Technical Manual
Contents
1. 4 SPEC HAYT gt 242 gt 8 5 2 Mme 1 EAE ago s ERI DRAIN 741 per Technical Manual 5 SYNESSO INSTALLATION DIAGRAM Easily cleanable Sturdy level and horizontal Capable of sustaining weights up to 300 Ibs 2 5 round hole drilled for hoses see Footprint for hole location Clearance 1 behind 3 in front Water requirement 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 Electrical requirements 1 Group 110v 60 hz 20 amp 1 Group 220v 50 60 hz 16 amp 2 Group 220v 50 60 hz 28 amp 3 Group 220v 50 60 hz 36 amp Incoming Water Water from pump to groups Treated water to Filtration System Hydra Electrical Requirements 2 Group 220v 50 60 hz 30 amp 3 Group 220v 50 60 hz 40 amp Drain hose ocated within 3 of machine Drainage requirements Located within 5 of the machine Drain hose should run as vertically away from the machine as possible Pump and Motor Located within 5 of the machine Dimensions H 6 5 x W 5 5 x D 9 5 Note Hydra hybrid machines have multiple pumps and motors MACHINE FOOTPRINT Water Requirements Proper water filtration and regula2. 15 f M38 51511 Lf st JATVA H M3H8 51 MNVL WV3ilS gt S SCC 422141 44271 O onn Li HYDRAULIC SCHEMATIC HYDRA LNOAV1 HLVd WWE ZL CL 13s 5 SCC 8261 Sco 15 Technical Manual Water to steam tank ONL 221244442266 Pump configurations Until serial number 356 Synesso s had a single inlet configuration as the stan dard 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 3 3 Skinner Valve Autofill configuration Technical Manual Pump and Motor oynesso uses Fluid o tec rotary vane pump which boosts incoming water pressure to 9 bar when the motor is acti vated Pressure can be adjusted by loosen ing the nut on the right side fitting and then turning the adjustment screw clockwise increasing pressure or counter clockwise decreasing pressure 1 5560 E 1 3690 1 4 1 5160 1400 M 2 1 C RAN lt 3 1 5510 1 5170 4 39 O TEc at ae fx gt 4 d 7 c fiai fore 1 5111 Single or Dual Hose Config 1 5112 Single Hose or
3. valve 3 Y as 314 p 2 y gt E Group 2 El Switch 200 gt Pree tel ast v s H 3 Hon ss n 3 ly Y 2 2 c 0 34 41 KS 21 HET 5 55 L z 3 17 nn 2 8 a e CIC 25 cot m 25 Te From Technical AMD Cove WA ELECTRICAL BOX The electronics box located underneath the machine contains all the incoming and outgoing power to the Synesso Since the 2 boxes represented below top group box bottom 1 group have many of the same components they have been labeled with numbers for matching components and the descriptions follow in the next pages 3 p Electrical Box_ 14 top of lid 13 12 11 munt 10 7 em 1 Group Electrical Box Technical Manual 25 ELECTRONIC SYSTEM 1 Brew relays Control voltage to the brew tank heating elements 2 Pump wires Carries 220v to the pump motors from the electrical box Contains 3 wires black 110 white 110v and green ground A fourth wire Red is used for bypass system control when appropriate 3 Power wire Provides 220v power to machine 4 Lid safety switch Safety device which cuts power to the control board when the lid is removed 5 Pump relays Controls voltage to th
4. Make sure the set point has not been changed Check that the relay is functioning properly Check that the connection to the temperature probe is intact and secure Steam Steam Pressure is machine can be set for steam pressure at over 2 0 Bar but there Pressure set for 1 8 Bar or can be side effects in the brewing process A small amount of water is Higher preheated in the steam tank for brewing If the temperature in the steam tank is set very high then this could allow for the preheated brew water to be too hot and cause some erratic brew temperature spikes There are ways to make this work if it is absolutely necessary to have a very hot steam tank Contact Synesso for more info Sudden loss of e Too much hot water has been used for Tea Americano rinsing or Steam Pressure warming cups while still steaming milk Allow the machine to recover Check temperature setting on the steam tank to make sure they are high enough for your application Watch steam gauge when pressure drops allow the heating elements to heat the cold water being introduced into the steam tank ee accurate and functioning tion filling e Water level probe auto fill needs to be de scaled or cleaned This probe is located behind the left side panel e Make sure level probe auto fill is working See Test Level Probe e Water is too hard The water level auto fill probe requires a low level mineral
5. A button at the same time for approximately 4 seconds Access to level 3 is only available from this screen Technical Manual 5 PROGRAMMING Menu Level 3 Volumetrics The functioning of Volumetrics is only applicable on machines with volumetric hardware If the machine does have volumetric hardware this indicator should always be left in the ON posi tion Technical Manual 55 PROGRAMMING Menu Level 3 Brew Groups The Brew Groups Present will be set to correspond directly to the physical definition of your machine and should not be altered without first contacting Synesso Technical Manual 56 PROGRAMMING Menu Level 3 Reset The Full Reset to Defaults option can be achieved by pressing the line 3 button This option will undo ALL changes that have been made to the machine This includes the Synesso programmed offsets serial number and machine configuration information It is highly recommended that you make note of all Synesso programmed settings before doing a Full Reset of the machine Technical Manual 5 PROGRAMMING Menu Level 3 Bypass The Bypass Hardware on the pump can be activated and deactivated from this screen If your machine has the bypass capability this program will be set to ON as indicated above Technical Manual 58 PROGRAMMING Menu Level 3 Hydra The Pump Configuration screen gives the option of selecting between SINGLE pump use or MULTIPLE pump us
6. to the wire on the outside m E Technical Manual 21 Technical Manual Electrical System The electrical system in a Synesso is relatively straighforward This chapter will cover the fundamentals of the electrical layout and function of the electrical features of the machine SAFETY NOTE Please use caution when working on any part of the Synesso electrical system Live current poses the risk of electrical shock harm permanent injury or death Take all appropriate precautions including turning off the machine breaker and or unplugging the unit prior to working on the machine The major components of the electrical system can be broken down into the following functional categories 1 Heating components temperature probes elements thermal resets and various parts of the CPU 2 Water control water inlet valves brew valves mix and hot water valves water level probes an various parts of the CPU rocker and brew preinfusion switches pump and motor 3 Operator feedback visual display The locations and descriptions of the components above were covered in the last chapter Hydraulic System with the exception of the CPU and display which will be covered in this chapter Technical Manual 23 Electrical System Wiring schematic 5V To SWITCHES voz LLLI S i VO Z LK EE 1 1 a iS Se 3NI1 Ca
7. clearance of 1 behind and 3 in front of the machine Make a 2 gt round hole through the counter top 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 preferably located directly underneath the machine A proper water filtration or softening system must be installed on the incoming water supply Water treatment systems will vary and it is important to use a system designed to match the needs of your specific area Most water filtration systems require periodic maintenance including 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 DAMAGE CAUSED BY IMPROPER WATER TREATMENT WILL NOT BE COVERED BY THE MACHINE WARRANTY There must be adequate room under the counter to locate the motor and pump This should be within 5 of the cold water supply line The pump should be easily accessible for potential adjustments and should have proper ventilation and a minimum of 3 clearance on all sides Dimensions of the pump and motor are 6 gt Height x 5 72 Width x 9 77 Depth A floor drain or sink should be readily available The best lo
