Summary of Contents for Aromat Cafe D4 Digital
- Page 1 Powerplex Digital Range Service Manual Powerplex Digital Range (D4 Digital, D5 Digital) Service Manual...
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Page 2: Notice
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. -
Page 3: Table Of Contents
Powerplex Digital Range Service Manual Table of Contents Notice Conventions Used in this Document. Introduction Using this Manual Understanding Fault Codes Powerplex Digital Control Panels 1.4 Powerplex Digital Set Up Panel 1.5 Powerplex D4di Selection Switch Membrane 1.6 Powerplex D5di Selection Switch Membrane Machine Supplied User Settings Power Options Engineer Configurable Settings... - Page 4 Servicing Control Panel and Display Removing / Refitting Control Panel Assembly Replacing the Control PCB Updating the PCB Processor Chip Servicing the Cooler Unit Removing / Refitting Cooler Unit Checking Product Detect System Replacing a Peristaltic Pump Motor Adjusting a Peristaltic Pump Servicing / Replacing a Heat Pump Cleaning / Replacing a Cooling Fan Cooler Unit Performance Testing...
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Page 5: Introduction
Powerplex Digital Range Service Manual Introduction D4 Twin Nozzle Digital D5 Digital The Powerplex Digital Coffee Dispensers The Powerplex digital range of coffee dispensers require minimal maintenance. The selection of procedures listed in this document is based on the service requirement history of Powerplex machines produced by Dass Manufacturing Limited since its launch. -
Page 6: Understanding Fault Codes
1.2 Understanding Fault Codes The table below describes the Fault Codes displayed on the Powerplex Digital Dispensers: Fault Description / Cause Overflow Float 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. -
Page 7: Powerplex Digital Set Up Panel
Powerplex Digital Range Service Manual 1.4 Powerplex Digital Set Up Panel Standby Prime Flush Switch Switches Switch Standby Mode Keyswitch The functions of the switches are described in the Powerplex Digital Dispenser User Guide which may be downloaded from the web site. 1.5 Powerplex D4di Selection Switch Membrane Digital Display Hidden Buttons... -
Page 8: Power Options
Powerplex D4di Button No. Speed Method Type Volume Strength Channel Preset Coffee 40:1 Preset Coffee 40:1 Preset Coffee 40:1 Preset Coffee 40:1 Preset Coffee 40:1 Preset Coffee 40:1 Preset Water Held ON Water The strength ratio 40:1 means 1 part of coffee concentrate is added to 40 parts of water. 1.8 Power Options Every machine leaving the factory is designed to provide a range of power options, selectable at installation. -
Page 9: Engineer Configurable Settings
Powerplex Digital Range Service Manual Engineer Configurable Settings It is necessary to open the cooler unit door to access the Control Panel switches. Standby Prime Flush Switch Switches Switch Standby Mode Keyswitch The Control Panel for the Powerplex Digital Range 2.1 Making Changes DASS Manufacturing Ltd. -
Page 10: Machine Supplied Settings
Note: Setting Elements on with Inlets = YES allows heating of water during filling by overriding the thermostat. Note: Setting Elements on with Selection = YES allows heating of water during dispensing by overriding the thermostat. 2.4 Machine Supplied Settings The machine was configured in the factory with the following Engineer Mode settings: Machine Type D4 3 product Coffee Enabled... - Page 11 Powerplex Digital Range Service Manual Menu Item Options Description Product Sensor Enabled Usually Enabled when machine is in use. Disabled Disabled to avoid wasting product when calibrating and as a temporary fix if sensors fail. Leak Detect Enabled Normally Enabled. Will show Fault if a leak is Disabled detected (see Section 1.2 Understanding Fault Codes).
