Bosch TCA640 Series Repair Instruction
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Bosch TCA640 Series Repair Instruction

Fully-automatic coffeemaker
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Table of Contents

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1
SAFETY ........................................................ 3
1.1
Safety instructions.............................................................. 3
1.2
Repair instructions ............................................................. 3
2
INSTALLATION ............................................ 4
2.1
Installation ........................................................................... 4
2.2
Scope of delivery ................................................................ 4
3
OPERATION ................................................. 5
3.1
Switching on the appliance................................................ 5
3.2
Filling up the pipe system .................................................. 6
3.3
Emptying the pipe system.................................................. 6
3.4
Controls ............................................................................... 7
3.5
3.6
Preparation ........................................................................ 20
3.7
Cleaning............................................................................. 23
4
COMPONENTS........................................... 26
4.1
Flowmeter .......................................................................... 26
4.2
Heater and NTC-sensor .................................................... 27
4.3
Brewing unit ...................................................................... 29
4.4
Gear unit ............................................................................ 34
4.5
Cappuccino / caffelatte frother ........................................ 38
4.6
Coffee outlet ...................................................................... 40
4.7
Drip tray ............................................................................. 42
4.8
Water filter ......................................................................... 44
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Fully-automatic coffeemaker
5
FUNCTIONS................................................45
5.1
Construction ..................................................................... 45
5.2
The perfect espresso........................................................ 47
5.3
Functional principle.......................................................... 47
5.4
Warming the cups............................................................. 47
5.5
The fluid system ............................................................... 48
5.6
Temperature...................................................................... 49
6
REPAIR .......................................................51
6.1
Reading out internal appliance data ............................... 51
6.2
Replacing the brewing unit.............................................. 52
6.3
General disassembly........................................................ 55
6.4
Replacing the thermal fuse.............................................. 56
6.5
Removing the coffee outlet.............................................. 58
6.6
Replacing the front panel................................................. 61
6.7
6.8
Replacing the steam pipe ................................................ 63
6.9
Solenoid valve replacement ............................................ 64
7
FAULT DIAGNOSTICS ...............................65
7.1
Malfunctions ..................................................................... 65
7.2
System and error messages ............................................ 71
7.3
Incoming goods inspection ............................................. 77
7.4
Service diagnosis ............................................................. 78
7.5
Troubleshooting ............................................................... 84
7.6
Measuring the coffee temperature .................................. 91

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Summary of Contents for Bosch TCA640 Series

  • Page 1: Table Of Contents

    Fully-automatic coffeemaker SAFETY ............3 FUNCTIONS..........45 Safety instructions.............. 3 Construction ..............45 Repair instructions ............. 3 The perfect espresso............47 Functional principle............47 INSTALLATION ..........4 Warming the cups............. 47 Installation ................4 The fluid system ............... 48 Scope of delivery ..............4 Temperature..............
  • Page 2 TECHNICAL SPECIFICATIONS ....92 Rating plate ............... 92 Power ................. 93 Temperatures ..............93 Dimensions and weight ............ 94 Filling amounts ..............94 Components ..............95 58300000120060_ARA_en_c.doc – 18.09.09 Seite 2 von 95...

  • Page 3: Safety

    SAFETY Safety instructions Repair instructions Danger! Caution! ► ► Repairs may be carried out by a qualified electrician only! NEVER attempt repairs by randomly replacing components! ► The user may be put at considerable risk and injured by ► ALWAYS proceed systematically and comply with the improper repairs! technical documentation for the appliance! ►...

  • Page 4: Installation

    INSTALLATION Installation Scope of delivery ► The installation location must be level and dry. All appliances are supplied with the “Welcome pack” starter kit and optionally with a gift box. ► Protect the appliance from splash water. ► There must be a minimum filling height of 420 mm. TCA640x TCA680x ►...

  • Page 5: Operation

    OPERATION The appliance conducts a self-test, Switching on the appliance heats up and rinses. ► Heating standby ► Pull the mains plug out of the cord store at the temperature rear of the appliance and connect according to ► the specifications on the rating plate. Moving the brewing unit to the upper end position ►...