8. content in order to detect the water and relay the information to the CPU Do not use deionized water in the machine On machines built prior to 01 01 2011 adjustment can be made to the level probe sensitivity control on the power board in the electronics box See Probe Sensitivity Photo Steam Valve Stem e Replace O Rings Purchase Rebuild Kit See Steam Valve Rebuild Seals Leak instructions for more info Auto Fill Valve e Check that the water to the machine has not been cut off or restricted Solenoid is turning OFF and On without Filling the Steam Tank e Confirm that auto fill delay is set to at least 5 seconds See Programming Guide e the machine is installed on a boat or other mobile platform increase the autofill delay as the water may slosh inside the tank and confuse the level probe Technical Manual 31 Working from a static tank and there is no pressure available to fill the steam tank Dual inlet machines will need a line boost pump or custom plumbing to operate from a static tank with no line pressure e Machine is not level Check to make sure the surface that holds the ma chine is level Slightly adjust leg height to create a level machine The Sight Glass e Water level probe auto fill needs to be de scaled or cleaned This Shows that the probe is located behind the side panel Water Level in the Steam Tank is either too High or too Low On machines built prior to 01 0
9. harmful Chloride 0 ppm any Chlorides can be corrosive and harmful Total Alkalinity Less than 100 ppm Chlorine 0 ppm Iron ppm oynesso s utilize 3 8 braided stainless hoses supplied with machine to connect the ater 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 sup plies 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 Technical Manual 12 HYDRAULIC SCHEMATIC DUAL INLET NOILVYNDIANOD HTINI HLVd YJ LVM dNOYD 339 HONOYHL MO 13 d31 VM 13 WV3LS SCC I SCC Sco Technical Manual HYDRAULIC SCHEMATIC SINGLE INLET 35055359 JNNA INIT M31VM JAWA X23H2 19089 34055344 3 8 W NOUVYLINJd C 3ATVA 23 2 ANVI WVilS NOUVMLSN3d XNVL CSV 1 ave 2101 LL 135 83 JAWA NOISNVAXZ IST I OL JAWA 4 0 3105 TWA OL JIYA
10. the pressure increases within the tank The expansion 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 to increase or counter clockwise to decrease Heat Exchanger tubes In order to maintain extremely stable brewing temperatures Synesso 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 to aid in the energy efficiency and thermal stability of the Synesso Cold Water Valve oynesso has 2 valves which provide water to the Americano tea spout the hot water valve and the 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 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 while turning it counter clockwise allows more cold water in synesso sets machines to have a steady flow of water at approximately 203 in bench te
11. the temperatures are to the set points then keeps this pressure inside for use in heating milk maintaining a hot water supply and pre heating the brew water in the heat exchanger tubes 2011 2 Group Cyncra Inlet right side 220 230 50 60Hz 100 ED Bil d FU 22 A S 7 ppm 2 e te 24 2729 a 22 2 26 Technical Manual 19 Major Components of the Water Outlet Left Side Cyncra prior to 2011 Temperature probes Steam 2 2 actuator gt 3 rod Steam gauge _ 27 l tube Steam Steam tank thermal overload switches Steam shut off valve 2nd position Brew tank brew tank fill tube oP a pee Brew tank Heating element 151 position brew Low level probe ian fill tube 1st and 2nd position brew tank fill tubes After travelling through the steam boiler the heat exchangers 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 oynesso 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 This allows the user to set different temperatures on each group as well as functio
12. through 04 groups 1 4 OT Over temp over 220F 104 4C UT Under temp under 180F 82 2C for 1 min while group is trying to heat PR Pump relay on timeout relay has been held open for 5 minutes BP Bypass valve open timeout valve has been held open for 5 minutes ST Steam system LW Low water probe is dry an audible alarm will also sound FP Fill probe is dry for 1 min an audible alarm will also sound FV Fill valve open timeout valve has been held open for 5 minutes OT Over temp over 270F 132 2C VM Volumetric system Unexpected flow while group is off leaking or filling Example After backflushing group 2 was not returned to the off position After 5 minutes the machine registered a BRBVO2 and a 2 error At that time the machine shut off both the brew valve and the pump relay to ensure they would not be damaged They will remain off until the group is returned to the off far right position which allows the group to return to normal operation Technical Manual 53 PROGRAMMING Menu Level 2 Return To Level 1 Line 1 and 2 indicate that you are on the Return To Operation Mode screen Pressing the line1 button will cycle back to the Temperature Display screen on menu level 2 Pressing the line 3 button will cycle back to menu level 15 Display Default Overview screen In order to enter menu level 3 press and hold both the line 4 button and the
13. 1 2011 The manual fill switch located on the front of the electrical box has been depressed Use the hot water spout to drain the steam tank until the fill solenoid opens and the tank begins to refill e you are working from a static tank then you must use a line pressure boost pump to provide the pressure needed to fill the steam tank Contact your dealer service provider or the Synesso factory for more information regarding static tank installations e Machine is not level Check to make sure the surface that holds the ma chine is level Slightly adjust leg height to create a level machine Debris is stuck the water control fill valve See Water Control Valves Steam Tank is Slow On machines built prior to 01 01 2011 Test zone 5 functionality to Recover Pres Turn down the set point for zone 4 a few degrees below zone 5 m sure up zone 5 by a few degrees and confirm that the temperature rises to the new set point m If the temperature has risen then zone 5 is functioning properly 0 Test zone 4 functionality See Test zone 5 above for instructions e f either zone is not working properly then see Cold Zone and Tanks will Not Heat to Full Temperature in the Electronics section e Calcium and scale buildup can insulate and cause reduced efficiency in heating elements If calcium and scale buildup is an issue be sure to descale your machine on a regular basis oteam Drip at t
14. 457 18 457 29 736 40 1016 Depth 23 1 584 23 584 23 1 584 23 584 Weights amp 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 20 x30x31 20 x30x31 41 32 31 49 x32 x31 Boxed Dimensions L x W x H m m 908x 62x78 508x762x787 1042 762 7 87 1245x813x 87 Plumbing Compression 3 8 OD 3 8 OD 3 8 3 8 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 E E CE Technical Manual 9 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 automatically 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
15. Hydra Config 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 2809 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 next page shows the steam tank autofill configuration All 3 of the water control valves are now Parker 2809 Upgrade kits are available through Synes 16 Major Components of the Water Inlet System Vacuum breaker Cyncra prior to 2011 Brew gauge D Pressure Relief Valve under hose Heat Exchanger Tubes Sight Glass Steam inlet Hot water valve check valve Steam tank water inlet valve Drain tube from brew tanks l SAN gt 9 NS A 8 GA Steam tank fill pm ae hose Drain box Brew Tanks Mi i Cold water Expansion Check valve adjuster valve Drain hose valve Coffee inlet hose Water Inlet Components Fill Line Brew Gauge The brew gauge reflects pressure in the brewing system On a standard Synesso there is one gauge for the entire brewing system on a Hydra each brew tank has its own brew gauge The gauge normally moves bet
16. OK you find an error code EX AABB refer to the Error Log codes on page 26 To cycle to the next display screen in the menu level the BG 1 Temperature Control screen in this case press the button to the left of line 1 Technical Manual 40 PROGRAMMING This is the second screen of the display BG1 Temperature Control Line 1 of the BG1 Temperature Control screen indicates the current temperature being recorded by the first position brew group s temperature probe LOW in this example Once this temperature reaches the set point it will continuously cycle up and down by small increments as the electronics balance the temperature Line 2 is indicating the set point of 203 0F 95 0C Line 3 indicates the length of time that the stage 1 timer timed preinfusion will run Line 4 indicates the length of time that the stage 2 timer will run This option will ONLY be available on machines that are equipped with pump bypass systems See page 22 for more information To change the temperature set point press the button for line 2 The current temperature setting 203 0F will begin to flash To alter the temperature press the A or buttons until the desired temperature is reached Press the button to the left of line 2 to confirm the temperature point The number will stop flashing Line 3 indicates the amount of Stage 1 or Line Pressure Pre infuse time that will elapse before the pump is initiated Line pressure can be altere