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Page 12: Obtaining Replacement Parts
Obtaining Replacement Parts 3.1 Illustrated Parts Catalogue A printable Illustrated Parts Catalogue may be downloaded from the Technical Web site. 3.2 Using Web Site To access the technical web site go to www.aromat-info.com and select Technical Documents. This will take you to the Technical Centre which is in both English and German. -
Page 13: Preparing The Powerplex Digital For Servicing
Powerplex Digital Range Service Manual Preparing the Powerplex Digital for Servicing WARNING: To avoid electric shock, when the casing panels are being removed, the dispenser MUST be isolated from the mains power supply. Note: Unless essential for any work being carried out, we recommend that the valve for the mains water service to the machine also be closed before servicing the machine. -
Page 14: Removing The Casing Panels
4.3 Removing the Casing Panels WARNING: Before removing any of the Casing Panels the machine MUST be isolated from the mains power supply. Note: The machine should only be powered ON with the panels removed if the engineer can satisfy himself that it is safe to do so. For many of the servicing operations, only the Top Panel needs to be removed. -
Page 15: Disconnecting / Reconnecting Power Supply Cabling
Powerplex Digital Range Service Manual 3 Refit the Lower Side Panels by sliding the panels into position and tightening the three screws securing it to the Side Frame and bottom lip of the Side Panel. 4 Refit the Cup Stand Assembly by reversing the instructions in Section 4.3. 5 Refit the Door Assembly by reversing the instruction in Section 4.3. -
Page 16: Disconnecting / Reconnecting Water Supply
4.6 Disconnecting / Reconnecting Water Supply Note: When the Powerplex is powered OFF, water will not flow through the inlet valve. Tools required: 1 1/8” AF Spanner Suitable Bucket or Container To disconnect the dispenser from the Mains Water Supply: 1 Ensure that the mains valve is closed. -
Page 17: Servicing Tank And Water Supply
Powerplex Digital Range Service Manual Servicing Tank and Water Supply It is not necessary to remove the tank to undertake maintenance of the Powerplex’s water supply components. However, instructions for removing / replacing the tank have been included at the end of this section. 5.1 Replacing the Water Inlet Valve The Water Inlet Valve is located inside and fitted onto the Water Inlet Valve Plate, mounted behind the Cup Stand Assembly. -
Page 18: Setting Water Outlet Valve Flow Rate
2 Remove the Cooler Unit as described in Section 7.1. 3 Drain the tank as described in Section 4.7 - steps 2 to 5. 4 Open the hose clamp to allow water to pass. Close and reopen the clamp as necessary until the level of the water in the tank is below the Valve Inlet. - Page 19 Powerplex Digital Range Service Manual Tools required: No. 2 Pozidrive Screwdriver 1 litre calibrated container Timer with second hand 8mm hexagonal key (or 8mm flat end screwdriver) To adjust the flow rate for the ‘water for coffee’ Outlet Valves: 1 If installed, remove the Cooler Unit as described in Section 7.1, and refit connectors to the Control PCB.
- Page 20 15 If necessary, adjust the Left Valve by turning the screw anti-clockwise to increase the flow and clockwise to decrease the flow. One full turn of the screw will change the volume by approximately 50 ml. Valve Body Adjustment Screw 16 Carefully dispose of the water and repeat the operation until the level in the container is 500 ml.
- Page 21 Powerplex Digital Range Service Manual Selection 7 = TYPE Coffee Volume = 55 Channel = 3 10 Operate the Right Faucet and set to: Selection 6 = Enabled Speed = 1 Selection 6 = Preset Selection 1 = TYPE Water Volume = 55 11 Scroll through the menu until SET UP MODE is displayed again and turn the Mode Change keyswitch back to normal dispense mode.
