1 SAFETY FUNCTIONS INSTALLATION OPERATION REPAIR COMPONENTS FAULT DIAGNOSTICS...73

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1 1 SAFETY Safety instructions Repair instructions INSTALLATION Installation Scope of delivery OPERATION Switching on the appliance Controls Preparation Changing the standard settings Cleaning Descaling COMPONENTS Structure Flowmeter Heater and NTC-sensor Control module and appliance software Service door Brewing unit Gear unit Ceramic valve (2-way valve) Hot water / steam nozzle REPAIR INSTTRUCTTI I ION Fully-automatic coffeemaker 4.10 Coffee outlet Drip tray Water filter FUNCTIONS The perfect espresso Operating principle Warming the cups Diaphragm regulator with blow-off valve Reduction angle with blow-off valve (alternative) Temperature Overview of the symbols REPAIR Replacing the brewing unit General disassembly Replacing the thermal fuse Removing the coffee outlet Remedial actions for Error 8 - message FAULT DIAGNOSTICS Malfunctions System and error messages Incoming goods inspection Service diagnosis Troubleshooting Measuring the coffee temperature _ARA_en_f.doc Seite 1 von 102

2 8 TECHNICAL SPECIFICATIONS Rating plate Power Temperatures Dimensions and weight Filling amounts Components _ARA_en_f.doc Seite 2 von 102

3 1 SAFETY 1.1 Safety instructions 1.2 Repair instructions Danger! Caution! Repairs may be carried out by a qualified electrician only! The user may be put at considerable risk and injured by improper repairs! Electric shock may occur if live components are touched inside the appliance! Do not touch components in the appliance. Even the modules can be live! Before commencing repairs, ALWAYS disconnect the appliance from the power supply! If tests have to be conducted while the appliance is live, ALWAYS use a residual-current-operated circuit-breaker! The protective conductor connection must not exceed the standardised values! This is essential for personal safety and appliance function! When repairs are complete, perform a test in accordance with VDE 0701 or the corresponding national regulations! Following each repair, conduct a leak and performance test. NEVER attempt repairs by randomly replacing components! ALWAYS proceed systematically and comply with the technical documentation for the appliance! Components become hot during operation. Before commencing repairs, leave the appliance to cool down. As a rule, printed-circuit boards are not repaired but are completely replaced with original spare parts. Exceptions are documented separately. Risk of scalding! Hot water / steam nozzle or auto-cappuccinatore frothing-up nozzle (optional) become very hot. Take hold of the nozzles by the plastic parts only, not by the metal parts. Keep body parts away from the nozzles and do not aim it to yourself or anyone else. When steam or hot water is released, the nozzles may initially sputter! _ARA_en_f.doc Seite 3 von 102

4 2 INSTALLATION 2.1 Installation 2.2 Scope of delivery The installation location must be level and dry. Protect the appliance from splash water. There must be a minimum filling height of 420 mm. Connect and operate the appliance only in accordance with the specifications on the rating plate. Operate the appliance indoors and at room temperature only. Do not place the appliance on a hot surface (e.g. heating plate) and never use it close to an open flame. All appliances are supplied with the Welcome pack starter kit Welcome pack The Welcome pack starter kit contains the parts required to start up the appliance: 2 Cleaning-tablets Test strip for determining the local water hardness 2 Descaler-tablets (for 1 descaling process) Scoop and screw-in aid for water filter (depending on model) Operating instructions in different languages as well as a quick reference guide Information on cleaning the appropriate milk-frothing aids (steam nozzle or auto-cappuccinatore) is also enclosed _ARA_en_f.doc Seite 4 von 102

5 3 OPERATION 3.1 Switching on the appliance WARNING Risk of damage! Do not use coffee beans which have been glazed, caramelised or treated with other additives containing sugar. These will damage the grinding unit! Note: When the appliance is used for the first time or if the appliance has not been used for a prolonged period, the first cup of coffee still does not have the full aroma and should therefore not be drunk. Pull the mains plug out of the cord store at the rear of the appliance and connect according to the specifications on the rating plate. Remove the water tank and fill with fresh, cold water. Observe the max mark. Re-attach the water tank. Fill the bean container with fresh coffee beans. Preferably use espresso beans or bean mixtures for fully automatic machines. Set mains switch at the back of the appliance to I. Set function selector to coffee brewing process. Press Standby button. The system is rinsed and heated up. The appliance conducts a selftest, heats up and rinses. Heating up to standby temperature Moving the brewing unit to the upper end position Pump starts, 50 ml of water are conveyed through the coffee outlet. Brewing unit returns to basic position The appliance is ready to use when the illuminated rings around the standby button and the coffee dispensing button are lit green and a coffee symbol is displayed Filling the pipe-system If the appliance is completely drained and steamed out, the water line system must be filled when the appliance is switched on for the first time: Rinse symbol lights up. Press the coffee dispensing buton _ARA_en_f.doc Seite 5 von 102

