Aromat Cafe D420 User manual
1
D420 Service Manual
Service Manual
D420
Coffee Dispenser
2
Notice
Every effort has been made to ensure that the information contained in this document is up to
date and correct. However, neither the author, the publisher nor the manufacturer will accept
liability for any loss or damage caused resulting from any errors in or omissions of information
contained in this document.
This document may not be copied without the permission of DASS Manufacturing Ltd.
Document Change History
Issue Status Date
010 Draft1 30/05/06
020 Draft 2 05/06/06
030 1st Publlished 06/06/06
040 2nd Publ/d 26/06/06
Conventions Used in this Document
All instructions are given as viewed from the front of the machine.
Descriptions of the components referred to mostly match those used in the Illustrated
Parts Catalogue.
There are no bolts used in the construction of the machine. Hexagon headed screws are
referred to as Set Screws.
DASS Manufacturing Ltd.
SBC House, Restmor Way, Wallington, Surrey, SM6 7AH, United Kingdom.
Tel: +44 (0)20 8669 8012 Fax: +44 (0)20 8669 9529
Email: [email protected] Web: www.aromat-uk.com
© Copyright 2006, DASS Manufacturing Ltd. All rights reserved
Document No: TD D420 03 001
3
D420 Service Manual
Table of Contents
1 Introduction 5
1.1 Using this Manual 5
1.2 Understanding Fault Codes 6
1.3 The Control Panel 6
1.4 Setup Mode 7
1.5 Machine Supplied User Settings 7
2 Engineer Configurable Settings 8
2.1 Making Changes 8
2.2 Putting the D420 into Engineer Setup mode 8
2.3 The Engineer Menu Structure 9
2.4 Machine Supplied Settings 9
3 Obtaining Replacement Parts 10
3.1 Illustrated Parts Catalogue 10
3.2 Using Web Site 10
3.3 Obtaining User name and Password 10
3.4 Locating Part Illustration, Description and Number 10
3.5 On-line Parts Enquiry Form 10
3.6 Exploded View Assembly Drawing 10
4 Preparing the D420 for Servicing 11
4.1 Preparing a Suitable Work Area 11
4.2 Noting Machine Settings 11
4.3 Removing the Casing Panels 12
4.4 Refitting the Casing Panels 12
4.5 Disconnecting / Reconnecting Power Supply 13
4.6 Disconnecting / Reconnecting Water Supply 14
4.7 Draining the Tank 14
4.8 Draining Water Inlet Hose Pipe 15
5 Servicing Tank and Water Supply 16
5.1 Replacing the Water Inlet valve 16
5.2 Replacing Water Outlet Valves 16
5.3 Setting Water Outlet Valve Flow Rate 17
5.4 Replacing Heating Elements 19
5.5 Replacing Boiler Temperature Control Thermister 21
5.6 Calibrating the Thermister 21
5.7 Replacing Boiler Over Temperature Thermostat 23
5.8 Replacing a Float Microswitch 23
5.9 De-scaling the Tank 24
5.10 Cleaning Water Outlet Valves 25
4
6 Servicing Control Panel 27
6.1 Removing / Refitting Control Unit Assembly 27
6.2 Updating the PCB Processor Chip 27
6.3 Replacing the Control PCB 29
6.4 Replacing Set Up or Prime/Flush Membranes 29
6.5 Replacing the Display Unit 30
7 Servicing the Cooler Unit 32
7.1 Removing / Refitting Cooler Unit 32
7.2 Checking Product Detect System 32
7.3 Checking for Channel Changeover 33
7.4 Replacing Peristaltic Pumps 36
7.5 Adjusting a Peristaltic Pump 37
7.6 Replacing Heat Pump 39
8 Servicing the Power Supply Unit 40
8.1 Removing / Refitting PSU 40
8.2 Removing / Refitting PSU Cover Panels 41
8.3 Replacing a Relay or the Contactor 42
8.4 Replacing the Switched Mode PSUs 43
8.5 Replacing the PSU PCB 44
9 Technical Specifications 46
9.1 General Specifications 46
9.2 Main Looms Diagram 47
9.3 The Control PCB 48
9.4 PSU wiring diagram 49
Appendices
A Calibrating a Suitable Container 50
B Recommended List of Tools 51
C Machine Settings Form 52
D Cleaning and Sanitising Instructions 53
E PSU front Cover Label 54
5
D420 Service Manual
1 Introduction
1 2 3 4
Coffee at its Finest ...