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Page 22: Replacing Heating Elements
5.4 Replacing Heating Elements There are three elements installed. Elements are extracted and installed through the tank lid aperture. Refer to the illustration in the Parts List. WARNING: The machine must be completely isolated from the Mains Power supply when changing any electrical component. Tools required: No. -
Page 23: Setting Up Elements
Powerplex Digital Range Service Manual 13 Allow the machine to refill with water and check for any leaks. 14 Power OFF and isolate the machine from the Mains Power Supply. 15 Refit the Cup Stand Assembly, the Cooler Unit and Top Cover. 5.5 Setting Up Elements The number of Elements that may be used is determined by the supply and current available. -
Page 24: Replacing A Temperature Control Thermostat
5.6 Replacing a Temperature Control Thermostat The boiler temperature control thermostat assembly is situated on the Thermostat Tank Lid Assembly, on top of the tank. The Boiler Thermostat is used to set the water top temperature; the Economy Thermostat is used to set the minimum operating temperature Tools required: No. -
Page 25: Replacing A Temperature Safety Thermostat
Powerplex Digital Range Service Manual Silicon Stopper Boiler Overfill Detection Microswitch Water Level Control Microswitch 4 Reconnect to the Mains Power Supply and power ON the machine. 5 Insert the thermometer probe approximately 6” (15 cm) into the tank. 6 Turn both Thermostat Controls to the plus position Thermostat Thermostat Bracket... -
Page 26: Replacing A Float Micro Switch
Tools required: No. 2 Pozidrive screwdriver 7mm socket 18mm or 19mm deep socket 10 mm or 11mm spanner To replace a boiler over temperature thermostat: 1 Power OFF and isolate the machine from the Mains Power Supply. 2 Remove the Cooler Unit as described in Section 7.1. For the Boiler Over Temperature Thermostat: 3 Note the cables connected to the Thermostat and ease off the connectors. -
Page 27: Descaling The Tank
Powerplex Digital Range Service Manual 3 Disconnect the cables to the micro switch. 4 Undo the two screws securing the micro switch to the bracket, being careful not to lose the securing nuts. Retain the screws and nuts. 5 Slide the switch arm out of the float rod eye. 6 Fit the new micro switch by reversing the above procedure, taking care not to overtighten the screws or damage the connector tabs. -
Page 28: Cleaning Water Outlet Valves
5.11 Cleaning Water Outlet Valves If the FLUSH switch is used to descale the valves on a regular basis, the valves should not need to be removed and descaled. However, if they have not been descaled regularly, when the tank is descaled, it is possible that the valves do not seat correctly, which could cause a slight leak. -
Page 29: Removing / Refitting Tank Assembly
Powerplex Digital Range Service Manual 5.12 Removing / Refitting Tank Assembly Note: To service the Powerplex’s water supply sub components, it is not necessary to remove the Tank Assembly. Tools required: 7 mm Socket No. 2 Pozidrive Screwdriver To remove the Tank assembly: 1 Remove the Cooler Unit as described in Section 7.1. -
Page 30: Removing / Refitting A Tank Lid Assembly
5.13 Removing / Refitting a Tank Lid Assembly It is necessary to remove one of the Tank Lid Assemblies when replacing Elements or checking that the Water Level and Overflow Floats are functioning correctly. WARNING: Water in the tank may scald. Tools required: No. -
Page 31: Servicing Control Panel And Display
Powerplex Digital Range Service Manual Servicing Control Panel and Display Controls for the Powerplex Digital dispensers are found on both the Control Panel Assembly and the Door Assembly. 6.1 Removing / Refitting Control Panel Assembly The Control Panel Assembly is located on top of the Cooler Unit. It comprises the Control PCB, the PCB Mounting Plate and the Programming Mode Keyswitch. -
Page 32: Updating The Pcb Processor Chip
To replace the Control PCB: 1 Note all Engineer and Customer settings as described in Section 4.2. 2 Power OFF and isolate the machine from the Mains Power Supply. 3 Remove the casing Top Cover as described in Section 4.3. 4 If required, label the connector blocks and looms. - Page 33 Powerplex Digital Range Service Manual 5 Gently place the new Processor Chip on the clasp shelves, with the Dimple towards the RH end of the PCB, ensuring it is central and the pins align with the sockets. With a light touch you should feel that the pins are located correctly. 6 When you are sure the Processor Chip is properly located, gently push down on the chip until both clasps click into the locked position.
