RS-BunaCafe kit. Installation manual internal version.

Transcription

1 RS-BunaCafe kit Installation manual internal version

2 Contents 1. Introduction Recommended equipment Kit contents Optional kit Disassembly the coffee machine Drilling the front panel Kit installation Electrical Schema

3 1. Introduction This manual is used for installation of the PID kit for the coffee machine Rancilio Silvia (internal version) developed by BunaCafe - PROFNET s. R. O.. Rancilio Silvia's name and trademark owned exclusively by Rancilio Macchine per Caffè. S.p.A. Because the installation is performed on a device using a 230V AC voltage, it should be installed by a person with adequate electrical skills. The person performing the installation of this kit must be aware of the risks that may occur in case of improper installation. A particular risk of electric shock, burns and other injuries (in the worst possibly fatal injury). Before starting the installation please first read the entire manual. From now any modification of the machine will result in loss of warranty. The user manual describes in detail how the kit works. You'll also find instructions on the various versions of the kit and the available options. The material is identical for all three versions (S, M, and L). The upgrade to a higher version is done in software. The manual also includes installation instructions for optional equipment (pressure gauge, LED, water level sensor). We will be very happy if after installation you will share with us experiences, suggestions and ideas on possible improvements to the actual electronics, software, and this manual (obchod@bunacafe.eu). We provide you full support in case of problems / questions during installation, please contact us Recommended equipment Tool: Phillips screwdriver PH2, PH1. Screwdriver flat 2-3mm, 4-5 mm. Screwdriver Torx T10 (p Included in the kit). Allen key 6. Flat spanner M5.5, M7, M10, M12, M13, M14, M16. Drill for metal 3.5 mm. For cutting holes: Drill bit 2-3mm. Drill bit 10,5mm. Round crown drill bit 52mm. Flat file, half round and round file. Files for deburring. Not required but recommended: Flat tweezers Extended Phillips screwdriver PH1. Long Pliers. Pliers. Socket wrench M5.5, M7. Plumber sealant. 3

4 3. Kit contents Fig 01. Overall view of the contents of the kit including optional extras Fig 02. Power module Fig 03. Display module Fig 04. Control module Fig 05. Control module box opened Fig 06. SSR Fig 07. Ties 6 pieces Fig 08 Torx Fig 09. Front panel for display module T10 with buttons 4

5 Control module mounting Screw M3x20 / T10 s washers and nuts (cylinder head) Screw M3x16 / T10 s washers and nuts (cylinder head) Screw M3x16 / T10 s washer and nut (countersunk) 2x screw 2,9 x 6,5 / T10 Mount the power module 2x screw M3x10 / T10 2x varistor 2x screw M3x20 / T10 Fastening lid of the box control 2x screw M4x12 s washer and nut Mount power module on L fixture 2x nylon spacer M3 x 5 Mount display module with front panel Teflon tape "L" fixture Silicone protective tubing Cabling: Cable. 1 Cable. 2 Cable. 3 Kab. 2 Cable. 4 Cable. 6 Cable. 5 Cable. 10 5

6 4. Optional kit Manometer (pressure gauge): Pressure gauges with glycerine filling, capillary cap nuts, manometer holder, T-piece Water level sensor: Screws brass M4x30 Nut and washer. Cable. 9 Cable. 7 LED: Cable. 8 6

7 5. Disassembly the coffee machine After unpacking coffee machine from the box, remove the water tank and drip tray with grid. Remove the top cover of the coffee machine (stacking cups) unscrewing the four cross head screws. Fig. 13. Fig. 1 Fig. 2 Fig. 3 Continue removing the rear cover of the coffee machine by loosening the screws does not have to unscrew entirely see figures 4 to 5, only allow that they can be simultaneously ejected from the rear cover frame. Furthermore, loosen the screw, see Figure 6 - Trimming cover - below the bottom of the reservoir with a Phillips screwdriver. For complete removing of the cover it needs to be stretched over the width of the cover sheet and eject backwards under constant expansion - you need to pay attention to the possibility of scratching the paint to overturning the cover plate under the tank, so you need to carefully take off the back cover while stretching. Fig. 4 Fig. 5 Fig. 6 7