6 3.2 Controls Mains switch Standby button Warning: The mains switch on the rear of 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. The appliance is in stand-by mode. If the appliance is isolated from the mains with the mains switch, the next time the appliance is switched on, a self-test is run and the brewing module is re-initialised. Do not actuate the mains switch during the brewing process. When the appliance is switched on again, malfunctions and damage may occur. Do not switch off the appliance with the mains switch until the appliance has been switched to stand-by mode with the standby button. 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. The illuminated ring around the button flashes during this process. During the coffee brewing process the standby button is assigned a Stop function. Press this button to end the current brewing process at any time Switching on a cold appliance: When the standby button has been pressed, the appliance heats up and is then rinsed. The illuminated ring around this button flashes. Coffee cannot be brewed until the illuminated ring stops flashing Switching on a warm appliance: The illuminated ring around the standby button is lit constantly. Coffee can be brewed The appliance is not rinsed if: or it was still warm when switched on there was no coffee from the last brew before the appliance was switched off _ARA_en_f.doc Seite 6 von 102

7 3.2.3 Function selector Coffee dispensing button DANGER Risk of scalding! When steam or hot water is released, the nozzles may initially sputter! Rotate the function selector to draw coffee, hot water or steam: 1. Drawing hot water via hot water/ steam pipe. 2. Drawing coffee via brewing unit to the coffee outlet. 3. Drawing steam via hot water/ steam pipe. Steam can be drawn after the appliance has heated up to steam temperature. After steam has been drawn, coffee can be brewed again immediately. Press the coffee dispensing button to start the coffee brewing process. During the brewing process the green illuminated ring flashes. If the coffee dispensing button is pressed again, the coffee brewing process ends early. (The grinding process is ended, the brewing process is stopped, and the brewing unit is emptied.) Ready to use mode is indicated by the illuminated ring which is lit constantly _ARA_en_f.doc Seite 7 von 102

8 3.2.5 Filling quantity selector This rotary knob is used to select the amount of liquid which is required Coffee strength selector The amount of coffee to be ground can be changed by rotating the coffee strength selector. This setting affects the aroma and flavour, the caffeine and acid content as well as the formation of the crema. Single cups Double cups Small espresso approx. 25ml 2 small espresso approx. 50ml Espresso approx. 40ml 2 espresso approx. 80ml Small coffee approx. 80ml 2 small coffees approx. 160ml Coffee approx. 125ml 2 coffees approx. 250ml Large coffee approx. 160ml 2 large coffees approx. 300ml XXL coffee approx. 220ml 2 XXL coffees approx. 360ml Note: The permitted filling quantity tolerance is +/ 5 ml. The filling quantities for 2 large coffees and 2 XXL coffees are not the same as the double filling quantity for corresponding single cups. Therefore aromatic coffee can still be brewed even when there is the maximum amount of liquid selected. Amount of coffee powder can be selected between very mild 7 g and extra strong 14 g. very mild approx. 7 g mild approx. 8 g normal approx. 9 g normal plus approx. 10 g strong approx. 12 g extra strong approx. 14 g The amount of ground coffee powder is monitored in the brewing unit and corrected by compensation of the grinding unit running time _ARA_en_f.doc Seite 8 von 102

9 3.2.7 Cleaning button When the red illuminated ring lights up around the cleaning button clean, the appliance must be cleaned. Coffee can still be brewed. To start the cleaning cycle, press the clean button for approx. 3 sec. Use cleaning tablets Mat.-no ! Descaling button When the red illuminated ring lights up around the descaling button calc, the appliance must be descaled. Coffee can still be brewed. To start the descaling cycle, press the calc button for approx. 3 sec. Use liquid descaling agent Mat.-no ! _ARA_en_f.doc Seite 9 von 102