Dispense Extension Hose
Mounting Plate
Control Panel
Door LatchRH Cooler Unit Door
Dispense Extension Hose
Hot Water Only Button
LH Cooler Unit Door
Coffee Mixing Chamber
and Coffee Nozzle
Power ON / OFF switch
Adjustable Leg
Hot Water Nozzle
The D420 Coffee Dispenser requires minimal maintenance. The selection of procedures listed
in this document is based on the service requirement history of other machines produced by
DML.
To attain the highest levels of quality and reliability, the D420 will undergo continuous design
development during its life cycle. This document will therefore be updated regularly to reflect
any changes.
WARNING: Before replacing any major component, it is essential that the machine is
isolated from both the power and water supply.
1.1 Using this Manual
This manual describes the processes for the machine’s operation, how to obtain
replacement parts and instructions for carrying out the most probable maintenance
procedures.
In order to avoid the repetition of basic tasks, the document has been carefully sectioned
to enable the service engineer to extract the relevant sub sections for reference when on
site.
It is designed to be updated on a regular basis and will not be published in hard copy,
although a pdf version will be available for downloading from the DASS Technical Web
Site. Before carrying out any maintenance on the machine, the service engineer should
consult the web site and either download the latest pdf version of the entire document or
print off the relevant individual (html) web pages.
To identify the parts referred to in this manual, you may find it useful to view the D420
Illustrated Parts Catalogue, available from the web site.
As this manual is under constant review and development, any comments or advice from
service engineers that would improve the document would be welcomed. Please email
any comments to [email protected].
6
1.2 Understanding Fault Codes
The table below describes the D420’s Fault Codes:
Fault Description / Cause
Overflow Too much water in tank
Float Fault Logical fault. Overflow detected but insufficient water in
tank. Possible stuck float or faulty switch.
Thermostat Trip Thermostat has detected boiler overheat. Possible faulty
thermostat.
Possible Leak Actual leak or there has been no dispenses over 15 boiler
refills. This can occur due to evaporation in the tank.
Lack of Water During normal operation after machine has filled for the
first time, the inlet valve has been open for more than 15
minutes. Possible main water valve closed, low water
pressure or faulty inlet valve.
Lack of Water #1 The initial water fill from empty has taken longer than 25
minutes. Possible inadequate water flow or pressure.
Water overheat Thermister has detected water is too hot. Tank water
temperature is higher than top temperature setting.
Possible faulty thermister.
1.3 The Control Panel
12
1
PRIME PRIME
FLUSH
2
34
3
PRIME PRIME
FLUSH
4
Standby Mode switch
Display Panel
Product Low warning lamp
Mode keyswitch
SERVICE warning lamp
Product Channel PRIME button
Boiler Valve FLUSH button Boiler Valve FLUSH button
Product Select buttons Product Select buttons
LH Cooler door lock
Machine READY lamp Down button
Enter button
Up button
RH Cooler door lock
STOP button
O
I
Note: On some earlier models, the Mode keyswitch is located on the top left side of the
control panel and the Standby rocker switch is located on the top right side of the control
panel. It may be necessary to open the cooler unit doors to access these switches.
7
D420 Service Manual
1.4 Setup Mode
To view the user settings, put the machine into SETUP MODE by turning the Mode
keyswitch.
SETUP MODE
Press Selection
The menu options are:
• Selection
• Speed
• Strength
• Set Channel?
