are also hot. Undoing such

systems spontaneously, or touching these components or

drinks can result in severe personal injury from burns or

scalds, or in material damage.

 For this reason, you should disconnect pipes and con-

tainers only after the system has been carefully depres-

surised and/or vented. Wear suitable protective gear

when carrying out such work (goggles/gloves).

 For this reason, when carrying out maintenance work on

the machine or its interior, you should make sure that you

do not sustain scalds or burns.

 Allow the machine to cool down before starting mainte-

nance work.

Chapter 1 Safety regulations

6 SMSO-2-02.01- 15.07.03

Pressure container

Hydraulic systems in drinks machines may be under pressure.

Undoing such systems can result in severe personal injury or

material damage caused by the ejection of materials under

force, or by flying parts.

When carrying out any work to pressurised drums (as well as

to pipes and screw fittings) you should take care to do the

following:

 Never open pressure containers.

 Take suitable precautions (depressurise, serve products)

to ensure that these systems are depressurised before

maintenance work is carried out.

 For this reason, you should disconnect pipes and con-

tainers only after the system has been carefully depres-

surised and/or vented. Wear suitable protective gear

when carrying out such work (goggles/gloves).

Spare parts

 For all maintenance work use only original spare parts

obtained from the manufacturer of the machine.

 Do not make any changes of your own (improvisations) to

the machine, especially not to those parts that are critical

to safety. If you make changes to parts that are critical to

safety the result could cause life-threatening accidents or

severe injury.

 The use of unsuitable spare parts could lead to a loss of

guarantee.

Cut injuries

 The sharp edges of the metal parts of the framing can

cause injuries. When working on the machine wear suit-

able clothing and work gloves.

 Never reach into the bean container or touch the grinder

blade inside the grinder. The extremely sharp grinder

blades can cause severe personal injury.

Screw fittings

 Many screw fittings can only function reliably when the

screws are tightened to the specified torques. For this

reason you should always ensure that you tighten such

fittings to the specified torque.

 Always use suitable and checked torque testing tools and

ensure they are inspected at the prescribed intervals.

Sealing materials

 The sealing material used in screw fittings may come into

contact with drinks or the ingredients for drinks. Unsuit-

able sealing material can affect the foodstuffs, or could be

destroyed by the drinks or by the ingredients.

 For this reason only use sealing material that is permitted

for use in the food processing industry. Always comply

with the recommendations given in the product documen-

tation issued by the manufacturer concerned.

Corrosion resistance of materials

 Various metals in contact with one another can decom-

pose electro-chemically under the effects of certain fluids.

This corrosion damage is not normally visible and can

cause unexpected openings and leaks , or the pressure

containers may burst. Severe injury or material damage

can be caused as a result.

 Therefore, when carrying out maintenance work, please

only use materials that are appropriate for the system

concerned. Always follow the relevant assembly instruc-

tions when installing different types of metal.

Chapter 1 Safety regulations

SMSO-2-02.01- 15.07.03 7

1.2 Electronic regulations

1.2.1 General

DANGER TO LIFE

When carrying out any work on electrical

appliances, fatal injuries may be caused by

electric shock, if live parts are touched.

Even at low voltages, contact with live parts

can also cause bodily harm to people; such

work must be carried out only by authorised

and qualified electricians.

1.2.2 Checking electrical circuits

When carrying out any maintenance work you must observe

the following working rules.

Checking while disconnected from power supply

If possible, always check the electrical circuits when they are

disconnected from the power supply. Disconnect the machine

as follows:

1. Isolate the machine (fully disconnect)

2. Make sure that it cannot be switched on again (lock and

label the switch)

3. Ascertain that it is fully disconnected (if necessary check

for external voltage from linked systems).

Checking while connected (exceptional situations only!)

If you do in fact need to check the machine while it is con-

nected to the power supply, it is essential that you observe the

following rules:

1. Only use tools with insulated and voltage-tested handles.

2. Place covers, casings or other suitable measures to en-

sure that it is not possible to come into accidental contact

with live parts.

3. Ensure the unit is placed in an insulated location, and in

all cases use the voltage-tested gloves.

4. Do not carry out such tests alone, but always ensure that

another person with first aid skills in treating electric

shock is present, who in the case of an emergency can

take quick action.