  • Page 6: Filling Up The Pipe System

    Filling up the pipe system Emptying the pipe system For production reasons the water line system in the appliance must Risk of damage! be filled again when the appliance is switched on for the first time: The appliance must be emptied if there is a risk of frost (e.g.

  • Page 7: Controls

    Controls 3.4.2 Mains switch 3.4.1 Accessories The mains switch on the rear of Coffee outlet can be moved higher (up to 125 mm) the appliance switches the power supply on or off. When the mains switch is switched on, the illuminated ring on the standby button lights up green.
  • Page 8 3.4.3 Standby and P button ► Switch on the power switch: Appliance enters standby mode The Stand-by button switches on and starts the appliance or switches it from brewing mode to stand-by. When the standby button has been pressed, the appliance heats up and is then rinsed.
  • Page 9 3.4.4 Function switch Coffee dispensing button 3.4.5 ► Press function switch to draw hot Press the coffee dispensing button to start the water or steam: coffee brewing process. During the brewing process the green illuminated ring Risk of scalding! flashes. When steam or hot water is ►...
  • Page 10 3.4.6 Filling quantity selector 3.4.7 Coffee strength selector This rotary knob is used to select the amount of liquid which is The amount of coffee to be ground can be changed by rotating the required. coffee strength selector. This setting affects the aroma and flavour, the caffeine and acid content as well as the formation of the crema.
  • Page 11 3.4.8 Cleaning button 3.4.9 Descaling button When the red illuminated ring lights up around the When the red illuminated ring lights up around the cleaning button clean, the appliance must be cleaned. descaling button calc, the appliance must be descaled. Coffee can still be brewed.
  • Page 12 3.4.10 Adjusting the grinding unit 3.4.10.1 Service-Sticker To make sure that the grinding unit will be adjusted correctly a sticker Dependent on the roasting degree and on the oil rate of the used is added on the right cover of the appliance. coffee beans the grinder setting must be changed ►...

  • Page 13: Changing The Programming / Standard Settings

    3.5.2 Displayed language Changing the programming / standard settings To change the displayed language to the required national setting: The appliance has been set at the factory so that coffee can be brewed without any additional programming. To change these ►...
  • Page 14 3.5.3 Water hardness 3.5.3.2 Degrees of water hardness Setting German French Determine the water hardness with the enclosed test strip or ask your local water supplier. 1–7 1–13 Test strip for determining the water hardness, mat. no.: 05 6317 8–15 14–27 16–23 28–42...
  • Page 15 3.5.4 Water filter 3.5.4.1 Inserting the water filter ► appliance must A water filter available as an accessory (mat. no.: 46 1732) can be switched on and ready to use. inserted in the water tank. ► Place a vessel with a capacity When approx.
  • Page 16 3.5.4.2 Changing the water filter 3.5.4.3 Removing the water filter ► ► appliance must appliance must switched on and ready to use. switched on and ready to use. ► ► Place a vessel with a capacity Using screwing aid, of at least 500 ml under the hot unscrew the water filter in an water nozzle.
  • Page 17 3.5.5 Temperature 3.5.6 Current time The coffee temperature can be set or The current time can be input and saved. The time is required to use changed. the timer function. ► ► Press and hold down button P appliance must for at least 3 sec.
  • Page 18 3.5.7 Timer 3.5.7.2 Deactivating the setting The switch-on time remains saved even if there is a power failure or This function can be used to set the time at which the appliance is to the mains switch in the appliance is actuated. switch on automatically.
  • Page 19 3.5.9 Displaying the brews 3.5.10 RESET function The number of the already brewed Possible from standby mode only! espressos, coffees and ground coffees ► Switch the appliance to standby mode by pressing the is displayed here. The brews are Standby button. counted automatically.