17. Synesso testing method Adjustment to this setting is not recommended without thorough testing The Synesso testing method is as follows Using a bottomless portafilter dose out 16 18 grams of coffee into a 14 gram basket with a thermal probe inserted 1 8th of an inch from the surface and in the middle of the puck packing and tamping the grounds in the basket as usual The thermal probe is then wired to a FLUKE thermometer to relay the actual temperature of the water flowing through the puck while pouring a 2 ounce shot This process is repeated a minimum of 3 times per brew group in order to get the most accurate reading This reading is then applied to line 3 by pressing the corresponding button Use the A buttons to select the desired setting and then confirm the selection Inserting the temperature on line 3 will automatically set the line 4 offset The Offset on line 4 can be altered to achieve the same effect as inputting a temperature on the Puck temperature line Changing the offset will correspondingly alter the puck temperature This offset point should not be altered without thoroughly testing the puck temperature as mentioned above To cycle to the next display screen press the button next to line 1 Technical Manual 49 PROGRAMMING Menu Level 2 Steam Tank Offset Line 1 indicates that you are on the Steam Tank Offset screen Line 2 indicates the actual water temperature at the steam tank temperature pr
18. Technical Manual O 2 gt Un synesso Inc 309 S Cloverdale C41 Seattle WA 98108 tel 206 764 0600 fax 206 764 0601 www synesso com info Synesso com This Service Manual is intended for use by qualified service technicians only Technical Manual 2 Table of Contents Safety and 100 4 Pages 4 5 eria Pages 6 10 Hydraulic System pp Pages 11 21 Electrical 5 Pages 22 27 Troubleshnoollhg usn ese boe ideo aborto Pages 28 35 Periodic Pages 36 39 Programming Instructions Pages 40 62 Technical Manual 3 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 e Turn the machine off and shut off the incoming water supply e 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 ch
19. amperage see specifications chart on page 9 for your model install a matching plug on the power cord provided with the Synesso machine 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 Synesso 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 nec essary to install an in line Buck Boost transformer to increase this voltage e 1 2 Group 220 Volt Machines require a 1 0 KVA transformer 3 Group 220 Volt Machines require a 1 5 KVA transformer Technical Manual 8 Specifications for the Synesso 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 x3 Brew Tank Capacities Liters 1 9 1 9 1 9 X 2 19 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
20. art Line 4 indicates the settable time at which your power save mode will end Enabling the power save mode will drop the temperature in the brew group s to 180F 82 2C and the steam tank to 220F 104 4C for the time span set This will help conserve energy while preventing maintenance issues that occur due to depressurizing and re pressurizing when machines are turned off and on This will also allow the machine a shorter amount of time to reach full temperature and stabilize after the power save mode has ended Press the line 1 button to cycle to the next display screen Technical Manual 52 PROGRAMMING Menu Level 2 Error Log Line 1 indicates that you are on the Error Log screen Line 2 indicates the last error that occurred If no error has occurred this line will simply read NO ERROR Line 3 indicates the date and time that the last error has occurred If no error has occurred this line will be blank Line 4 gives the option to clear the Error Log To cycle through the Error Log use the A W buttons Cycling through the Error Log will change the date and time on line 3 to match the displayed Error Code time of occurrence To clear the Error Log press the button associated with line 4 Error log key Logs are in format AA system code BB subsystem code group or section effected BR Brew system BV Brew Valve open timeout valve has been held open for 5 minutes 01
21. cation is directly under the installation site of the machine The drain hose should descend steeply for proper drainage An electrical receptacle and matching plug rated at the proper voltage and amperage is required within 3 of the location of the machine Plug ends are not included with the machine Below are the recommended cord plug ends for the Synesso machines 1 Group 110 V UL listed 20 amp 1 Group 220 V UL listed 20 amp 2 Group 220 UL listed 30 amp e 3 Group 220 V UL listed 50 Technical Manual T 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 The 24 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 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 NOTE The Synesso 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 rated for the proper voltage and
22. d Electronics All zones read LO e Check to make sure the element breaker is ON Zones will read LO until the temperature in that zone reaches 175 F An individual zone e Test the connections at the probe and 1 LO e Test thermal overload over temperature switch On machines built prior to 01 01 2011 Test the fuse for that zone Test continuity between the ends to check for a blown fuse Test that voltage from ground to the fuse reads 110v e DISCONNECT POWER TO THE MACHINE FOR THIS TEST Test continuity from the heating element posts to ground and the resistance between the posts e f all these tests prove to be ok and the LED for the relay on the power board inside the electrical box is ON then the relay has failed An Individual Zone Reads or Above 250 F and the Cor responding Tank is Cooling Tanks will Not Heat e Clean dust and debris from electronics box Take a soft brush clean to Full Temperature paint brush to loosen debris and use a small vacuum hose to remove loose debris Cold Zone e Solid State Relays can fail in either the ON or Off position TRAINED OR AUTHORIZED PERSONNEL ONLY e Relay has failed in the ON position The heating elements will not turn off and they will overheat to a point where the thermal overload switch will trip and break the circuit to the element With power ON test for voltage at the fuse voltage is not presen
23. d out Running e Check the pump switch in the group top to make sure it is engaging and has not failed See Brew Switch Adjustment eCheckthatthe pump relay in the electrical box functions correctly ___ EM e Check in the group top that the brew solenoid switch is engaging and While Pump is on has not failed See Brew Switch Adjustment section for more info Brew Solenoid is stuck closed be caused by soap residue not fully flushed after cleaning e Brew Solenoid coil may have failed Check that coil magnetizes when group is in preinfuse and brew positions Jet be plugged See Jet Clearing Procedure Water filter may be plugged Check and Replace if necessary Slow Water Flow e Debris is stuck in the water flow restrictor jet See Jet Cleaning Proce more than 10 dure seconds to pour 2 ounces of water Water filter be clogged and should be changed Brew Gauge Flut e Water is in the gauge or tube Remove the gauge and tube blow out ters or Vibrates the water and reinstall Machines made after 240 use a thinner longer gauge tube which eliminates flutter If your machine is made before 240 and this issue becomes unacceptable contact your dealer service pro vider or the Synesso factory to purchase a retrofit tube Brew Tem Readout for Brew e he control must detect a temperature one increment 0 5 F on original perature Water Temperature machines or 0 1 F on curren
24. d using abrasive cleaners or cleansing pads Take extra care on the mirror finish stainless steel surfaces 2 Make sure the steam wands and tips are free of milk built up It is always best to clean the steam wand and tip after each use Approved espresso industry cleaners can be used to help dissolve milk built up 3 The drip tray drip tray grates cup tray grates and portafilters should be removed and cleaned every day If you clean the portafilters in the dishwasher first remove the filter baskets and insert springs before placing all items in the dishwasher Changing Portafilter Gaskets oynesso uses an 8 mm gasket with grooves in the outside edge to help with ease of installation and to allow trapped air and water to escape without contacting the coffee 1 Remove the diffuser screen and screw 2 Use a small Awl or a screw driver to pry the old gasket out then clean the area thoroughly to remove any leftover gasket material 3 Install the new gasket with bevel side up using a small amount of food grade grease or vegetable oil 4 Work your way around the gasket pushing it up into place with the rounded end of a wrench 5 Take the basket out of your portafilter and engage it to make the final seat of the gasket Pull hard to make sure there is no air trapped above the gasket 6 Install the diffuser screen and screw Technical Manual 3 Periodic Maintenance Maintenance Schedule Daily 1 Back flush each brew group a few times without