8 Remove the black metal cover under the tank by unscrewing the two cross-bolts, see figure. 7 Fig. 7 For cutting the hole for the display and control buttons it is convenient and comfortable for work to take off the front cover but it is also possible to carve a hole directly on the cover fitted on the machine. It depends on your decision. To remove the cover all switches must be removed. Disconnect connectors from switches and neon. Figures 8 and 9. Fig. 8 Fig. 9 Remove switches and neon tube from the front panel and remove by pulling the control valve, steam / water from the front panel Figure 10. Switches can be remove by pressing the locking elements with a flathead screwdriver. Locking elements are located on a pair of top and bottom of the switches. Use caution when removing switches, which could scratch the front panel. Fig. 10 8

9 Loosen the screws securing the front panel. They are located beneath the brew head inside the front panel see figure 11. Fig. 11 Unscrew the four screws holding the front panel in the frame of the machine. Figures 12 and 13. Remove the front panel. Fig. 12 Fig. 13 Unscrew the two screws on the chromium head cover and remove it by tilting. Fig. 14 to 16 Remove the lower front cover by unscrewing the two screws. Fig. 14 Fig. 15 Fig. 16 9

10 6. Drilling the front panel Cutting holes for the display and the gauge can be a tricky step depending on the equipment and the experience of each. Therefore, here we will only give our brief recommendations. After removing the Rancilio logo on the front panel, we will use the holes left by the logo for fixing the display. But first, we will use these holes to attach a template to mark the buttons and the display. Figure 17. Fig. 17 Insert in the red holes the M3x20 countersunk screws and insert them in the holes left by removing the Rancilio logo. With an appropriate tool (awl) mark the centers of the holes for the buttons or the corners of the display. Another option is to draw the window by placing the display plate of stainless steel. Cutting the display window must be greater than about 0.5 to 1 mm on each side. Mark the center of the gauge on the front panel of the machine. The vertical axis of the gauge coincides with the vertical axis of the power switch and orange light. The horizontal axis of the pressure gauge is located at half the distance between the bottom of the front face and the bottom of the power switch. Before cutting and piercing the front panel it is highly recommended to protect it using masking tape or sheet to avoid any risk of scratching. Carefully drill the holes for the buttons and remove the metal deposits to avoid damaging the front panel. It is better to pre-drill with a smaller diameter drill bits in order to not damage the panel. You can create the display windows with a suitable cutting disc in stainless steel, for example with a Dremel like tool. For the pressure gauge you can drill the hole with a round crown drill bit 52mm. Deburr different holes. Check the dimensions by placing the plate of stainless steel. The holes for the buttons and the screen should be slightly larger (about 1 mm) so that the display can be embedded properly. The buttons must also have the necessary clearance for their proper handling. Fig. 18 Fig

11 7. Kit installation Disconnect the three-way valve and remove the spacer according to figure 20a. Fig. 20a Place the control box lid and mark the locations of the holes with an awl. Fig.20b. Fig. 20b Align the bottom mark previously made to the control box with the bottom hole of the SSR relay. Then mark the location of the upper hole of the relay, figure 21. Fig

12 Drill 3 holes using a drill bit diameter 3.5 mm at the marked locations. Mill the first hole as Figure 22 so that the head of the M3x16 screw does not exceed from the surface. When drilling be careful not to damage the wiring present on the other side of the wall. Insert the countersunk screws M3x16. Figure 23 Fig. 22 Fig. 23 On the other side of the wall attach the SSR relay with a washer and M3 nut as Figure 24. Fig. 24 Mounting the pressure gauge: Unscrew the hose from the pump (M13 nut) and use a wrench M10 or M12 to counter twist on the sleeve of nylon. Figure 25. Fig. 25 Unscrew the elbow of the pump with a wrench M12 Figures

13 Fig. 26 Fig. 27 Prepare the tee by applying an appropriate seal on it e.g.: Teflon tape or sealant suitable for drinking water and high temperatures. Screw the connector to the nylon sleeve according to figures To avoid damaging the threads eventually leave 1 or 2 thread exceed. The length of the connector could also damage the pump strainer if it was too inserted. Fig. 28 Fig. 29 If you use a plumber sealant remember to respect the drying time indicated before performing a pressurization test. Example of using Teflon tape in Figure 89. Installation of the electronics. We will start by the control module. Fig. 30a Fig. 30b Fig. 30c 13