  • Page 20: Preparation

    Preparation 3.6.1 Espresso / coffee preparation with beans Using the filling quantity selector, Using coffee strength The fully automatic coffee espresso machine grinds fresh coffee set the required amount of coffee selector, amount beans for each brewing process. and the number of cups. ground coffee.
  • Page 21 3.6.2 Espresso / coffee preparation with ground coffee 3.6.3 Frothing up milk, preparing latte macchiato Warning! Warning! Risk of damage! Risk of scalding! Risk of burns! ► ► Do not use whole beans! When the steam button is pressed, some steam may spray out.
  • Page 22 3.6.4 Heating up drinks with steam 3.6.5 Preparing hot water Warning! Warning! Risk of scalding! Risk of burns! Risk of scalding! Risk of burns! ► ► When the steam button is pressed, some When the hot water button is pressed, some steam may spray out.

  • Page 23: Cleaning

    Cleaning Risk of electric shock ► Before cleaning the appliance, pull out the mains plug. ► Never immerse the appliance in water. ► Do not use a steam cleaner. Risk of damage! Do not use any scouring agents! 3.7.1 Daily cleaning of the appliance ►...
  • Page 24 3.7.2 Cleaning the CAPPUCCINO / CAFFELATTE nozzle The nozzle and valve must be cleaned immediately to ensure ► To clean thoroughly, disassemble all parts and clean with a optimum milk froth. Even the slightest milk residue will impair the soft brush in a mild detergent solution. frothing up result! Note! Dried-on milk residue is very difficult to remove.
  • Page 25 3.7.3 Cleaning the brewing unit The brewing unit can be taken out of the appliance for cleaning. ► Switch off the appliance with the mains switch. ► Release the service door on the right-hand side of the appliance with a coin or a flat screwdriver and open. ►...

  • Page 26: Components

    4.1.1 Design and function COMPONENTS Water is pumped in from the water Flowmeter tank flows through flowmeter. The composition of the coffee Water supplied mixture is a well guarded secret of connection pipe in the lower coffee roasting section of the housing (D). establishments.

  • Page 27: Heater And Ntc-Sensor

    Heater and NTC-sensor 4.1.2 Connection diagram 4.2.1 Heater (Instantaneous water heater) In the instantaneous water heater the water for coffee production or hot water/steam purchase is heated up. The flowmeter itself does not supply an output voltage but simply switches the signal connection to 0 volt earth (actuated) or leaves it open (unactuated).
  • Page 28 4.2.2 Characteristic of NTC-sensor Temperature R min R nom R max 25 °C 9,78k 10,00K 10,22k 95 °C 0,77k 0,78k 0,80k 140 °C 0,232k 0,234k 0,237k 58300000120060_ARA_en_c.doc – 18.09.09 Seite 28 von 95...

  • Page 29: Brewing Unit

    Brewing unit Ground coffee pours through the filling shaft (2) into the brewing The brewing unit forms the central element in the espresso machine. chamber and is compressed. Hot water is introduced under pressure The brewing unit extracts the aroma, flavour and bitter agents from the via the water supply (4) and forced through the ground coffee.
  • Page 30 4.3.2 Sequence of the brewing cycle 4.3.2.1 Grinding and metering 4.3.2.2 Compression Coffee beans are ground in the grinding unit (A). The ground coffee is The grinding unit stops. The gears control the brewing unit to the conveyed into the open brewing chamber via the funnel (B). The upper end position.
  • Page 31 4.3.2.3 Brewing 4.3.2.4 Emptying The brewing process starts. The pressure pump conveys the water When the programmed amount of water is reached, the pump stops. into the brewing unit. The brewing head (D) is moved up by the water The pressure in the brewing chamber drops and the coffee dregs are pressure, thereby increasing the volume in the brewing chamber.
  • Page 32 4.3.3 Removing the brewing unit The brewing unit is accessed by opening the service flap on the right- hand side of the appliance. Once released, the brewing unit can be taken out of the appliance for cleaning. 4.3.3.2 Locking mechanism 4.3.3.1 Basic position When locked, the brewing chamber is prevented from moving.
  • Page 33 4.3.4 Compensation of the grinding unit running time The electronics module measures the number of the voltage changes The amount of ground coffee which is generated by the grinding unit (connection A) caused by the switching processes which occur depends on the running time of the grinding unit. immediately before the pressure pump switches on and can therefore detect whether and how much ground coffee has been metered.