10 3.2.9 Adjusting the grinding unit Dependent on the roasting degree and on the oil rate of the used coffee beans the grinder setting must be changed Bright roasting, low oil rate - adjust finer Dark roasting, high oil rate - adjust more coarsely The correct grinding unit adjustment is crucial for the coffee taste, the strength and the flavour of the coffee Service-Sticker To make sure that the grinding unit will be adjusted correctly a sticker is added on the right cover of the appliance. Note: A very fine grinding unit setting in combination with a very high amount of ground coffee can cause malfunctions especially by using dark roasted coffee beans with high oil rate. Risk of damage: Adjust the grinding unit only while the grinding unit is running! Otherwise the appliance may be damaged. Open right cover of the appliance. Press the coffee dispensing button to start a brewing cycle. While the grinding unit is running, turn the knob to select the degree of grinding: The smaller the dots the finer the ground coffee. The new setting will not become apparent until the second or third cup of coffee _ARA_en_f.doc Seite 10 von 102

11 3.3 Preparation General: Prewarm cups on the cup shelf or fill with hot water and rinse out Using coffee beans This coffee machine grinds fresh coffee beans for each brewing process. Turn function selector to coffee position. Select the desired amount of coffee and numbers of cups with the rotary knob. Select the preferred coffee strength with rotary knob. Place a cup under the outlet. If required adjust the height of the outlet. Press the coffee dispensing button. The brewing cycle runs automatically. Note: If ADD BEANS is displayed despite a full beans container, the grinding unit might be empty and must still be filled up with ground coffee. Therefore press the coffee dispensing button again to make sure that there is enough ground coffee filled in the brewing unit Using preground coffee WARNING Risk of damage! Do not add whole coffee beans or instant coffee! Add a maximum two scoops of pre-ground coffee. A second type of coffee can be used. Pre-ground coffee can be filled into the brewing unit via the coffee duct. Open the right cover of the appliance. Open ground coffee duct flap (A). Add one or two level scoops of medium-fine ground coffee to the ground coffee duct. Close the ground coffee duct flap and the right cover of the appliance. Press the coffee dispensing button. If coffee is not brewed within 90 seconds, the brewing chamber is emptied automatically in order to prevent overfilling. The appliance is rinsed _ARA_en_f.doc Seite 11 von 102

12 3.4 Changing the standard settings The appliance has been set at the factory so that coffee can be brewed without any additional programming. The following settings can be changed: Water hardness Water filter Setting the water hardness Water hardness 4 is preset It is important for the descaling programme that the water hardness is set correctly. If external water softeners are used in the domestic water system or if filtered water is used, select water hardness 1 Determine the water hardness with the enclosed test strip or ask your local water supplier. Test strip for determining the water hardness, mat. no.: Hardness 1 Hardness 2 Hardness 3 Hardness 4 Descale alarm after 220 litres Descale alarm after 100 litres Descale alarm after 70 litres Descale alarm after 40 litres Degrees of water hardness Setting German French _ARA_en_f.doc Seite 12 von 102

13 Change setting The appliance must be in stand-by mode. Only the illuminated ring around the stand-by button is lit. Simultaneously press and hold down the calc and clean buttons for at least 3 sec. The display changes to: Press calc descaling button until the illuminated rings for the desired water hardness light up. If the illuminated ring around the cafe button flashes, the filter can be set. Press cafe button once. The selected water hardness is saved. Note: The number of the illuminated rings around the control buttons symbolise the selected water hardness. Hardness 1 Hardness 2 Hardness 3 Hardness 4 The appliance now switches on automatically. As soon as the illuminated rings around the stand-by and cafe buttons as well as the coffee cup sign in the display are lit, the appliance is ready for use again. If you do not press the calc descaling button for 90 seconds, the appliance returns to coffee dispensing mode without saving any settings. The previously set water hardness is retained _ARA_en_f.doc Seite 13 von 102