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Page 34: Servicing The Cooler Unit
Servicing the Cooler Unit Refer to the relevant Powerplex Illustrated Parts Catalogue to identify the parts referred to in this procedure. A pdf version is available from the DASS Technical web site. 7.1 Removing / Refitting Cooler Unit WARNING: DO NOT lift the Cooler Unit out of the dispenser by holding the Cooler Unit Door as this can cause damage to the door panel and hinge assemblies. - Page 35 Powerplex Digital Range Service Manual Coffee Enabled Water Disabled Product Sensors Enabled The PRODUCT EMPTY LEDs should all be lit. 8 Exit Engineer Setup mode, and in SETUP Mode: For D4di Dispensers, change Product Selection Button 1 to: Speed = 1 Selection 1 = HELD ON Selection 1 = TYPE Coffee Channel = 1...
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Page 36: Replacing A Peristaltic Pump Motor
7.3 Replacing a Peristaltic Pump Motor The Peristaltic Pump is an integral part of the concentrate delivery system of the Cooler Unit. The Peristaltic Pump will need to be partially disassembled before the motor can be removed. It is not necessary to remove the complete Pump Mounting Plate Assembly to undertake this operation. -
Page 37: Adjusting A Peristaltic Pump
Powerplex Digital Range Service Manual 11 Undo the three screws to remove the Pump Cover for the Motor and Gearbox Assembly being replaced. The Rotor, Peristaltic Pump Tube and attached tube connectors can also be removed and retained for reinstallation. 12 Remove the Nylon Washer and retain for reinstallation. - Page 38 On D4di Dispensers: (Go to Instruction 19 for D5di Dispensers.) 7 Note customer’s settings and set Product Selection Button 1 to: Selection 1 = Enabled Speed = 2 Selection 1 = Preset Selection 1 = TYPE Coffee Volume = 55 Sel 1 = Strength = 40:1 Channel = 1 8 Press Enter until SET UP MODE is displayed and turn the Mode Change...
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Page 39: Servicing / Replacing A Heat Pump
Powerplex Digital Range Service Manual 26 If the reading is not exact, put the machine back into Engineer Setup mode and scroll through to Peris 1 Speed. 27 Initially adjust the offset to +2 to increase the dispense volume or -2 to decrease the dispense volume and repeat instructions 10 to 12. - Page 40 5 Open the door, undo the four small screws securing the black Back Plate and remove to expose the back of the can cold sink. 6 Undo and remove the three countersunk screws in a triangular formation for the Heat Pump Assembly to be serviced or replaced. 7 Close the door and place the Cooler Unit with the door face down onto the folded towel or blanket on the bench.
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Page 41: Cleaning / Replacing A Cooling Fan
Powerplex Digital Range Service Manual 17 Remove any surplus compound. Flat Nylon Washers Insulator Spring Washers 18 Place the flat washers and spring washers onto the M3 x 35mm screws and insert through the Nylon Insulator in the Peltier Cold Sink and into the holes in the Powersink. -
Page 42: Cooler Unit Performance Testing
7.7 Cooler Unit Performance Testing To comply with all NSF requirements, In normal operation the Concentrate at a temperature of 2°C placed into the Cooler Unit should not rise to above 6°C within four hours, at an ambient temperature of 30°C. To test the Cooler Unit at an ambient temperature of 25°C: Tools required: Digital thermometer... -
Page 43: Checking The Cooler Unit Thermostat
Powerplex Digital Range Service Manual 7.8 Checking the Cooler Unit Thermostat The Cooler Unit Thermostat is mounted on the inside of the Pump Cover Panel. The thermostat will be in the ‘contacts made state’ meaning that all power to the Peltier Elements passes through. -
Page 44: Replacing Cooler Unit Door Gasket
7.10 Replacing Cooler Unit Door Gasket The door gasket should be cleaned regularly with hot soapy water. Concentrate deposits can cause the gasket to stick to the Cooler Unit Body which can tear or damage the gasket. In such case the gasket will need to be replaced. Tools required: Stanley Knife To replace the Cooler Unit Door Gasket:... -