14 Carefully separate the processor board (blue) from the control board (green). To avoid bending the connectors, be sure to separate the cards in parallel. When reassembling the two cards you must ensure to match the connectors on both cards at the risk of damaging them irreparably. Fig. 30a, 30b, 30c. Prepare screws M3x16 and M3x20 pan head and the plastic washers M3, see Figure 30. Fig. 30 The USB port on the processor board slides into the case. The M3x20 screw must be inserted into the bottom hole, it also serves to fix the SSR relays. Figures Fig. 31 Fig. 32 Make sure that the processor board is in contact with the right edge of the box. Figure 32. Attach the housing to the frame as well as the relay. Figures 33a and 34. Fig. 33a Fig. 34 Power cables (red and blue) pass through the hole in the frame where also passes the hose from the pump to join the power module. 14

15 Reconnect the connectors to the coil 3-way valve and route them that they ran along the box as shown in Fig. 33a and 33b. You can help by turning the coil connectors, first loosen the bottom nut under the coil with a flat wrench M16. Fig. 33b Brew head temperature sensor Remove the screw (Allen) from the brew head. Let the copper seal the hole. Insert the bolt into the hole of temperature sensor and apply sealant around the perimeter of the screw at the end of the thread. Firmly tighten the screw on the head. See Figures Fig. 35 Fig. 36 Make sure the sensor is tight and directed as shown Fig.37. It should be tilted in order to let the stainless steel plate during reassembly. Fig

16 Front panel Reassemble stainless steel plate on the top of the group. Figure.38. Fig. 38 Insert the pressure gauge on the front panel of the coffee machine. To facilitate insertion, it should better to remove the rubber filler cap and replace it after installation. Attach the gauge with the mounting, see Figures Tighten carefully to avoid bending the front panel. Fig. 39 Fig. 40 Screw the capillary pressure gauge and tighten the lock nut. This will seal them. Do not overtighten the nut as it could break the solder of the capillary head. Place the front panel on the machine, pass the capillary pressure gauge through the hole in the frame where already passes the flexible hose from the pump. The drain pipe of the discharge valve must not be bent or crushed, water must be able to flow freely. Figures 41 and 42. Wait before attaching the front panel of the machine, it will make easier the handling of the wiring. Fig. 41 Preparing the Wiring [Cable 1]. Insert the switch controlling the steam in its location. Connect the lower left pin with its original cable (two black wires), the lower right connector with its original cable (two red wires). Please have the cable 1 (see page 5). Connect the upper left pin with the red wire of the cable 1 as shown in Figure 43. Connect the upper right pin with the original cable (1 gray wire). 16

17 Fig. 43 Fig. 42 For a good functioning (elimination of transient states and comply with EMC standards) switches from hot water and coffee distribution must be equipped with varistor but this is not mandatory. This adjustment eliminates interference generated by switching on and off switches that might in some way affect the operation of the electronics, display, etc. If you opt for this change, solder the supplied varistor (varistor provided may be different from those shown in the example) to the switch according to Figure 44. Solder them so as to leave the connector entirely free as in figure 45. Fig. 44 Fig. 45 Insert the hot water switch into its slot and connect the lower left pin with its original cable (two black wires). On the bottom right connector, connect the original cable (two red wires). On the upper left pin connecting the two black wires of the Cable 1. See Figure 46. The right upper connector remains free. The other end of the black wire of the Cable 1 route along the reinforced hose through the hole in the frame to the pump. It is the phase of the 220V power supply. 17

18 Fig. 47 Fig. 46 The original connector with two white wires remains disconnected and it is recommended to isolate it with an electrician's tape or other appropriate way to ensure that it is not in contact with conductive metal parts of the coffee machine. As in Figures 47 and 48 insert the last switch in the front panel of the machine. Connect the lower left pin with the original cable (black wire) and the lower right pin with the original cable (red wire). On the upper left connector, connect the double lug of the red wire of the Cable 1 and on the upper right connector connect the double lug of the blue wire of Cable 1. Orient lugs as shown in Figure 47 (free lug upwards). On the double lug of the red wire connect the original cable with white wire. On the double lug of the blue wire connect the original cable with an orange wire See Figure 48. Obr. 47 Fig. 48 Pass the connector with five wires of Cable 1 to the control box by sliding it between the frame and the stainless steel plate from the front panel as in Figures 38 and