  • Page 34: Gear Unit

    Gear unit Note: From production date FD8701 on the drip tray is monitored by an additional micro switch in the The gear unit is the drive for the brewing unit. appliance. If the drip tray is pulled out, the micro switch The gear motor is actuated at +/–...
  • Page 35 4.4.3 Cam on the gear unit The position of the brewing unit is detected with two micro switches S1 and S2. These two switches are able to define three positions. When the appliance is switched on, the switch status of the micro switches is checked and transmitted to the control module.
  • Page 36 4.4.4 Drainage valve The drainage valve (B) connects the water inlet (A) to the brewing unit and drains the system at the end of the brewing cycle. 4.4.4.1 Home position Warning! When the gears are in the home position, the drainage valve is open. Malfunction The cam (E) of the actuator must then be in the illustrated position.
  • Page 37 4.4.4.2 Brewing position 4.4.4.3 Drainage position When the gears move into the brewing position, the drive shaft rotates Once the brewing process is complete, the water pump switches off. with the actuator (D) in an anti-clockwise direction. The brewing unit is moved upwards. The connection to the drainage The transmission motor turns the input shaft with tripping device (D) valve is closed with the water back through about 8°...

  • Page 38: Cappuccino / Caffelatte Frother

    4.5.1 Settings Cappuccino / caffelatte frother The Cappuccino / Caffeelatte frother is used to prepare milk with or without milk foam. Before using the appliance, ensure that all parts are firm and are assembled without any gaps. All parts must be clean and free of milk residue, otherwise the frothing result will be affected.
  • Page 39 4.5.3 Cleaning The Cappuccino / Caffeelatte frother can be disassembled for cleaning without a tool. All individual parts can be cleaned with a mild detergent solution and soft brush. 4.5.4 Function Steam is conveyed into the Cappuccino / Caffeelatte frother (2) via the steam pipe (1), flows through the frother and generates a low pressure in the intake component.

  • Page 40: Coffee Outlet

    Coffee outlet The pump pressure conveys the brewed coffee from the brewing unit to the coffee outlet. The coffee runs into the coffee outlet (B) via a silicone hose (A). The brewing system opens here and the coffee flows into the overflow (C).
  • Page 41 4.6.1 Coffee outlet with optimised overflow An improved coffee outlet was introduced from production date FD8606. A newly introduced jug (1) in conjunction with changes to the distributor (2) and to the distributor cover (3) ensure a more even outlet with lower right – left tolerances. The coffee outlet is available only as a complete, pre-assembled spare part with or without chrome-plated outlet sleeves and replaces the previous coffee outlet.

  • Page 42: Drip Tray

    Drip tray 4.7.1 Tray contacts The tray contacts (A) detect whether ► the drip tray has been inserted. ► the drip tray has been filled with water. If the drip tray has not been inserted, an electric circuit is opened. TRAYS MISSING is displayed.
  • Page 43 4.7.2 Detection springs The drip tray features two tray contacts (A). When the drip tray is pushed all the way into the appliance, the detection springs (B) catch against the tray contacts from below. Therefore the following states can be measured ►...

  • Page 44: Water Filter

    Water filter The filter cartridge is screwed directly into the water tank. The filter cartridges can be used for all appliances belonging to this series. Carbon hardness, contents (e.g. chlorine) which impair taste and odour, heavy metals and other substances are reduced to protect the machine.

  • Page 45: Functions

    FUNCTIONS Construction 5.1.1 Overview, right side 1 Grinder compensation microswitch 2 Coupling for coffee outlet 3 Connection for steam nozzle 4 Brewing unit locked microswitch 5 Drainage valve outlet 6 Cams for releasing the brewing unit 7 Drive coupling for brewing unit 8 Brewing unit lock 9 Grinder 10 Grind setting...
  • Page 46 5.1.2 Overview, left side 1 4 bar outlet valve 2 Fluid distributor T-piece 3 Heating element 4 Brewing unit locked microswitch 5 Transmission unit 6 Power switch 7 Water tank coupling with valve pusher 8 Flow meter 9 Mains interference suppression filter 10 Diagnostics connector 11 Controller board with display 12 Controller unit (logic module)

  • Page 47: The Perfect Espresso

    The perfect espresso For steam or hot water dispensing, the solenoid valve opens the A genuine espresso is prepared according to a specific extraction system. Hot water or steam flows out of the steam nozzle. The process in which the water is forced under high pressure through pressure in the system remains low and the outlet valve remains finely ground coffee in order to release all the flavours.