Page 45: Tools Required
Powerplex Digital Range Service Manual Tools required: Pair Long Nosed Pliers No. 1 Pozidrive screwdriver WARNING: DO NOT lift the Cooler Unit out of the dispenser by holding the Cooler Unit Door as this can cause damage to the door panel and hinge assemblies. Note: Before removing the Cooler Unit, ensure that the coffee concentrate can has been removed and the concentrate delivery system has been flushed through. -
Page 46: Servicing Dispenser Door Assembly
8.1 Replacing the Selection Switch Membrane This is the panel around the display used to adjust machine settings. On the D4 Digital machine the panel includes the Product Selection Buttons. The function keys and indicators are integrated into the panel and in the event of failure, the entire panel must be replaced. -
Page 47: Replacing Translation Pcb
Powerplex Digital Range Service Manual 2 Open the door and undo the four M3 x 12mm pozidrive screws to remove the Display PCB Assembly Cover. The Translation PCB will be exposed. 3 Very carefully disconnect the Display Unit Assembly loom from the Translation PCB. -
Page 48: Servicing The Power Supply Unit
Servicing the Power Supply Unit Should the Powerplex PSU fail, it would normally be swapped for another. Replacement of the main components can then easily be carried out in the workshop. 9.1 Extracting / Refitting PSU Assembly It is not necessary to extract the PSU Assembly to disconnect and reconnect the mains power supply. -
Page 49: Replacing The Toroid Pcb
Powerplex Digital Range Service Manual To replace the Relay and Regulator PCB: 1 Extract the PSU Assembly as described in Section 9.1. ..2 At the Relay and Regulator PCB, disconnect the loom to the Cooling Fans, the loom to Toroid PCB and the loom to the AC Connection PCB. ..3 Starting from one end, pinch the 5 PCB Supports one by one with the long nosed pliers and lift to release the Relay and Regulator PCB. -
Page 50: Replacing A Toroid Transformer
..7 Turn the PSU Assembly up side down and unscrew the four M4 x 6mm screws to separate the Toroid and Cooling Fan Housing from the PSU Housing. ..8 Holding both the Toroid and Cooling Fan Housing and the PSU Housing, turn the assemblies the correct way up and lift out the Toroid and Cooling Fan Housing assembly. -
Page 51: Replacing The Ac Connection Pcb
Powerplex Digital Range Service Manual 8 Feed the bolt through the Cooling Fan Housing and Toroid Assembly; fit the washer and nut. Tighten the nut. Note: If necessary, the bolt must be cut back to provide a minimum gap of 10mm between the two facing Toroid Transformers. -
Page 52: Replacing The Coding Pcb
7 Unscrew the six Polytop screws and remove the Coding PCB from the Switch Plate assembly. 8 Unscrew and remove the trim rings and nuts securing the three Element Selector Circuit Breakers to the Switch Plate but do not extract yet. 9 Disconnect the Mains Power Supply cables from the 4 Way Terminal Block. -
Page 53: Replacing An Element Selector Circuit Breaker
Powerplex Digital Range Service Manual 9.7 Replacing an Element Selector Circuit Breaker The Element Selector Circuit Breakers are fitted to the inside of the Switch Plate and may only be replaced by extracting the PSU Assembly, removing theCable Tray, Relay and Regulator PCB and Switch Plate assembly. -
Page 54: Replacing Neon Lamp
9.9 Replacing Neon Lamp The Neon Lamp is fitted to the Switch Plate and may only be replaced by extracting the PSU Assembly, removing the Cable Tray, Relay and Regulator PCB and Switch Plate assembly. Refer to the exploded view drawing of the PSU Assembly to identify parts. Tools required: 8mm Spline socket No. -
Page 55: Replacing A Cooling Fan
Powerplex Digital Range Service Manual 9.11 Replacing a Cooling Fan The Cooling Fans are fitted to the Cooling Fan Housing and may only be replaced by extracting the PSU Assembly, and removing the Cable Tray. Refer to the exploded view drawing of the PSU Assembly to identify parts. -