25. d with either a pressure regulator or a boost pump To change the Stage 1 time press the button associated with line 3 The current time will begin to flash To alter the time on the indicator press the A or buttons until the desired time is reached Note setting the Stage 1 timer to 00 will automatically set the Stage 2 timer if present to 00 Once the desired time is reached press the line 3 button to save the Stage 1 time The number will stop flashing If a time is set for Stage 1 the user will be able to activate the timed preinfusion program by moving the group head handle all the way to the left into the brew position The brew valve will open and the pump will turn on after the designated number of seconds for Stage 1 time have elapsed Line 4 indicates the amount of time that the pump bypass if present will operate Stage 2 time be gins once the Stage 1 time has finished Operating the bypass while the pump is running as occurs in Stage 2 allows a settable reduced pressure point between line pressure and pump pressure To change the Stage 2 time press the button for line 3 The current set time will begin to flash To alter the time on the indicator press the A or Y buttons until the desired time is reached Once the de sired time is reached press the button associated with line 4 to confirm the Stage 2 time The number will stop flashing To cycle to the next display screen in the menu level press the butto
26. detergent 2 Wipe down the entire machine 3 Remove portafilters baskets and springs drip tray and grates cup tray grates and clean thoroughly These items are all dishwasher safe 4 Slowly pour a pitcher of hot water down the drain Weekly 1 Back flush each brew group using an espresso industry approved detergent 2 portafilters and the removed filter baskets in an approved espresso industry detergent and water solution overnight 3 Rinse thoroughly before reassembling and using your portafilters 4 Carefully remove screens from each brew group using a short handled screwdriver and soak in a similar solution as the portafilters 5 Rinse screens thoroughly before installing and using Make sure you install the screens before brewing any shots of espresso Failure to do so may plug the drain lines with coffee grounds Do NOT over tighten the screws Gently turn them until they are snug but not past that point Monthly 1 Check your water filtration system and make sure the cartridges and filters are changed as needed In areas of high mineral content hard water high particulate count or in very busy locations the filtration systems will need to be checked more often Quarterly 1 Change portafilter gaskets closely inspect diffuser screens and filter baskets change if showing wear Call an authorized repair representative to perform routine maintenance 2 Check legal policies that may prohibit you from completing the next ste
27. e In the case of a Hydra the pump configuration will be set to MULTIPLE Otherwise it will be set to SINGLE These selections will be set at the Synesso factory and should not need to be altered Technical Manual 59 PROGRAMMING Menu Level 3 PID Tune Line 1 indicates that you are on the PID Tune screen The proportional integral derivative controller PID controller is a sequence of algorithms using separate finely tuned parameters to achieve a desired set point Synesso strongly recommends against altering these parameters Line 2 indicates the level at which the Gain Proportional Gain 15 set Line 3 indicates the level at which the Gain Integral Gain is set Line 4 indicates the level at which the D Gain Derivative Gain is set Technical Manual 60 PROGRAMMING Menu Level 3 Serial Number The Machine Serial Number is the designated identification given to the machine according to the month year and order of completion This method of identification may be used to help diagnose any issues or determine any specific needs that may arise during the life of this machine For this reason the machine serial number should not be altered Technical Manual 61 PROGRAMMING Menu Level 3 Return Line 1 indicates that you are on the Return screen Line 2 indicates the option to return to menu level 1 5 operation mode Line 3 indicates the option to return to menu level 2 s settings mode Tec
28. e pump motor and inside the electrical box Synesso recommends changing your portafilter gaskets every 3 to 4 months See the changing portafilter gaskets procedure on page 33 Every nut bolt screw and connection is assembled using Red Loctite Blue Loctite or Food Grade Grease e Red Loctite Seals very quickly and the seal is permanent until heated to at least 500 F To release this sealant the safest heat source is a Heat Shrink Gun e Blue Loctite Seals quickly and holds firm but can be broken without the use of heat Red sealant is used on pipe threads all brass that is not connected to a copper tube and 6 32 threads Blue sealant is used on nuts screws and brass flow jets Food Grade Grease is used on all tube fittings flared stainless steel and brass any moving parts steam valves steam wand steam actuators brew and pump switch rollers and all stainless steel nuts and bolts 5 16 or larger this will keep them from galling Re apply when disassembly and reassembly is needed SPECIAL NOTE VARIOUS TECH BULLETINS ARE REFERRED TO IN THE FOLLOWING TROUBLESHOOTING SECTION I E SEE TEST LEVEL PROBE etc PLEASE CONTACT Synesso TECH SUPPORT TO OBTAIN THESE AND ANY OTHER TECH BULLETINS YOU REQUIRE Technical Manual 28 Category Symptom Possible Reasons and Solutions Brew Pres Brew Gauge Reads e This is normal When the brew tanks heat the water expands and the sure or 11 to 12 Bar w
29. e pump motors 6 Element breaker Controls voltage to all heating elements in the machine Electronics power switch Turns the machine off and on If the machine is plugged into an electrical source the light will be lit red in the On position 8 Conduit Tube Tube containing power and signal lines to elements switches and valves 9 Power board Controls heating elements valves and level fill system 10 Ribbon cable Transfers signals from display board to power board Volumetrics and shot timers use additional ribbon cables 11 Level probe wires and connectors Connect level probes to power board and ground 12 Temperature probe connections Connect temp probes to display board 13 Steam tank element relays Controls voltage to steam tank heating elements Located on lid 14 Heat sink Dissipates heat produced by the element relays Located on lid Technical Manual 26 9990 79 902 90196 BINS JWOMHOD HINOS 60 OSSHNAS dAnd JAIA SSVdA8 dAnd JAVA SSVdA8 3 lVA SSVdA8 dW d 3AIYA SSVdAS8 3313 013 504 1544 HOUMS 15 9 PPP Lf 7102 AV dNNd 1 AVALS L1 SI 038 21 SI 3018 2 Technical Manual Troubleshooting General Notes Many problems can be prevented or minimized by installing the proper water filtration system changing your filters often and regularly cleaning the dust and debris away from th
30. e the A buttons to select the desired scale Fahrenheit Celsius followed by the line 2 button once again to confirm the selection All temperature readings on the machine will now be in the se lected scale The Brew Valve s can be set to the ON or NORMAL position in order to help with draining the brew group s on volumetric machines Setting the Brew Valve function to the ON indicator will ac tivate the brew valve s allowing the pressure to be bled from the brew group s Once the pressure is bled turn the Brew Valve setting back to NORMAL and attach the appropriate drain hose to the brew group s drain tube Set the Brew Valve indicator back to ON once the drain hoses are secure ly attached This will allow the water in the brew group s to fully drain in approximately 5 minutes When the brew group s are finished draining set the Brew Valve indicator back to the NORMAL setting If the draining process takes longer than 5 minutes the machines safety programming will automatically turn the brew Valve indicator to the NORMAL setting while exiting back to the Display Default Overview screen An error message will also be sent to the Error Log that the brew valves have timed out If more time is needed return to the Temperature Display screen and set the Brew Valve display back to the ON position to finish the procedure To set the brew valve s to ON or back to NORMAL press the button associated with line 4 Use t