14 3.4.2 Water filter A water filter available as an accessory (mat. no.: ) can be inserted in the water tank. When approx. 50 l of water have run through (corresponds to approx. 400 brews) or after 2 months at the latest, the effect of the filter is depleted. The filter must then be replaced. (Risk of bacteria!) Insert filter into the water tank, then change the appliance settings according to instructions enclosed with the filter. Note: Do not insert the filter if the red illuminated ring around the calc button on the appliance is lit. The appliance must be descaled first. Before descaling the appliance, take the inserted water filter out of the water tank. If softened water from a domestic softening system is used, a water filter is not required. If the change filter system message is displayed, immediately replace or remove used water filters. If no new water filter is inserted, adjust the water hardness. To activate the filter and ensure correct function, the inserted filter must be rinsed. Observe the following points Inserting the water filter The appliance must be in stand-by mode. Place a vessel with a capacity of at least 500 ml under the hot water nozzle. Insert the water filter according to instructions enclosed with the filter. Simultaneously hold down the calc and clean buttons for at least 3 sec. The display changes to: Keep pressing the calc button until the filter symbol lights up. Acknowledge by pressing the cafe button. Rotate function selector to draw hot water. The appliance rinses the filter automatically. Water is conveyed into the collecting vessel (approx. 2 minutes). The water may be a little cloudy, do not drink it! If the turn on coffee system message is displayed, turn function selector back to brew coffee. The appliance is ready for use again _ARA_en_f.doc Seite 14 von 102

15 Changing the water filter Screw in a new water filter. Switch the appliance to stand-by mode. Place a vessel with a capacity of at least 500 ml under the hot water nozzle. Using the screwing aid, unscrew the water filter in an anti-clockwise direction. Simultaneously hold down the calc and clean buttons for at least 3 sec. Acknowledge by pressing the cafe button. Rotate function selector to draw hot water. The appliance rinses the filter automatically. Water is conveyed into the collecting vessel (approx. 2 minutes). The water may be a little cloudy, do not drink it! If the turn on coffee system message is displayed, turn function selector back to brew coffee. The appliance is ready for use again Removing the water filter Switch the appliance to stand-by mode. Using the screwing aid, unscrew the water filter in an anticlockwise direction. Simultaneously hold down the calc and clean buttons for at least 3 sec. Press calc descaling button until the illuminated rings for the desired water hardness light up. (The number of the illuminated rings around the control buttons symbolise the selected water hardness). Acknowledge by pressing the cafe button. The appliance is ready for use again _ARA_en_f.doc Seite 15 von 102

16 3.5 Cleaning DANGER 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! WARNING Daily cleaning of the appliance Wipe the outside of the appliance with a damp cloth. Remove water tank, rinse out and fill with fresh water. Pull drip tray forwards and remove. Empty drip tray (1) and dregs drawer (2) and clean with mild detergent solution. Only dregs drawer (2) can be cleaned in the dishwasher! Thoroughly clean drawer contacts (3) on all sides and dry. Note! Coffee or water residue between the drawer contacts may result in error messages. Extract or wipe out the appliance interior. If the appliance is cold when switched on, the appliance is rinsed automatically _ARA_en_f.doc Seite 16 von 102

17 3.6 Descaling The lime content in drinking water causes calcification of the thermal block, the hose system and the valves in the appliance. This affects the flavour of the coffee and reduces the service life of the appliance. To ensure optimum quality, descale the appliance regularly Descaling alarm The correct setting of the water hardness is important for the descaling indicator. Test strip for determining the water hardness, mat. no.: Hardness litres Hardness 2 Hardness 3 Hardness litres 70 litres 40 litres If the illuminated ring around the calc descaling button lights up red when the appliance is switched on and the request to descale the appliance is indicated on the display, the appliance must be descaled immediately. Descale the appliance according to the following instructions, otherwise the appliance may be damaged. WARNING Never descale the appliance with vinegar or vinegar-based substances. Do not interrupt the descaling programme. Never drink the liquid. If water hardness 1 is set, the request to descale the appliance is indicated after 220 l of water. (1 7 dh) If water hardness 2 is set, the request to descale the appliance is indicated after 100 l of water. (8 15 dh) If water hardness 3 is set, the request to descale the appliance is indicated after 70 l of water. (16 23 dh) If water hardness 4 is set, the request to descale the appliance is indicated after 40 l of water. (24 30 dh) Degrees of water hardness Setting German French _ARA_en_f.doc Seite 17 von 102