 Never bypass any of the safety elements (fuses, safety

thermostats etc.)

 Safety fuses protect connected appliances from current

surges when an overload occurs, or in the event of a

short circuit. If the fuse values are too high, a fault could

cause material damage or a fire. Safety fuses should

therefore only be replaced with fuses having the same

nominal values.

 When checking electrical circuits please observe the

circuitry of each of the components. Transistor-switched

consumers in particular must be tested in accordance

with the semi-conductor elements. Incorrect measure-

ments can cause semi-conductors to become faulty.

Chapter 1 Safety regulations

8 SMSO-2-02.01- 15.07.03

1.3 Supply / Disposal

1.3.1 Drinking water connection

It is essential to comply with the installation plans (see “tech-

nical data” and local regulations when making the drinking

water connection.

1.3.2 Waste water connection

It is essential to comply with the installation plans (see “tech-

nical data” and local regulations when making the wastewater

connection.

1.4 Hygiene regulations

The International HACCP (Hazard Analysis and Critical Con-

trol Point) regulations contain food hygiene guidelines. Many

countries have further national hygiene regulations in addition

to HACCP.

In principle, coffee machines must be operated in accordance

with HACCP and with any national and industry hygiene regu-

lations in force.

1.4.1 Food regulations (milk)

 Do not use raw milk. Use only pasteurised or UHT milk.

Homogenized milk must always be used.

 Milk that has already been heated up or for which the

expiry date has lapsed may not be used.

 When using packaged milk, it is recommended for hygi-

enic reasons that the milk be used directly from the origi-

nal packaging.

 The milk in the refrigerator must be at a temperature of

approx. 3 °C to 5 °C If this rule is not followed, it is not

possible to serve a perfect product.

 Only refill with milk at a temperature no higher than 5 °C.

Never put warm milk in the refrigerator. It takes too long

to reach a temperature of 3 °C to 5 °C. The refrigerator

will also ice up. (Frequent defrosting required).

1.4.2 Using cleaning agents

In certain quantities, cleaning agents can be hazardous to

health. When the machine is cleaned, these cleaning agents

come into contact with many of the drink components (food-

stuffs). Residues from these cleaning agents may affect the

product quality and cause bodily harm. When carrying out

any cleaning work, make sure that the foodstuffs, cannot be-

come contaminated.

 Use only the cleaning agents and decalcifying agents

recommended by the machine manufacturer.

 Always carry out cleaning precisely as specified. (See

user manual and cleaning instructions).

 Rinse very thoroughly to ensure that no cleaning agent

residues are left in the systems.

 Take operational precautions to ensure that cleaning

agents and foodstuffs are stored separately. Ensure that

cleaning agent containers are clearly labelled, and that

the prescribed warnings are visible.

1.4.3 Using lubricants

 Machine lubrication can contain materials that are haz-

ardous to life and can cause symptoms of toxic poisoning

or paralysis or cause other damage to health.

 They should be used in coffee machines only where such

materials do not come into direct contact with the food-

stuffs or with the drinking water.

 Always check the applicable maintenance regulations to

make sure in which locations the various types of lubri-

cant may be used.

 Label the containers concerned to make sure you cannot

get the lubricant types mixed up.

 Ensure that you have an efficient working method that will

ensure that lubricants cannot, unnoticed, come into con-

tact with food either directly or indirectly.

Chapter 1 Safety regulations

SMSO-2-02.01- 15.07.03 9

1.5 Regulations for components

1.5.1 Rotary-vane type pump

 The rotary-vane type pump contains components that are

susceptible to damage from knocks or from pressure, and

which may be damaged if handled incorrectly.

 For this reason, it is essential that the pump be enclosed

in padding during transport. It must not be exposed to

knocks or shocks, must not be allowed to fall, or put un-

der stress in any way. (in a vice, clamps etc.)

1.5.2 Brewing unit

Damaged cylinder walls and pistons will no longer function

reliably. For this reason when dismantling / assembling this

component, make sure that no scratches are caused. Work

very carefully.

1.5.3 Grinder

 The grinding degree should be set only when the grinder

is operating.

1.5.4 Valves

 Most valves have a particular direction of flow. If they are

installed incorrectly the water system could malfunction or

a fatal or serious accident could occur. The direction of

flow is identified by means of arrows or by a connection

numbering system.