31. e transformer has failed see voltage output table below or the wires from the transformer to the display have been disconnected e On machines built prior to 01 01 2011 Proper transformer voltages to ground e The green wire is connected to ground and should have no voltage tential Heating Testing Heating Ele DISCONNECT MACHINE FROM POWER SUPPLY BEFORE TESTING Elements ments e Testwith an ohm meter across the element posts 2 Voltage Wattage Ohms 0015 1000 11 to 13 ___ 2004 1 220 2000 46 to 52 each loop 220 4000 23 to 26 each loop 220 5000 18 to 22 each loop e Test the element post to the element body and you should not get a reading of any kind If you get even a quick flash reading remove ele ment and inspect Leaks Hot Water Tap the drip is cold water the water control valve on the cold side of the mix valve is leaking Open and clean the cold water valve e f the drip is warm or hot water the water control valve on the hot side of the mix valve is leaking Open and clean the hot water valve oteam Wand e A small amount of water will naturally accumulate in the steam wand between uses if it is allowed to cool This is normal for any machine Make a habit of purging the steam wand of all accumulated liquids before and directly after steaming a pitcher of milk Technical Manual 34 e f the steam wand constantly drip
32. ecking 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 Tools and recommended Items required to fully diagnose service and maintain Synesso machines Meter reads volts amps and ohms The Fluke 5 600 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 Die and Tap 1 8 NPT and 1 4 NPT for Threads 10 32 and 3 8 16 Set of Allen Wrenches 3 32 15 the brass flow jet 9 64 for the brew valves 1 4 for steam valve seat echnical Manual 4 e Wrenches 11 32 1 4 5 16 3 8 7 16 1 2 9 16 5 8 11 16 3 4 12mm amp 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 e Hand cleaner Towels
33. ed method of energy conservation To cycle to the next display screen in the menu level press the button next to line 1 Technical Manual 43 PROGRAMMING Line 1 indicates that you are on the Hot Water Tap control screen Line 2 indicates the settable amount of time that the hot water tap will run before shutting off Line 3 gives the option of setting the hot water dispersion time by activating the tap and letting the water flow then shutting it off The machine will retain the duration of this pour and dispense for the same length of time when the hot water switch Is activated To change the Hot Water Tap time by tenths of a second press the button associated with line 2 Use the A V buttons to select the desired time followed by the line 2 button once again to confirm the selection The hot water tap will now dispense hot water for the allotted amount of time By selecting the line 3 Program Time you may set the desired time by placing the cup size you wish to fill under the hot water tap press the hot water button on the top of the machine let it reach the desired level and then press the hot water button again This will automatically set the amount of water just dispensed as the Program Time and the actual time in seconds will appear on line 2 To cycle to the next display screen in the menu level press the button next to line 1 Technical Manual 44 PROGRAMMING Line 1 of the Serial Number Disp
34. ed steel hoses _ Clean steam wand tips Steam tube ball valves Check drain manifold hose connections A checkmark in a box indicates that Electrical inspection this item was inspected but not re Ensure electrical box is clean and dry placed If a number is present in the Inspect amp clean temp probe connections box that indicates the quantity of this Check amp draw all zones part that was replaced 21 22 23 124 25 Other parts used Technician comments Suggested maintenance Technical Manual 39 PROGRAMMING This programming manual applies to all Synesso machines after serial number 203111051 These machines have a hand held wired keypad pictured below to allow the user to comfortably view and change the machine settings The machine must be on and at operating temperature to adjust the settings There are 3 menu levels accessible to technicians Menu level 2 may only be reached from level 1 and level 3 may only be reached from level 2 In order to access menu level 2 start on the Temperature Overview screen Press and hold both the line 4 button and up arrow for approximately 4 seconds The screen will cycle to the Temperature Display screen This is screen 1 of menu level 2 To reach menu level 3 On the Return to Operation Mode screen of menu level 2 press and hold both the line 4 button and the up arrow at the same time The screen will cycle to the Volumetrics screen which is sc
35. elected will all light up Place the portafilter used for back flushing into the selected brew group and press any button on the lit pad The machine will now back flush 10 seconds on followed by 10 seconds off for 5 cycles While cycling the button pad lights will go into chase mode to let you know it is currently engaged in the Auto Flush process Once the Auto Flush is completed remove the portafilter and thoroughly clean the diffuser screen The machine 15 now ready for use Manual If the machine does not have volumetric capabilities place the portafilter used for back flushing into the selected brew group and turn the actuator to the on position The machine will now back flush 10 seconds on followed by 10 seconds off for 5 cycles Once the Auto Flush is completed turn off the brew group to allow it to reset remove the portafilter and thoroughly clean the diffuser screen The machine is now ready for use The Auto Flush can be interrupted mid cycle by pressing any button on the selected brew groups button pad with a volumetric machine or by turning the brew group actuator to the off position on a manual machine Interrupting the program will cancel the auto flush process turning the indicator on the control panel back to Enable and resetting the program Technical Manual 42 PROGRAMMING NOTE Options for adjustments to brew groups 2 3 and 4 if applicable will appear on the following screens of the control panel interface Ad
36. he A buttons to select the desired operation mode followed by the line 4 button once again to confirm the selection Once finished with the draining procedures make sure the Brew Valve indi cator is set back to the NORMAL position in order to operate fully To cycle to the next display screen press the button next to line 1 Technical Manual 47 PROGRAMMING Menu Level 2 Steam Tank Fill Probe Line 1 indicates that you are on the Steam Tank Fill Probe control screen Line 2 of this display screen is showing a 5 second delay indicating that the fill probe will wait this long before turning on or off the steam tank fill valve To change the delay time press the button associated with line 2 Use the A buttons to select the desired time and then confirm the selection To cycle to the next display screen press the button next to line 1 Technical Manual 48 PROGRAMMING Menu Level 2 Brew Group 1 Offset Line 1 indicates that you are now in the Brew Group 1 Offset screen Line 2 indicates the actual water temperature at the selected brew group s temperature probe as it is maintaining your Set Temperature Line 3 represents the actual temperature reading of water flow through the puck Line 4 indicates the temperature adjustment made at the Synesso factory in order to create the exact temperature desired at the puck Puck Temperature on line 3 is determined at the factory according to the standard
37. he Steam e Steam valve seal is worn Replace by installing steam valve rebuilt kit Wand Wand Tip e Steam valve handle needs to be adjusted See Steam Valve Handle Adjustment 2 Steam valve is filled with milk residue Disassemble steam valve clean Water bubbles out e Wand ball o ring is worn replace with new teflon o ring from steam around wand pivot valve rebuild kit ball Wand is Hard to e Remove wand mounting nut clean and lubricate wand ball with food Move or Sticky grade grease replace wand ball o ring Steam Valve does e Steam valve handle needs to be adjusted See Steam Valve Handle not Open Fully Adjustment Hot Water Water Flows e f there is pressure in the steam tank and water to the machine is not Tap When the Switch is restricted this indicates the switch has failed Replace the switch On Technical Manual 32 Only Cold Water e Turn the mix valve clockwise until it stops This will cut off all cold water Flows when Switch flow If no water flows with the mix valve off the water control valve on is On the hot side of the mix valve has failed Only Hot Water e Check that the mix valve is not fully closed A fully closed mix valve will Flows when Switch only allow steaming water out to the hot water tap is On e f the mix valve is open a full turn and half and the water flow is still steaming and sputtering the water control valve on the cold side of the mix valve has faile