  • Page 48: The Fluid System

    The fluid system The pump (c) sucks the water out of the water tank (a) via flow meter (b). The water flows through the flow meter thereby causing the impeller inside to rotate. This generates electrical pulses which are used to determine the actual volume of water required. The pump generates a pressure of 5 - 8 bar.

  • Page 49: Temperature

    Temperature 5.6.1 Temperature pattern The temperature graph indicates the temperature pattern on the heater during operation. After coffee has been drawn, the appliance may be briefly disabled from reheating. As soon as steam has been drawn, coffee can be brewed again without waiting for the appliance to cool down.
  • Page 50 5.6.2 Temperature pattern, drawing espresso (40 ml) 5.6.3 Temperature pattern, drawing coffee (125 ml) Coffee outlet Brewing water Coffee outlet Brewing water Heater Heater NORMAL setting NORMAL setting HIGH setting HIGH setting MAXIMUM setting MAXIMUM setting 58300000120060_ARA_en_c.doc – 18.09.09 Seite 50 von 95...

  • Page 51: Repair

    REPAIR Reading out internal appliance data This function can display saved data: If the electronics module or the display does not support this function in the event of a fault, the current state of the appliance can be Appliance is in standby mode. determined by the labelling on the rear of the display and the logic ►...

  • Page 52: Replacing The Brewing Unit

    Replacing the brewing unit 6.2.1.2 Remove the brewing unit 6.2.1 Removing the brewing unit 1. Press the red knob on the handle and The brewing unit is accessed by opening the service door on the right- hand side of the appliance. 2.
  • Page 53 6.2.2 Inserting the brewing unit 6.2.2.1 Basic position 6.2.2.2 Inserting the brewing unit ► The brewing unit can only be replaced in the basic position. Service door is opened ► ► The brewing chamber is located completely underneath the Slide the brewing unit into the appliance in the basic position filling funnel.
  • Page 54 6.2.3 Greasing the brewing unit During a service, the O-ring for the coffee outlet (A), the lip seal surrounding the brewing head (B), the O-ring for the water inlet (C) and the coupling for the input shaft (D) must be thinly greased with food-safe special lubricating grease PARALIQ®...

  • Page 55: General Disassembly

    General disassembly Risk of electric shock! Pull out mains plug before disassembly. Appliance must not be live! DANGER! Tools: ► Torx-Screwdriver T10 6.3.1 Procedure: Remove the water tank (A) from the appliance. Remove back panel (E) to rear. Remove the aroma protection cover (B) from the bean container. Remove upper section of housing to rear and up.

  • Page 56: Replacing The Thermal Fuse

    6.4.3 Installation location Replacing the thermal fuse Screw with circlip The thermal fuse (STB) is a safety element which is Installation bracket used to prevent damage caused by the heater Heater overheating. To ensure correct function, it is essential to install the thermal fuse properly.
  • Page 57 6.4.4 Installing / replacing the thermal fuse: Insert installation bracket into the designated guide. (Ensure that the bracket is inserted according to the picture) ► Attach installation bracket with the corresponding screw and After removing the defective thermal fuse, circlip. comply with the following new steps to ensure correct installation: Following installation, check that the installation bracket on the...