 Safety valves can only comply

with their safety functions if they

are installed in the correct direc-

tion of flow. Incorrectly installed

valves can cause the pressure to

rise too high and the instant

heater or steam generator to

burst. Life-threatening injuries

and material damage could oc-

cur. When installing a safety

valve make sure that it is in-

stalled in the correct direction.

Safety valves must not be disas-

sembled, decalcified and reas-

sembled.

 Do not use valves with damaged lead

seal coating.

 Non-return valves have only one

direction of flow. If they are installed

counter to the direction of flow, the

water system could malfunction. The

direction of flow is indicated by

means of an arrow on the housing.

When installing a valve make sure

that it is installed in the correct direc-

tion.

 Observe the installation direction for all valves.

1.5.5 Unit control system and power PCB

 The battery on the unit control system could discharge, if

the strip conductor side (i.e. the underneath of the power

PCB) is touched by conducting surfaces. Therefore, al-

ways place the unit control system on a non-conducting

mat (ESD mat) etc.

 The unit control system will only function perfectly if the

PE conductor is correctly connected. Therefore when

changing the unit control system please make sure that

the PE conductor is perfectly connected to the power

PCB.

 Electrostatic discharge can destroy a power PCB . When

handling PCBs make sure that they cannot suffer electro-

static discharge and always store susceptible compo-

nents in anti-static packaging.

 Replacing the Flash-ROM and the EEPROM modules:

Make sure that the connection prongs are standing in a

straight row, and that that the notches on the housing

match the ones in the base.

1.5.6 Safety thermostats

 The safety thermostats can only

fulfil their function if they are cor-

rectly fitted and the connections

are not deformed. Incorrectly fit-

ted safety thermostats or ther-

mostats with deformed contacts

will malfunction or not function

at all, and they will therefore not

switch off the electrical circuits.

This gives rise to the danger of

the instant heater or the steam

generator bursting

. When install-

ing these items please note the

following:

 Heat conductivity from the instant heater/steam generator

to the safety thermostat must be perfect. All contact sur-

faces between the instant heater / steam generator, con-

tact sleeves and safety thermostat, and also the safety

thermostat threaded studs must be coated with a suffi-

cient quantity of thermo conducting paste.

 The flat plug connections must not be bent either during

assembly, nor, once installed, must they be exposed to

any mechanical stress whatsoever.

 After a safety thermostat has been triggered, the tem-

perature sensor must be replaced.

1.5.7 Level probe

 There are level probes of different lengths. A level probe

of the incorrect length can cause the steam generator to

malfunction.

 Use only level probes of suitable length for each steam

generator.

1.5.8 Instant heater / steam generator

 Instant heaters and steam generators are pressure con-

tainers and are checked as a complete unit after the

manufacturing process. Mechanical or chemical cleaning

and decalcification can weaken individual components

and welded seams. This gives rise to the danger of bursts

or leaks. Instant heaters and steam generators

should therefore never be decalcified either

mechanically or chemically.

Chapter 1 Safety regulations

10 SMSO-2-02.01- 15.07.03

1.6 Refrigerator

The refrigerator cooling system functions

only when the appliance is standing up-

right. In any other position the refrigerant

may not be drawn up by the compressor

and the appliance could then be damaged.

 For this reason, the refrigerator must always be operated

in an upright position.

 During transport, it must be laid down only on the right

hand side, and forwards (viewed from the front).

 Having been transported in a tilted position, it must be

allowed to stand upright for at least six (6) hours before it

is allowed to operate (i.e. before it is switched on).

 The heat from the cooling unit must be vented off. If cool-

ing is insufficient the cooling efficiency inside the

refrig-

erator

reduces, and the refrigerated goods are insuffi-

ciently cooled. Make sure that sufficient air can circulate

around the cooler and clean the cooling ribs periodically.

 Iced up evaporators reduce cooling efficiency and con-

sume more power. Defrost the appliance once the layer

of ice exceeds 3 mm in thickness. To defrost, switch off

the appliance (set the controller to zero). Do not use

sharp objects (such as a knife) to remove the ice layer

mechanically.

 When no longer required, the refrigerator must be dis-

posed of in accordance with local waste disposal regula-

tions.

 The start-up relay becomes warm when the motor starts.

It must be allowed to cool down before restarting. For this

reason do not switch the refrigerator on and off at short

intervals.