38. hen expansion valve is set to relieve excess water pressure at 11 to 12 Bar Flow Machine is Not Brewing Brew Pressure is e SINGLE INLET MACHINES ONLY see Brew pressure drops when LOW steam tank fills below e SINGLE PUMP MACHINES ONLY When brewing on one group and another group is activated some water will be diverted to the second or third group This will slightly reduce available brew pressure e Expansion valve may be set too loose Check that the pressure in the brew system reaches 10 12 bar while heating from a cold state If the pressure does not exceed brew pressure the expansion valve will need to be tightened cleaned or rebuilt e Check pump to make sure pressure is properly set Water supply hose to the pump may be kinked 2 Water filter be plugged Check and replace if necessary Brew Pressure e This is common to all single inlet espresso machines The water source drops when Steam is the same for the steam and brew tanks The pump is configured for a Tank fills SINGLE set amount of pressure and when the steam tank fills it diverts water and INLET MACHINE pressure away from the brewing process and into the steam tank If this is ONLY an unacceptable situation there are a few things you can do to minimize or eliminate the pressure drop e There is an auto fill probe delay setting in the programming that is set at the factory to 5 seconds This means that the auto fill probe
39. hnical Manual 62
40. ing it for 1 min an audible alarm will also sound FV Fill valve open time out valve has been held open for 5 minutes OT Over temperature over 270F VM Volumetric system UF Unexpected flow while group is off leaking or filling Example After manual back flush group 2 was not returned to the Off position After 5 minutes the machine will register a BRBV02 and a 2 error which translate to Brew System Brew Valve Group 2 and Brew System Pump Relay is timed out Group 2 errors At this time the machine will automatically shut off both the brew valve and the pump relay to ensure they will not be damaged They will remain off until the group is returned to the off far right position which allows the group to return to normal operation Technical Manual 46 PROGRAMMING The machine must be on and at operating temperature to adjust the settings There are 3 levels of programming Level 1 programs as discussed on the previous pages are also found in the Owners Manual Level 2 and 3 will be discussed in the following pages Menu Level 2 Temperature Display Line 1 O Line 2 O Line 3 O Line 4 O Line 1 indicates that you are on the Temperature Display screen Line 2 indicates the Temperature scale that you are currently in Fahrenheit or Celsius Line 4 indicates the operation status of the machines Brew Valve s To Change between temperature scales press the button associated with line 2 Us
41. justments for Temperature Control as well as Optional Features on these brew groups will be the same as the instructions for brew group 1 These screens are omitted from this manual for simplicity Line 1 The Steam Tank Temperature Control screen indicates the current temperature being recorded by the steam tanks temperature probe 216 9F in this example Once this temperature reaches the set point the digital display will continuously cycle up and down by small increments as the electronics balance the temperature Line 2 is indicating the factory set point of 250 0F 121 1C The adjustable set range for the steam tank is between 170 and 270F 76 6 132 2 Line 3 and 4 are indicating that loops 1 and 2 of the elements are activated To change the temperature set point press the button next to line 2 The current set temperature 250 0F will begin to flash To adjust the temperature settings press the A or Y buttons until the desired temperature is reached Press the button next to line 2 to confirm the new temperature point To turn off loop 1 or 2 of the element press the button associated with the appropriate line The indicator reading Active will begin to flash Press either the or Y button to select off followed by the line 3 or 4 button accordingly to confirm the selection Turning off either loop 1 or 2 of the element can be used as a troubleshooting procedure and is not a recommend
42. ker switch to the ON position and wait a few Technical Manual 10 Technical Manual 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 fac tory 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 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
43. lay indicates the software revision number Ex v1 04 Lines 3 and 4 on the display will indicate the serial number given to this machine This screen will show when starting up the machine Please have this number available if you contact technical support to aid in more rapidly identifying your machine Technical Manual 45 PROGRAMMING Error codes are displayed here In an effort to prevent damage to machines and to help operators troubleshoot issues Synesso has engineered several safeguards into the programming These codes will help users identify operational issues with the machine as well as automatically prevent greater problems from occurring By understanding these codes operators can remedy issues more quickly Error code key Error codes are in this format AABB AA system code BB subsystem code group or section experiencing the issue BR Brew System Codes BV Brew Valve open time out valve has been held open for 5 minutes 01 through 04 groups 1 4 OT Over temperature over 220F UT Under temperature under 180F for 1 minute while group is trying to heat PR Pump relay is on and timed out relay coil has been on for 5 minutes BP Bypass valve open time out valve has been held open for 5 minutes ST Steam system Codes LW Low water probe is dry meaning it is not in contact with water an audible alarm will also sound FP Fill probe is dry water is not touch
44. n without a group in the system if something has gone wrong with a 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 to easily drain the tank In order to drain a brew group remove the pressure from the brew groups by turning off the water cycling through the control panel to the Temperature Display screen on menu level 2 Turn the Brew Valve setting to ON which will allow a small amount of water to run out of the groups Once the water stops select NORMAL on the Brew Valve control line Remove the 1 2 plug fitting on the end of the drain and attach a 3 8 rubber line to drain the water into the drain pan Set the Brew valve control back to ON to completely drain the tank Heating element A 2 leg incoloy and stainless steel heating element which provides the heat for the steam boiler It is controlled by the thermal probes and will be shut off in the case of over heating or low water levels Technical Manual 20 Water Outlet Components cont Low level probe This probe detects when the water has dropped below the level of the probe in the tank sends a signal to the CPU which immediately cuts power to the heating element registers STLWOO error 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 relea
45. n next to line 1 Technical Manual 41 PROGRAMMING This is the third screen of the display BG1 Auto Bypass and Auto Flush Line 1 indicates the brew group to be adjusted Line 2 indicates whether the automatic bypass is currently ON or OFF This feature is only avail able on volumetric machines with bypass hardware installed Line 3 indicates the percentage of the shot that will be completed before the bypass turns on This option only appears when the Auto Bypass indicator on line 2 is set to ON Line 4 indicates the option to do an automatic back flush To program Auto Bypass press the button associated with line 2 The indicator in this case will begin to flash Use the A buttons to select ON or OFF Press the line 2 button again to con firm the selection If the Auto Bypass on line 2 is set to OFF nothing will be displayed on line 3 To set the percentage level on the bypass press the button associated with line 3 The percentage indicator will begin to flash showing it is ready to be adjusted Use the A buttons to select the desired percentage followed by the line 3 button once again to confirm the selection The bypass will now turn on after the selected percentage of the shot is completed The Auto Flush can be activated by pressing the button associated with line 4 Volumetric If the machine has volumetric capabilities the indicator lights on the button pad of the brew group s