  • Page 58: Removing The Coffee Outlet

    Removing the coffee outlet 6.5.1 Opening the coffee outlet 6.5.2 Loosening the coffee distributor ► ► To open the coffee outlet, insert a flat-tipped screwdriver into First remove the silicone hose (A). Remove the coffee the catch on the underside of the outlet slide (1.), loosen the distributor (B) after detaching the catches (C).
  • Page 59 6.5.3 Loosening the metal bands 6.5.4 Removing the metal bands ► The steplessly height-adjustable coffee outlet is braked by metal Using a flat-tipped screwdriver, press the metal band (A) bands on which magnets press. downwards. For subsequent removal: ► Press the outlet slide all the way down (1.) ►...
  • Page 60 6.5.5 Loosening the screw fittings When the metal bands have been removed, the screw fittings are accessible. Attachment of the outlet slide (2x Torx T10) Fastening screws for the front panel (3x Torx T10) 58300000120060_ARA_en_c.doc – 18.09.09 Seite 60 von 95...

  • Page 61: Replacing The Front Panel

    Replacing the front panel Tools: ► Torx- screwdriver T10 6.6.1 Procedure: Disassemble the appliance as described in the "General disassembly" section. Remove the coffee outlet as described in the "Replacing the coffee outlet" section, points 1. – 6. Undo two Torx T10 screws (1) on the lower front panel. Remove two cover caps (2) from screw holes (3).

  • Page 62: Steam Button And Operating Panel Replacement

    Steam button and operating panel replacement Tools: Clip operating printed board assembly (2) into the adapter ► with the cable pointing downwards. Pliers Insert two pins (7) into the adapter from the front, check the 6.7.1 Procedure: function (you can hear / feel the switch operate) Disassemble the appliance as described in the "General Snap the button into the adapter.

  • Page 63: Replacing The Steam Pipe

    Replacing the steam pipe Tools: ► Pliers ► Food-safe special lubricating grease PARALIQ® GTE 703 Mat.-no.: 31 0574 6.8.1 Procedure: Disassemble the appliance as described in the "General disassembly" section. Remove the front panel as described in the "Replacing the front panel"...

  • Page 64: Solenoid Valve Replacement

    Solenoid valve replacement Tools: ► Pliers ► Torx-screwdriver T10 6.9.1 Procedure: Note: Heating element / fluid system may still be hot. Cool the heating element manually Disassemble the appliance as described in the "General disassembly" section. Remove the front panel as described in the "Replacing the front panel"...

  • Page 65: Fault Diagnostics

    FAULT DIAGNOSTICS Malfunctions 7.1.1 Drawing coffee Complaint Cause? Remedial action ► ► Coffee temperature too low Cold cup or cold milk in the cup Prewarm cup or rinse out with hot water. Heat milk ► ► (Measure coffee temperature Brewing system not prewarmed (1st coffee brew- Prewarm brewing system;...
  • Page 66 7.1.2 Drawing coffee Complaint Cause? Remedial action ► ► Coffee has no “crema” Unsuitable coffee or beans no longer fresh Change coffee or use fresh beans ► ► (Layer of froth) Grinding unit setting not adjusted optimally to Adjust grinding unit setting. (Change degree coffee beans of grinding only while the grinding unit is running)
  • Page 67 7.1.3 Grinding unit Complaint Cause? Remedial action ► ► Coffee beans are not ground Grinding unit has not been adequately filled with Press coffee dispensing button again to start coffee another brewing process ► Empty and clean bean container. Use beans ►...
  • Page 68 7.1.4 Drawing hot water and steam / frothing Complaint Cause? Remedial action ► ► water steam Frother dirty or calcified Dismantle frother, clean carefully or descale function, too little steam ► ► Steam/hot water pipe dirty, blocked or calcified Clean or descale steam/hot water pipe ►...
  • Page 69 7.1.5 Cleaning and descaling programme Complaint Cause? Remedial action ► ► Cleaning programme does System too hot (message on display) Cool down system by drawing hot water not start ► ► Cleaning programme stops Ground coffee flap is not closed Close ground coffee duct flap and press the after addition of cleaning coffee dispensing button...
  • Page 70 7.1.6 Leaks Complaint Cause? Remedial action ► ► Water tank leaking Water tank, valve and sealing ring dirty or calci- Clean and descale water tank fied ► ► Water tank defective Replace water tank ► ► Water tank coupling leaking Cracks in water tank coupling Replace water tank coupling ►...