Chapter 2 General notes for service technicians

SMSO-2-02.02- 15.07.03 11

2 General notes for service technicians

2.1 Equipment

There are three important pre-requisites for all service techni-

cians in order that they can carry out efficient and cost-

effective maintenance to coffee machines.

 Material equipment

Service vehicle, tools, testing equipment, spare parts,

technical documentation.

 Technical knowledge

general technical knowledge, knowledge of the machine

functions, and an understanding of the process (how the

components interact and affect one another), the use of

testing equipment to diagnose faults quickly and clearly,

observing safety regulations and work hygiene rules, a

responsible manner of working with spare parts and con-

sumables.

 Versatile and craftsman-like skills

Coffee machines are extremely complex technical sys-

tems. Due to their compact structure, the system compo-

nents are very tightly packed and nested together. Any

person carrying out maintenance work must therefore be

a skilled craftsman and must work with great care. Main-

tenance work should be carried out with great care not

just to prevent the risk of injury, but also to avoid damage

as a result of careless or improper working methods.

This section contains information that is necessary to provide

a service technician with everything he requires. Having excel-

lent equipment still does not make a good service technician,

but on the other hand a very good service technician cannot

carry out maintenance work without suitable tools, utilities and

spare parts.

2.1.1 The principles of maintenance

A minimum stock is required in tools and testing equipment

(measurement instruments and accessories) so as to:

 be able to carry out maintenance work (preventative

maintenance)

 be able to carry out repairs to all systems (including the

refrigerator.

 to make adjustments in order to optimise product quality.

A well regulated and perfectly maintained set of tools / utilities

is also necessary in order to be able to comply with safety and

hygiene regulations during maintenance work. Here there are

two areas of safety regulations:

 Regulations covering product safety and its users

(settings, torques, use of lubricants, replacing safety

components, compliance with nominal values, etc.

 Regulations covering the personal protection of the

service technician and the machine material, (in particular

protection from: electric shock, scalds, hazards from

pressure containers, ESD etc.

2.1.2 Tools and test equipment

The illustration overleaf shows which tools and testing equip-

ment a service technician must have available as a minimum,

and as the optimum.

The minimum stock of tools can be expanded until it becomes

the optimum stock of tools and utilities.

2.1.3 Spare parts

The manufacturer does not provide special maintenance or

repair kits for maintenance and repair work. The “SO2 ser-

vice instructions” and the “Refrigerator service instructions”

tables are the basis of proper preventative maintenance.

These tables set down the number of coffee servings or the

service life in months for all significant components, after

which they must be replaced. These tables form the basis of

the type and quantity of spare parts that must always be to

hand before servicing commences.

The following rule applies as a recommendation for a mini-

mum spare parts stock :

 Twice the amount of materials stated in the SO-2 and

Refrigerator service instructions.

 1 x 063902 spare parts case, large for SO-2

 1 x 063903 spare parts case, small for SO-2

 1 x 063904 spare parts case for SO-2 foamer and

refrigerator

In addition to special spare parts, there should also be avail-

able a comprehensive assortment of screw fittings, pipes,

hoses, cables, and plugs. Please observe the differing condi-

tions of use and the usage instructions for these materials.

Make sure that you can carry out efficient servicing by carrying

a sufficient range of parts. You will find further information

relating to material specifications, dimensions tables and pro-

cessing instructions in the “screw fittings” section of the spare

parts catalogue.

Otherwise you should obtain and store spare parts in accor-

dance with the requirements and guidelines of the service

point concerned.

Chapter 2 General notes for service technicians

12 SMSO-2-02.02- 15.07.03

2.1.4 Hygiene measures

When carrying out maintenance work, hygiene measures must

be observed during every stage of work. This is also a re-

quirement of materials used. Besides taking personal hygiene

measures, such as wearing clean work wear, you must also

pay attention to cleanliness of tools and spare parts. There

must always be sufficient cleaning materials available for the

job in hand (large and small brushes, cloths, vacuum cleaner

etc.)

Occasionally these cleaning materials must be supplemented,

replaced, maintained and/or repaired.

2.1.5 Booster / Hotflush

Two machine series which differ greatly in design are de-

scribed and illustrated in this manual:

 Machines without boosters but with flush valve and a

complex temperature control for the instant heater

over-temperature 1/over-temperature 2. Refrigerator with

cold water rinse.