46. obe as the electronics maintain your Set Temperature Line 4 indicates the temperature adjustment made at the Synesso factory in order to create the exact temperature desired in the steam tank This offset should not be altered without first consulting cycle the next display screen press the button next to line 1 Technical Manual 50 PROGRAMMING Menu Level 2 System Clock Line 1 indicates that you are currently on the System Clock screen Line 2 indicates the programmable time for the machine in a 24 hr format Line 3 indicates the programmable date settings Line 4 stores the programmed date in the format indicated on line 3 Press the line 2 button followed by the A Y buttons to make appropriate adjustments to the 24 hr clock so that any alarms programmed will work correctly To adjust line 4 press the corresponding button followed by the A Y buttons to select the appropriate date Press the line 1 button to cycle to the next display screen Technical Manual 51 PROGRAMMING Menu Level 2 Power Save Mode Setup Line 1 indicates that you are on the Power Save Mode screen Line 2 of the Power Save Mode in this example 15 indicating the timers are ENABLED making adjustments to lines 3 and 4 available If line 2 reads DISABLED no further programs will be available on this screen Line 3 indicates the settable time at which your power save mode will st
47. p before continuing further Australain operators most not open the electronics box Please disconnect machine from the power supply Check inside the electronics box and gently remove any build up of dust or debris by using a soft brush and vacuum It is also important to keep dust and debris out of the vented ends of your pump motor Lack of airflow will shorten the life of the motor Important Machine service and repair procedures must be performed by authorized service personnel Technical Manual 38 Periodic Maintenance This is the form that Synesso uses when performing Preventative Maintenance visits Preventative Maintenance Visit Checklist Customer Phone Date Serial Number Basic Service Operational Inspection Inspect or rebuild steam valves Replace the following parts Inspect or rebuild water control valves Portafilter Gaskets 8 0 8 6 9 0 Clean adjust lube steam valve acutators Vacuum breaker VB o ring Inspect all tube connections Sight glass o rings Retorque element flange Hot water switch L Inspect drain system for leaks clogs _ Diffuser screens L Lube amp adjust roller switches Pump relay _ Grease brass on brew switch threads Inspect and replace if necessary E Inspect and clean autofill probe _ and motor Assess water hardness ___ valve EV rebuild Inspect for scale buildup Hot water tap aerator 11 Test brew pressure gauge Braid
48. r and bend the screw contact point away from the screw Technical Manual 35 Technical Manual Periodic Maintenance Proper and regularly scheduled cleaning and maintenance procedures are CRITICAL for trouble free and optimum quality performance from your Synesso espresso machine Back Flushing On the current generation of Synesso machines back flushing can be programmed for Auto Flush activation For Auto Flush activation please refer to the programming section of the Owners Manual page 21 1 Replace the filter basket with the provided blind filter basket a single solid basket without holes in one of the portafilters 2 Engage the portafilter in one of the brew groups turn the head to the BREW position and leave it there for 10 seconds Repeat several times in Auto Flush the machine will turn the group head on and off automatically for manual back flushing the operator must manually turn the group on for 10 seconds then off for 10 seconds This procedure should be performed on EACH brew group daily This process forces water through the inlet tube and drain system 3 When using an approved espresso industry detergent during back flushing follow the manufacturer s instructions It is extremely important to thoroughly rinse the blind filter basket and repeat back flushing several times with clean water to clear the system of any detergent residue Cleaning 1 Clean the surface of the machine using a soft damp cloth Avoi
49. r filter changes are a requirement to keep your factory warranty valid and your machine functioning properly It is highly recommended that you Legend contact a professional water filtration specialist in your area and have your water tested 1 group 39 5cm 16 to determine the proper filtration system It is important to note that many municipalities 2 group 67cm 26 m change their water sources throughout the year so periodic water tests may be necessary 3 group 94cm 37 9 Water Standards to keep your warranty valid 1 group 21cm 8 Total Dissolved Solids TDS 30 to 200 ppm parts per million 2 group 48 19 Total Hardness in ppm Less than 85 ppm 3 group 76cm 30 Foot diameter Total Hardness in grains 3 to 5 grains divide ppm 17 1 to get grains 7 3 1cm 1 25 for pH 6 pH to 8 pH d hoses em 9 Chloride 0 ppm any Chlorides can be corrosive and harmful 6 5cm 2 5 3 3 Total Alkalinity Less than 100 ppm z Chlorine 0 ppm View of top of Iron 0 ppm 1 group machine Steam handle I 3 echnical Manual 6 INSTALLATION To maintain the 1 year warranty an authorized or certified espresso service representative must perform the installation of this espresso machine Site Preparation The machine must be placed on a level horizontal surface that can be easily cleaned and 15 capable of sustaining a minimum of 300 Ibs of weight The surface depth should allow for a minimum
50. reen 1 of level 3 Press to move forward to the next screen Press to select this line Press to select this line Press to select this line These arrows change the value of the selected line Line 1 indicates the screen title in this case Temperature Overview Line 2 indicates the operable brew group s and the associated temperature s Line 3 indicates the operations of brew groups 3 and 4 if applicable Line 4 indicates the steam tank temperature to the left and error codes if any to the right On Line 2 of this Temperature Overview display screen brew group 1 represented as BG1 is reading LOW This indicates that BG1 is below the temperature probe s set range of measurement 170F 270F 76 6C 132 2C If the BG1 heating element is on element breaker in the left position for longer than 15 minutes and the indicator continues to read LOW refer to the error indicator on line 4 Check Error Log Codes on page 26 if needed The lowest programmable temperature is 180F 82 2C and the highest programmable temperature is 220F 104 4C The factory set temperature is 203F 95C To change brew groups factory set temperatures refer to page 21 The steam tank reading on line 4 will normally read the factory default setting of 250F 121 1C To change this temperature see page 23 The OK on the right hand side of line 4 is indicating that there are no errors being detected by the control system If in place of the
51. s warm water and is warm to the touch even after an extended time without use the valve will require a new seal Obtain and install a steam valve rebuild kit from your dealer service representative or the Synesso factory e Steam and or water bubbling out from around the steam wand pivot ball indicates that the steam wand ball o ring needs to be replaced This o ring is included in a steam valve rebuild kit Machines produced before 510 will likely benefit from the new teflon o ring which provides an im proved seal and wear resistance e f water leaks from the space between the steam wand handle as sembly and the side panel o rings on the brass pusher rod are worn and need to be replaced These o rings are included in the steam valve rebuild kit The pusher rod can be accessed by removing the side panel and pulling the pusher out from the steam valve Brew Groups Leaking diffuser indicates the brew valve is not sealing properly Open the valve and clean the sealing faces with a soft cloth Inspect the valve for scale and calcium buildup e f water bypasses the portafilter gasket and leaks out around the porta filter when properly engaged and brewing the portafilter gasket will need to be cleaned Use a soft brush and scrub any grounds from the surface of the gasket Rinse with hot water If the issue persists replace the por tafilter gasket General Nonde e Dirty brown water under the machine indicates the drain bo