  • Page 71: System And Error Messages

    System and error messages 7.2.1 Error messages 7.2.1.2 Error 5 7.2.1.1 Error1 Error 5 Error 1 Heater or thermal link is defective (interrupted). NTC temperature sensor is outside the measurement range. If this defect occurs while the appliance is operating in a warm state, the message “Unit is heating”...
  • Page 72 7.2.1.3 Error 8 Error 8 Initialisation of the brewing unit has failed. The brewing unit cannot be moved into the upper end position. This may be due to several causes, e.g.: ► Incorrect operation – the brewing unit was filled with too much preground coffee or with whole coffee beans via the ground coffee slot.
  • Page 73 7.2.2 System messages 7.2.2.1 Add water ADD WATER Water tank is empty (1) The water level in the tank is monitored by a float with magnet (A) / magnetic switch and software counter (pulses from flowmeter) in the appliance. (2) When the water tank has been filled, the float rises and actuates the magnetic switch.
  • Page 74 7.2.2.2 Add beans ADD BEANS No coffee beans in the bean container (a) ► Top up bean container with fresh coffee beans and press the coffee dispensing button to start a brewing process. ADD BEANS is not displayed until a brewing process ends, as the actual filling of the brewing chamber is measured during the brewing process.
  • Page 75 7.2.2.3 Fill up pipe-system 7.2.2.4 Brewing unit missing For production reasons the water line system in the appliance must be occasionally filled again when the appliance is switched on for the first time: The illuminated rings around the standby button and the coffee dispensing button flash and the following displays occur alternately: >...
  • Page 76 7.2.2.5 Empty trays 7.2.2.6 Trays missing EMPTY TRAYS TRAYS MISSING Dregs drawer or drip tray full or tray contacts dirty Drip tray not or incorrectly inserted ► Insert drip tray all the way When the drip tray is full of water, the tray contacts are inserted into the water.

  • Page 77: Incoming Goods Inspection

    Incoming goods inspection 4. Fill water tank The incoming goods inspection allows machine faults to be ► Water tank leaking? localised quickly and suitable repair measures to be initiated: ► Follow the sequence in the table. 5. Coffee preparation without coffee ►...

  • Page 78: Service Diagnosis

    Service diagnosis 7.4.2 Service diagnosis kit (Mat.-no. 34 0995) 7.4.1 Hardware requirements A service diagnosis kit is required to support diagnosis of the To operate the system without errors, the following minimum appliances by PC. This kit includes the following components: requirements must be satisfied: Hardware requirements: PC 486 or higher...
  • Page 79 7.4.3 Installing the software 7.4.5 USB service diagnosis kit Insert Start disk in drive “A” The scope of delivery is changed with the introduction of the new USB Insert software CD in drive service diagnostic kit (Mat.-no. 34 0995). Menu Start, Run, disk drive SETUP.EXE The power supply unit is no longer required because the scanner is Follow installation instructions supplied via the USB connection on the PC.
  • Page 80 7.4.6 Diagnostic plug 7.4.7 Input diagnostic ► The diagnostic plug on the appliance will be accessible when the left Data is read out. (Production, statistical, service, customer appliance flap is opened and the cover (A) is removed. The data) transparent protective cap over the diagnostic plug must be removed ►...
  • Page 81 7.4.8 Service fault bits 7.4.10 Definition of “minor” / “major” service Analyse internal 0 Check encoder cable 7.4.10.1 Minor service appliance fault. 1 Coffee heating sensor – short-circuit Descale appliance 2 Coffee heating sensor – interruption Service fault bit Take out and clean brewing unit 3 Steam heating sensor –...

  • Page 82: Fault Code

    7.4.11 Individual test 7.4.14 Service stamp The following options can be selected: The service stamp is input via the following form: Upgrading factory settings 7.4.14.1 Group definition (the latest parameters are transferred from the PC to the appliance) Specific fault groups are allocated to the working points. When a Statistics working point has been selected, its fault group is activated for (Only data is read out of the appliance without any change to the...

  • Page 83: Work Code 2

    7.4.14.3 Contents 7.4.15 Service data Special software is required to analyse the data from the service Number of services 1 – 255 systems. Major fault code 001 – 999 This software is executed at each start of the service system. Fault code 1 001 –...