19 Insert the main switch and the orange light in the front of the machine. On the bottom left switch connector plug the brown wire on the lower right connector plug the blue wire. On the upper left plug the original cable connector with two black wires and on the upper right connector plug the original cable with two red wires. Please have the Cable 3, connect the double lug to the bottom connector of the orange indicator light. Connect the black wire to the original free socket from the Cable 3. Then connect the upper pin of the indicator light with the yellow original cable as shown in figures 49 and 50. Attach the front panel of the coffee machine, four bolts on the frame and two screws on the head of the group, the same as during disassembly as shown in Figures 11, 12 and 13 The Cable 3 should follow the power cable to the SSR relays and pump. Fig. 49 The remaining blue wire of Cable 1 must be connected to cable with two gray wires from the right thermostat on the boiler (without the red dot) see figure 51. Fig. 50 Fig. 51 Please have the 2A cable, remove the cable with two red wires present on the left boiler thermostat (the one with a red dot) and connect it to cable 2A see figures 51 and 52. Take the cable 2B, remove the cable with two yellow wires present on the right boiler thermostat (the one without the red dot) and connect the cable 2B see figure 51. Then route the cables through the hole on the frame to the SSR relays. See Figure 53. Fig. 52 Fig

20 Connect the end of the Cable 2A and 2B to the SSR relays as in Figure 54. Note: Cable 2B that is provided in the kit can have a different color (it can be red or blue). Connect the Cable 4 to the SSRs with the correct polarity! The ends of the Cable 4 and the Cable 2 must be sent to the other side through the hole in the frame to be connected to the control module. See figure 54. Then set up the protection cover of the SSR relay. Figure 57. Fig. 54 Unplug the connector with a white wire from the pump. Isolate and fix this connector as it will be no longer used. Connect in its place the black wire of Cable 1. Figures 55 and 56. Fig. 55 Fig. 56 To facilitate handling, it is possible to rotate the pump, replace it after completing the connections. Screw the flexible and the capillary of the manometer to the T-connector. Hold the connector with a wrench M11 - M12 depending on the type used, see Figure 57. Tighten the capillary nut so that it do not move. It is not necessary to tighten it too much, it may cause damage.. Fig. 57 Fig. 57a Fig. 57b Pass the Cable 7 through the frame hole where the 3-way valve is located. Hold the end with the clamp of the water inlet hoses. See figures 57a and 57b. 20

21 At this point, it is recommended to perform a pressurization test. Pressure test: Immerse the two tubes into a container with enough water. Open the valve dispensing water / steam and put a container under the nozzle. Turn on the power switch and the switch of dispensing hot water. Wait until the water begins to flow smoothly from the nozzle. This will fill and bleed the boiler. Close the valve dispensing water / steam. The system is pressurized. On the manometer you should watch the opening pressure of overpressure valve about 10 to 12 bar and the outlet tube of OPV will leak water. Check capillary manometer at both ends that are not apparent water leaks then the whole T-piece and the screw head which is mounted the temperature sensor. Alternately open and close the valve. If leaks appear, it is necessary to tighten or seal the screw head. If everything is correct, you can continue. Water lever sensor: The water level sensor consists of two brass screws. The low water level is detected when the level drops below the first screw. Sometimes a trickle of water still on the tank wall between the two screws when the water level goes down, this can create a connection between the screws and thus delay the detection of low level. The screws should be placed on the side of the tank, careful not to position them at the support of the filter cartridge. Beware also not too low place the lower screw on the tank in order to put the nut. Place the upper screw at the desired detection level. Drill a 3.5 mm diameter hole. Place the two loops of the cable 9 on the screws and insert the screws into the tank by applying previously Teflon tape or mastic alimentary to create the seal. Tighten everything right, let dry, and then make sure the tank is still sealed. Figures Fig. 58 Fig. 59 Fig. 60 Fig

22 Mounting the power module: Attach the bracket as shown in Figure 62 with the M4 screws. Fig. 62 Fig. 63 Attach the power module to the bracket using two screws 2.9 x 6.5. Figure 63. Connect the green and yellow wire from the power supply to the boiler Figure 64. Then connect the Cable 3 as the phase and the blue wire of the Cable 2a as the neutral on the power module, see figure 65. Connect the red and the blue wires (12V out) of the power module to the same colored wires of the control module, see Figure 65. Fig. 64 Fig

23 Boiler temperature sensor. Prepare the Cable 5 sensor and insert the black silicone sleeve with a longitudinal cutting. Figures 66 and 67. Fig. 66 Fig. 67 Loosen the thermostat without red dot on top of the boiler. Insert the temperature sensor between the thermostat and boiler. The white insulating part must stay outside. Use several black silicone sleeves and arrange them between the boiler and thermostat so that when you will tighten the thermostat, it will apply a uniform pressure. Do not overtighten so as not to damage the sensor. Figures Fig. 68 Fig. 69 Carefully insert the plugs of various sensors on the control module board. Figures Fig