52. sing 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 overload switch Cuts power to the element if the temperature exceeds 280 F 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 High level probe Detects whether the desired water 2011 3 Group Cyncra outlet left side level has been reached A small amount of Voltage Alternating UP A Wwe Currents 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 counter clockwise 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
53. st Pressure Relief Valve PRV The PRV is a safety release for the steam boiler which opens and releases pressure if the boiler rises 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 Technical Manual 18 Water Inlet Components cont Sight Glass Connected to the steam tank by two tubes 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 Check Valve see Brew tanks check valve description Page 17 Steam Inlet Water Control Valve When the upper level probe detects an absence of water it sends a 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 Inlet Fill Line Dual inlet machines only This is the incoming 3 8 steel braided 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
54. t TURN THE POWER OFF TO THE MACHINE and test element leads for continuity to ground and for resistance across the leads e Relay has failed in the OFF position Heating element turns off because of lack of signal No other parts should be affected Remember when testing for voltage the solid state relay requires some load to function A failed open heating element a tripped switch or a failed fuse will make a solid state relay appear to have failed or be OFF If the LED at the relay is ON and there is no power at the relay On machines T prior to 01 01 2011 Test the fuse Technical Manual pt Cm Check reset switchonthetank o for continuity to ground and for resistance across the leads e Hf all of these tests are ok relay has failed OFF Display is Blank e If the red power switch is in the ON position and is NOT lit there is lack LEDS are lit of power to the machine Check your circuit breaker Check the wall plug if applicable e f the red power switch is in the ON position and is lit check that the lid of the electronics box is tightly secured to the box There is pressure switch on the right side of the box which interrupts power to the electron ics when the lid of the electronics box is loose or removed e On machines built prior to 01 01 2011 If the power switch is lit the safety switch is properly engaged and the display is still dark Either the low voltag
55. t machines above the set point before it Varies by a Few sends a signal to turn off the heating element This will allow the elec Degrees tronics to show a reading just above the set point The energy from the heating element and the tube for the preheated incoming water are within 1 25mm from the location of the temperature probe in the brew tank The pick up tube for brew water is at the top of the brew group and is in the most temperature stable water in the tank The readout can show a temperature of a few degrees above your set point but your brew water is actually at the set point Brew Temperature Be sure to allow 20 40 minutes from the time the machine is powered up Reads Low as the temperatures need to stabilize Ambient temperature and airflow can change how quickly the machine reaches stablility Check that the element breaker is in the ON position Check that the fuse on the power board as well as the relay are both functioning properly BEBE Check that the brew tank thermal overload switch has not been tripped 33 5 Check that the connection to the temperature probe is intact and secure Make sure the set point has not been changed Technical Manual 30 Brew Temperature Display temperature will climb during brewing as high temp water from Reads High the steam tank heat exchanger enters the brew tank This is normal and the water dispensed will be at your set point not the displayed tempera ture
56. to the OFF position Volumetric machines Activate the pitcher button on the right side of the keypad Once the water flows in a steady stream press the pitcher button again to stop the water 5 Make sure the water level in the sight glass reads at least 72 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 on the brew gauge The brew gauge is found on the right hand side of the brew group 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 e Clockwise to INCREASE pressure e Counterclockwise to DECREASE pressure 9 Please allow at least 72 hour of warm time before using your Synesso espresso ma chine to brew shots or steam milk The steam gauge located on the left side of the first brew group 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 unplug the cord taking care to NOT touch the metal prongs on the plug end Turn the electronics ON OFF red roc
57. waits to fill until it senses a continuous signal to fill for 5 seconds and it does not stop filling until is senses a continuous signal to stop filling for 5 seconds This stops the auto fill valve from turning off and on if the water in the steam tank is making intermittent contact with the probe due to internal water movement e Minimize Increase your auto fill probe delay setting to 10 seconds This will reduce the number of times that your steam tank fills It will also increase the fill time each time the valve opens The water level in the steam tank will vary more e Eliminate If you can provide 2 separate sources of water a steam tank source and source run through the pump for brewing it is possible to custom plumb your machine so that this issue is eliminated This takes time skill and extra parts All machines made in 2008 and after have this dual inlet system as a standard feature Retrofit kits are available check with your dealer service provider or the Synesso factory for more infor mation about this upgrade No Brew Pressure Failed pump needs to be replaced Pump Motor is Run ning 21 The line between the pump and the water supply may be collapsed or kinked Technical Manual Water filter may be clogged and should be changed No Brew Pressure e Check that the pump reset button on the face of the control box white Pump Motor is Not button with 10 on it is not tripped poppe
58. ween 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 Tank Check Valve Check valves prevent water from going the wrong way in the hydraulic system Water flow should only go one direction and the check valve ensures that pressuized water from inside the tanks cannot overwhelm the incoming water pressure and go backwards Coffee Inlet Fill Line Single inlet and Hydra machines would have this line only Supplies the brew tanks with water passing first through the heat exchangers Technical Manual 17 Water Inlet Components cont 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 maintain a steeply vertical path to the floor drain Drain tube from brew tanks This copper manifold allows water from the brew valves to discharge 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 As the tanks heat
59. x is script clogged or overloaded Remove the right side panel and clear any ob structions in the drain box Be sure the drain hose has an even steady slope toward the floor drain Kinks dips or flat runs will slow or stop the flow of waste water from the machine drain e A small amount of water may splash between frame panels during a steam wand purge or when rinsing the drip pan The water will then drip onto the countertop or frame of the machine This is normal e Clean water under the machine or on top of the electrical box indicates an internal leak Remove the side panels and facias until the source of the leak is determined Contact your dealer service representative or the Synesso factory for more info on fixing your specific leak General Coffee Crema is e Grinder burrs are dull Replace immediately Thin with Large Bubbles amp Tastes Astringent __________ Coffee is ol e Brew temperature may be set too low e See Vacuum Breaker Explanation Portafilter e Portafilter ears will wear over time allowing the handle to swing further before the basket is fully engaged Use of taller gaskets 8 5mm or even 9 0mm will extend the usable life of the portafilter Ask your dealer ser vice provider or the Synesso factory for more info Diffuser Screen is e This is most likely caused by over filling the portafilter basket with cof Loose fee This causes the expanding coffee puck to push against the diffuse
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