  • Page 84: Troubleshooting

    Troubleshooting Troubleshooting: Danger! If tests have to be conducted while the 1. Check power supply (220–240 VAC) appliance is live, ALWAYS use a residual- If there is no electrical meter available, temporarily insert and operate current-operated circuit-breaker! another electrical device on the same socket. →...
  • Page 85 Appliance does not switch on 5. Check voltage at power module output to transformer (220–240 VAC) Check voltage on plug CP2B on power module. ► No voltage ? defective power module (if voltage between F1 and F2 = 220–240 VAC) ►...
  • Page 86 7.5.3 Grinding unit is not functioning 2. Check voltage on power module grinding unit output Fault description: The voltage for the grinding unit is measured on plug CP6 on Grinding unit is not running terminals 3 = GND (black) and 2 = 230 VDC (transparent). The Possible faults: grinding unit must be actuated by a coffee brewing process.
  • Page 87 7.5.4 Pump is not functioning 3. Check voltage on thermostat input Fault description: Before the voltage can be checked on the pump itself, the thermostat Pump is not actuated / is not pumping must be tested for function. The pump must not be overheated! Possible faults: The voltage is measured at the thermostat input –...
  • Page 88 7.5.5 Heater is not functioning Fault description: 3. Check voltage on thermal fuse input Is not heating, error message ERROR 1, ERROR 5 The operating voltage of the heater (= 230 VAC) is measured at the thermal fuse input (brown = under the insulation sleeve) and on the Possible faults: blue terminal on the heating element.
  • Page 89 7.5.6 Brewing unit is not functioning Fault description: 2. Check voltage on power module brewing unit output Brewing unit no longer moves To check the voltage at the power module brewing unit output (=12 VDC), open the appliance. Using the Torx T10 screwdriver, unscrew Possible faults: all rear panel screws and remove the rear panel.
  • Page 90 7.5.7 Magnetic steam valve is not functioning Fault description: 3. Check voltage on magnetic steam valve connectors Steam valve does not open The operating voltage of the magnetic steam valve is measured on the terminals of the valve. Possible faults: The magnetic valve must be actuated by pressing the steam button.

  • Page 91: Measuring The Coffee Temperature

    Measuring the coffee temperature Test voltage: 230 V +/- 3 V Procedure: Switch on the machine with the main switch, press the standby button. Wait until the illuminated ring around the standby button stops flashing (heating-up and rinsing phase has ended). Set filling quantity: coffee (approx.

  • Page 92: Technical Specifications

    TECHNICAL SPECIFICATIONS Rating plate Voltage The rating plate is situated on the control panel holder behind the drip tray panel. VIB (sales identification designation) Customer service index Newly launched appliances are given the customer service index “01”. The customer service index is increased to “02”, “03”, etc.

  • Page 93: Power

    Power Temperatures 8.2.1 Mains voltage Fahrenheit established 0°F as the stabilized temperature when equal amounts of ice, water, and salt are mixed. He 230 – 240 V / 50 Hz then defined 96°F as the temperature "when the 120 V / 60 Hz thermometer is held in the mouth or under the armpit of 8.2.2 Connected load...

  • Page 94: Dimensions And Weight

    Dimensions and weight 8.4.2 Cable length 8.4.1 Appliance dimensions Approx. 1.1 m Height 345 mm Width 273 mm 8.4.3 Weight of machine Depth 480 mm Approx. 12,2 kg Height between coffee outlet and drip plate 75 mm – 128 mm Filling amounts 8.5.1 Capacity...

  • Page 95: Seite 1 Von

    Components Operating voltage 5,0 V DC Display Supply voltage 11,5 V DC Logic p.c.b. (Controll unit) Operating voltage 5,0 V DC Supply voltage 16,0 V DC Speed – motor 3000 r.p.m. (no load) Drive – brewing unit Transmission ratio 451 : 1 (6,6 r.p.m.) Power 4,0 Nm (from spindle) Primarily - power supply...

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Tca680 series

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