Scroll through the options by pressing the Enter button.
1.5 Machine Supplied User Settings
The machine was configured in the factory with the following user settings:
Button No. Speed Volume Strength Channels
1 3 10 gal 40:1 1&2
23 5 gal 40:1 1&2
32 Airpot 40:1 1&2
43 10 gal 40:1 3&4
53 5 gal 40:1 3&4
62 Airpot 40:1 3&4
The strength ratio means that 1 part of coffee concentrate is added to 40 parts of water.
Note: These settings may have been changed by the Installation Engineer to suit the
customer’s requirements.
8
2 Engineer Configurable Settings
1 2
1
PRIME PRIME
FLUSH
2
3 4
Standby Mode switch
Display Panel
Mode keyswitch
Product Channel PRIME buttons
Product Select buttons Product Select buttons
Down button
Enter button
Up button
STOP button
Boiler Valve FLUSH button
Note: On some models, the Mode keyswitch is located on the top left side of the control panel
and the Standby Mode Switch is located on the top right hand side of the control panel. It may
be necessary to open the cooler unit doors to access these switches.
2.1 Making Changes
DASS Manufacturing Ltd. will not accept liability for any damage or losses caused as a
direct result of any changes made to the machine by the service engineer when carrying
out any of the procedures described in this manual. All replacement parts used in the
D420 dispenser should be approved by DASS Manufacturing Ltd.
2.2 Putting the D420 into Engineer Setup mode
1 Turn the Mode keyswitch to put the machine into SETUP MODE.
2 Press PRIME 1 and then PRIME 2; the following will display:
ENGINEER SETUP
Press
3 Press the Enter button. The display will change to:
Temp Display
Fahrenheit
Scroll through the menu by pressing the Enter button.
9
D420 Service Manual
2.3 The Engineer Menu Structure
In ENGINEER SETUP mode, the following settings may be changed:
• Temperature Display
• Maximum Temperature
• Enable / Disable Coffee
• Enable / Disable Water
• Product Choices
• Peris Speed Offset
• Enable / Disable product Sensors
• Enable / Disable Leak Detect
The D420 Installation Guide provides basic instructions for changing these settings.
2.4 Machine Supplied Settings
The machine was configured in the factory with the following user settings:
Temp Display Fahrenheit (USA) or Celsius (EU)
Set Max Temperature=194F or 95C
Coffee Enabled
Water Enabled
Product Choices 2 + 2
Product Sensors Enabled
Leak Detect Enabled
Note: Peris Speed Offsets will differ between machine and pumps.
Note: These settings may have been changed by the Installation Engineer to suit the
customer’s requirements.
10
3 Obtaining Replacement Parts
3.1 Illustrated Parts Catalogue
A printable illustrated parts catalogue can be downloaded from the PDF Bank on the
Aromat Technical Website.
3.2 Using Web Site
To access the technical website go to: www.aromat-info.com and click on Technical
Documents. This will take you to the Technical Centre which is in both English and
German. A Username and Password is required to enter the site.
3.3 Obtaining User name and Password
Complete and send the on-line Registration Form or send an email to:
3.4 Locating Part Illustration, Description and Number
Select Parts Lists from the left menu and then D420 at the top of the Navigation page.
Select the version to reach the Parts Lists overview page. Clicking on an assembly
image will open a new window with an annotated exploded view of that assembly.
Clicking on the assembly menu will take you to the relevant section in the parts list.
Parts Lists Overview Page
3.5 On-line Parts Enquiry Form
Having located the part, selecting Parts Enquiry from the left hand menu will open a new
window with an on-line form. Complete the form and press SEND. A representative of
DASS Manufacturing Ltd. will get back to you with prices and availability of parts as soon
as possible.
3.6 Exploded View Assembly Drawing
A printable composite exploded view of the D420 assembly can be downloaded from the
PDF Bank on the Aromat Technical Website.
Table of contents