Page 56: Technical Specifications
10 Technical Specifications 10.1 General Specifications Height: 31.1 ins (79 cm) depending on foot/leg adjustment Depth: 23.6 ins (60 cm) Width: 17.5 ins (44.5 cm) Net weight: 154 lbs (70 Kg) Operating weight: 220 lbs (100 Kg) Power Options: Single phase connections have the option of utilising one two or three elements. Three phase connections utilise all three heating elements. -
Page 57: Main Looms Diagram
Powerplex Digital Range Service Manual 10.2 Main Looms Diagram Boiler Safety Tank Outlet T/stats Valves Inlet Valve Heater Elements Float Thermostat Assembly Control PCB Mode Change Switch Cooler Unit Peris Cooler Display Translation Pumps T/stat Unit Selection Peltier Cooler Sensors Switch Membrane Elements Unit Fans... -
Page 58: The Control Pcb
10.3 The Control PCB Translation PCB PSU Loom Door Membrane Connector Connector Thermostat Lid Loom Connector Translation Float Lid PCB - Door Loom Membrane Connector Connector D5 Door Loom Connector Translation PSU Loom PCB - Display Connector Connector Cooler Unit Processor Loom Chip... -
Page 59: Control Board Leds
Powerplex Digital Range Service Manual 10.4 Control Board LEDs Elements Major Fault Power ON Inlet Valve 2 Inlet Valve 1 Outlet Valve 3 Outlet Valve 2 Outlet Valve 1 Limit Relays Outlet Valve 1 Outlet Valve 2 Outlet Valve 3 Peltiers Processor Chip... -
Page 60: Psu Looms Diagram
10.5 PSU Looms Diagram Control Relay and Regulation PCB Toroid PCB Safety Outlet Outlet T/stats Valves Valve 1 & 2 Inlet Toroid 2 Valve Boiler Tank Toroid Heater Heater Heater Toroid 3 Element 1 Element 2 Element 3 Switch Plate Assembly Element Element Element... -
Page 61: Relay And Regulator Pcb
Powerplex Digital Range Service Manual 10.6 Relay and Regulator PCB Fuse 3 T4A 250v Fuse 2 Slow Blow 5A 250v Toroid Loom Connector Fuse 1 T10A 250v Slow Blow Valves and Thermostats Loom Connector PSU Cooling Fans Loom Connector Control PCB Loom Connector 3rd Outlet Valve Loom Connector... -
Page 62: Ac Connection Pcb
10.7 AC Connection PCB Relay and Regulator PCB Loom Mains Supply AC Connection Block Loom Element 3 Element 2 Element 1 Mains AC Supply Plate Connection... -
Page 63: Toroid Pcb
Powerplex Digital Range Service Manual 10.8 Toroid PCB To Relay and Regulator PCB AC Connection PCB Connector To 18v To 25v To 12v Toroidal Toroidal Toroidal... -
Page 64: Appendices
Appendices: Electrical Installation Instructions... -
Page 65: B Recommended List Of Tools Required To Service The Powerplex
Powerplex Digital Range Service Manual Recommended List of Tools required to Service the Powerplex 3mm terminal screwdriver 6mm flat end screwdriver No.1 Pozidrive screwdriver No. 2 Pozidrive screwdriver – 6” No. 2 Pozidrive screwdriver – 10” No. 2 Pozidrive screwdriver – Stubby 6mm AF socket 7mm AF socket 8mm AF socket... -
Page 66: C Machine Settings Form
Machine Settings Form PPdi Customer Machine Settings Engineer Name: Service Date: Mach Ref. No: User Configured Settings: For PPD5di settings, use columns 6, 7 and 8. Faucet: Product Button / Faucet: Selection (Enabled / Disabled): Speed (1 / 2): Selection Method (Preset / Held ON): Selection Type (Coffee / Water): Dispense Volume (number): Selection Strength (Ratio):... -
Page 67: D Cleaning And Sanitising Instructions
Powerplex Digital Range Service Manual Cleaning and Sanitising Instructions CLEANING AND SANITISING THE Powerplex DISPENSER ON SITE. Cleaning the dispenser and sanitising the concentrate channels should be undertaken daily. WARNING: To avoid Injury, exercise caution when handling hot liquids. When handling chemicals exercise precautions as defined by the chemical manufacturer. -
Page 68: Contact Details
Contact Details: 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: support@aromat-uk.com Web: www.aromat-uk.com Document No: EN PPDI 03 001...
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