 Machines with boosters and refrigerator unit with hot

water rinse (HOTFLUSH).

The corresponding changes to the coffee machine were im-

plemented to the refrigerator simultaneously. The machine

series differ by serial number and a certain production date.

Reference is made to these dates in this manual in all sections

which contain both descriptions. Illustrations generally have a

BOOSTER or HOTFLUSH „stamp".

Series number and production date

 Machines without boosters, with flush valve and their

refrigerator with cold water rinse:

Production date up to 1.4.2002

Serial number to 505123

......... 01.04.2002

......... Serial no. 505123

 Machines with booster and refrigerator with hot water

rinse (HOTFLUSH).

Production date from 2.4.2002 on or

Serial number from 505124

02.04.2002 .........

Serial no. 505124……

Illustrations with "Stamp"

The different and partially fundamental mechanical hydraulic

design of the machine is also resulting in corresponding

changes to the programming. Individual parameters can no

longer be set. Therefore, the corresponding settings must be

made for the booster (see "Programming manual").

Service tools and test instruments (see next page)

1 These tools and test instruments are the minimum items required to carry out maintenance work.

2 These tools and test instruments should also be available as a minimum stock of tools in order to carry out the highest

quality of maintenance work. These are principally instruments that provide good service particularly for repair work on ma-

chines. Specific fault diagnosis requires the corresponding relevant test instruments to enable individual systems and com-

ponents to be tested in a very flexible manner. Nowadays ESD protection equipment is considered to be basic equipment,

as are lubricants, to enable certain components to undergo perfect repair. The temperature gauge shown is an add-on to

the multimeter, but a separate temperature gauge may also be used.

3 Water hardness tester set A complete set contains all the test equipment and chemicals needed to ascertain carbonate and

overall hardness

4 Anti-static containers for flash-ROMs and EEPROMs

5 EEPROM extraction tool

6 Flash ROM extraction tool

7 Temperature gauge: can be an accessory to a multimeter or can be in the form of a separate measuring instrument

8 Antistatic mat with ground cable and wrist strap

9 Antistatic packaging for printed circuit board (Power PCB / EHS)

10 Scales and measuring cup or container to weigh ground coffee

11 Teflon tape in various widths

12 Insulating tape

13 Thermo conducting paste

14 Food grease

15 Grease for use with plastics

16 Micro brush

Chapter 2 General notes for service technicians

SMSO-2-02.02- 15.07.03 13

Chapter 2 General notes for service technicians

14 SMSO-2-02.02- 15.07.03

2.2 Service instructions

2.2.1 Service intervals for the Ambiente-2 coffee machine (Index e, 30.06.2003)

Servicing must take place after every 45,000 coffee servings, or every 12 months

A = Parts relevant to safety (see this section)

No. 1-22 = check no. (see Section „Instructions on check numbers 1-22")

Description of part

Part

no.

After 45,000 coffee serv-

ings or after 12 months

After xx months or

max. counter reading

C R R

Instant heater – coffee to 12/2000

Instant heater – coffee from 01/2001

A

065‘111

1

36 months

60 months

(Section "Safety-relevant

parts, point 1")

Supply pipe 063‘404

2

HW valve pipe 063‘205

3

Safety valve

A

065‘240

R

3/2-way brewing valve

2/2-way brewing valve

063‘206

063‘215

R

Draining valve 061‘029

R

Instant heater brewing valve pipe 063‘405

3

Booster 061‘823

4

Instant heater – tea to 12/2000

Instant heater – tea from 01/2001

A

061‘164

1

36 months

60 months

(Section "Safety-relevant

parts, point 1")

Supply pipe 063‘204

2

Safety valve

A

065‘240

R

HW valve tea 063‘215

R

Steam generator to 12/2000

Steam generator from 01/2001

A

061‘156

1

36 months

60 months

(Section "Safety-relevant

parts, point 1")