24 Connection of the control module. Plug the connector of the flat cable (Cable 10) so that it faces up to the plate. The red wire on the left. Figure 71. When you reconnect the control board to the processor board, be careful that the pins are connected to the correct connector. A poor connection can cause the destruction of the two boards, so be 100% sure that the boards are properly connected. Fig. 71 Fig. 72 Fig. 73 Connect the white wire to the connector as shown in Figure 74. Continue by connecting the various elements as in Figure 75. Fig. 74 Fig

25 If you use LED option, connect them as shown in Figure 76. Organize cables and protect them with the white silicone tube included in the kit. Fasten them with cable ties also provided and make sure to minimize the surface area in contact with the boiler. Figures 75 and 77. Arrange the cables in the manner of Figure 76. During the installation, let the connectors of SSR relay and Cable 1 disconnected. At the end of the installation and before closing the module cover, it is recommended to test the coffee machine. Fig. 76 Fig

26 Arrange and tie the cables together using cable clamps so they do not touch metal parts of the coffee machine. They must be securely bound and be at a sufficient distance so that the vibrations do not make them be in contact with metal parts. The boiler temperature sensor should be left off. See figure 78 Fig. 78 Connect the end of the Cable 10 where ferrite is located on the display. Figure 79. Fig. 79 Attach the display module and stainless steel plate on the front of the machine. Use countersunk screw Torx M3x20 and use 5mm nylon spacers. Tighten them so that the display can t moves and that you can press the control buttons. The buttons must not get stuck. The LCD may be deformed if tightened too strongly, this may affect the display. Figures 80 and

27 Fig. 80 Fig. 81 Connect the flat Cable 10 to the display module. Figure 82. Fig. 82 Before closing the control module it is recommended to test everything. Check that everything is properly connected and working properly. Especially check the correct operation of the LEDs as well as the calibration of temperature sensors. During installation, it is possible that the calibration resistance is maladjusted. To calibrate temperature sensors, disconnect the SSR relay and adjust the sensors so that they display the ambient temperature. If there is a small difference between room temperature and the temperature measured by the sensors, it is not necessary to recalibrate it. Fig. 83 Calibrate the sensors by turning the variable resistor, figure 84. Fig

28 Once all devices are connected (sensors, display, relay, LED), close the control module by taking care to not pinch the cables. Use the two Torx screws M3x10 countersunk heads. Figure 83. Please have the rubber pad that replaces the metal spacer necessary for fixing the right part of the front panel. Insert the pad between the control module and the machine frame. If the pad has difficulty to be inserted you can recut it. Figures 85, 86, 87, 88. If the pad does not stay in position, it can be held in place by pin or hard wire. Figure 86. Fig. 85 Fig. 86 Fig. 87 Fig. 88 Machine reassembly. Make sure all cables are connected properly. Start by replacing the black cover plate at the tank as shown in Figure 7. Put the chrome cover at the top of the group. You can use a screwdriver to lift the stainless steel plate on the head of the group. Be careful to prevent scratching. Replace the panel by sliding it behind the chrome cover and leaving out the LED cables. Screw the panel using two screws and then finish by screwing the chromed plastic cover. Figures 14 and 15. Attach the back panel of the coffee machine. Attach it to the frame using two screws. Check the alignment of it before tightening the screw located inside the machine. See Figures 4, 5, 6. If you previously removed the nuts of the frame put them back in place. Then align and fasten the front panel of the machine. It remains for you to set the LED below the front panel. Degrease surfaces with alcohol. The LED modules are equipped with double-sided 3M tape. Simply remove the protective film and place the module. Strongly pressing it for a few seconds until they stick. Fig. 89 E.g.: Usage of Teflon tape to seal the joints. 28

29 8. Electrical Schema Main SW RTD2-1 RTD2-2 RTD1-1 RTD1-2 HEAT-1 HEAT-2 RTD Head RTD Boiler SSR Heat SSR Heat N L PE 165 C t o PT100 M Pump Z 3Way Water SW U U Steam SW Brew SW Sys-5 Pump Sys-2 Sys-1 Brew SW L N PE Sys-4 Sys-3 Steam SW + 12V 29