Supply pipe 063‘304

2

Level probe 067‘068

5

Safety valve

A

065‘240

R

Safety valve pipe 065‘154

2

Steam valve 063‘715

R

Feed valve 063‘215

6 36 months

Grinder motor 062‘431

7 100‘000

Grinder blade 065‘007

8 80‘000

Brewing unit 065‘000

9 70‘000

Lower piston with O-ring system 065‘316

R

Outlet piston 065‘310

R

Friction ring for 065316 065‘191

R

Lower piston / outlet piston O-ring 065‘190

R

Piston motor 063‘322

10 100‘000

Flow meter 061‘226

11 36 months

Non-return valve 063‘208

12 36 months

Pump distribution block pipe 063‘455

13 36 months

Distribution block - instant heater pipe Tea 063‘518

13 36 months

Distribution block – steam generator pipe 063‘519

13 36 months

Distribution block – flow meter pipe 063‘452

13 36 months

Instant heater – tea outlet pipe 063‘455

13 36 months

Steam valve outlet pipe

Steam valve – outlet / refrigerator pipe

063‘523

063‘455

13

36 months

Flowmeter – instant heater- coffee 063‘450

13 36 months

Brewing valve - brewing unit pipe 063‘453

13 36 months

Brewing unit - outlet pipe 063‘513

13 36 months

Brewing valve - booster 061‘986

13 36 months

Booster – brewing unit 061‘987

13 36 months

Pump 065‘384

14

Motor 065‘003

15

C = check R = replace

Chapter 2 General notes for service technicians

SMSO-2-02.02- 15.07.03 15

Description of part

Part

no.

After 45,000 coffee serv-

ings or after 12 months

After xx months or

max. counter reading

C R R

Pump inlet filter 067‘186

16

36 months

Hose connection 067‘766

17

36 months

Outlet house w/o refrigerator

Outlet hose with refrigerator

063‘353

063‘345

18

36 months

2.3 Instructions on check numbers 1-22

Note 1

Make a visual check of the instant heater 065’111 / 061’164

and the steam generator 061’156.

 If one of the elements is not watertight and is indicating

traces of calcium externally at the heater connections or

the welded seams, it should be replaced.

 If one of the elements on the interior has heavy deposits

of calcium. It should be replaced.

 The instant heater and the steam generator must not be

decalcified.

 Make a note of the check on the test certificate (see

section on “safety-relevant parts”).

Note 2

 Make a visual check for seal and calcium deposits, pay

special attention to the drilled holes at the side.

 If the drilled holes on the side are clogged with calcium

deposits, this normally means that the safety valve is

faulty. This means that some water is always flowing back

through the safety valve.

Note 3

 Visual check for calcium deposits, damage,

contamination and seal of pipe.

Note 4

Check the drilled hole in the booster for calcium deposits and

coffee residues. If it is heavily soiled, the booster must be

completely replaced. Check the booster temperature (110

o

C)

after the machine has been switched on.

Note 5

 Visual check for calcium deposits and seal

Note 6

 Visual check for calcium deposits and wear on the seal.

Note 7

 General condition of the motor. The “grinder empty”

message must be checked.

Chapter 2 General notes for service technicians

16 SMSO-2-02.02- 15.07.03

Note 8

 Check the grinding operation (grain size) and adjust if

necessary. If this is not possible, the grinder blades

065’007 must be replaced in pairs. When fitting the

grinder blades, make sure that the pitch circle of the

fastening holes for each of the blades are different.

Note 9

 Replace the lower piston 065’316 and the outlet piston

065’310.

 Replace the O-rings 065’190 and grease lightly with

grease 067’399 suitable for use in food applications. The

brewing unit is always lubricated according to the

lubrication plan 1.5.5929 / 1.5.6239 (see chapter

"Function Description, Lubrication Plan for the Brewing

Unit").

 Replace the O-rings 065’191, these must not be

greased.

 We recommend that the brewing piston should be

replaced after every 50-70,000 strokes. If the machine is

not more than 3 years old, the friction piston set 2000,

062’600 can be fitted.

 After the brewing unit has been cleaned, carry out a

functional check and leaks test.

Note 10

 Check the piston motor for clearance on the drive shaft

and at the connection with the housing.

 In addition you should also check that the piston motor

is fitted into its retainer free of play.

Screws 1660003 must be tightened to a torque of 10 Nm.

Note 11

 The flowmeter should be checked for calcium deposits,

contamination and mechanical wear. Replace O-ring

064’464 after opening.

065’190

065’191

Loctite 243

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Schaerer Ambiente 2 User manual

Schaerer Ambiente 2 User manual

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