18 3.6.2 Descaling programme Warning! Never descale with water filter inserted! The descaling programme starts only if the FILTER programming is not active Starting the descaling programme Take the filter out of the water tank and set the water hardness. The descaling programme lasts approx. 35 minutes. While the descaling programme is running, processes and handling modes are displayed. 1. To start the descaling programme, hold down the calc button for at least 3 seconds. Pull drip tray out of the appliance. Empty and reinsert drip tray and dregs drawer. 2. This display is indicated irrespective of the actual filling of the trays and ensures that the descaling cycle is not interrupted. 3. Fill water tank up to the mark (0.5 l) with warm water and add descaling agent or Fill water tank with 0.5 l of ready mixed descaling solution. If using descaling tablets, add two tablets. Observe the dissolving time of the tablets (approx. 4 6 minutes)! 4. Place an appropriately large collecting vessel under the steam nozzle. Rotate function selector to draw hot water. 5. The illuminated ring around the calc descaling button flashes. The appliance is descaled automatically. Descaling solution (approx. 250 ml) is conveyed in intervals into the collecting vessel. Wait for the next display. (approx. 10 minutes) _ARA_en_f.doc Seite 18 von 102

19 Descaling programme 6. Rotate function selector to coffee brewing process. The appliance is descaled automatically. Descaling solution (approx. 250 ml) is conveyed in intervals into the drip tray via the drainage valve. 7. In doing so, the water tank is completely drained. Wait for the next display (approx. 10 minutes) 9. Remove water tank, rinse out, fill with fresh water and re-insert. Empty collecting vessel and place back under the steam nozzle. 10. Rotate function selector to draw hot water. The appliance is rinsed automatically. Water (approx. 150 ml) is conveyed in intervals into the collecting vessel. 8. Pull drip tray out of the appliance, empty and reinsert. 11. Wait for the next display. (approx. 4 minutes) Rotate function selector to coffee brewing process _ARA_en_f.doc Seite 19 von 102

20 Descaling programme 12. The appliance is rinsed automatically. Water (approx. 300 ml) is conveyed in intervals into the drip tray via the drainage valve. Wait for the next display. (approx. 4 minutes) The descaling programme does not start: The descaling programme starts only if the FILTER programming is not active. Take the filter out of the water tank and set the water hardness. 13. Pull drip tray out of the appliance and empty. Carefully clean contacts of the drip tray on all sides and dry. Ensure that there is no ground coffee residue or water droplets between the tray contacts. Re-insert drip tray and dregs drawer. 14. The appliance is rinsed automatically. The descaling process is complete. The illuminated ring around the calc descaling button goes out. The appliance is ready for use again. If the descaling process is terminated prematurely, the descaling alarm is not cancelled. WARNING! Never descale the appliance with the filter inserted! The descaling programme does not start if the temperature of the heater is too high. Symbol flashes 5 x. Cool down the system by drawing off approx. 1 cup of hot water. When the required temperature has been reached, the descaling process can be started _ARA_en_f.doc Seite 20 von 102

21 4 COMPONENTS 4.1 Structure Overview, left side 1 Mains suppression filter 2 Diaphragm controller (pressure controller) 3 Mains transformer 4 Flowmeter 5 Pump 6 Watertank valve support 7 Gear unit 8 Power electronics module 9 Control electronics module 10 Heating element 11 Service plug Note: From production date FD8701 on: Implementation of a second thermal fuse on heater. Drip tray monitoring by an additional microswitch _ARA_en_f.doc Seite 21 von 102

22 4.2 Flowmeter The composition of the coffee mixture is a well guarded secret of the coffee roasting establishments. To ensure that an excellent coffee can be produced from this secret, the coffee beans must be roasted carefully and the coffee machine controlled precisely unless the dosage is constant, the quality of the coffee cannot be maintained. The flowmeter (A) is installed on the suction side between the water tank (B) and pump (C). To ensure a precise measurement result, the flowmeter must be operated in a horizontal position Design and function Water is pumped in from the water tank and flows through the flowmeter. Water is supplied via the connection pipe in the lower section of the housing (D). Water is discharged via the connection pipe in the upper section of the housing (A). The two halves of the housing are sealed with a silicone seal (B). The fan impeller (C) with the two attached magnets is rotated by the water flow. The Hall-IC in the upper section of the housing (A) generates square pulses which measure the actually required amount of water. When installing the flowmeter, ensure that the direction of flow is correct. An arrow on the flowmeter housing indicates the direction of flow _ARA_en_f.doc Seite 22 von 102

23 4.2.2 Connection diagram 4.3 Heater and NTC-sensor 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). Square pulses are generated in the upper section of the housing via the Hall-IC. Wrong connection of + voltage, signal and earth destroys the flowmeter. Prevent inductive faults via the cable! Do not lay the cable together with supply cables to consumers. Therefore the water is pumped in a stainless-steel pipe (A), which is cast in together with a heating resistor (B) in an aluminum block _ARA_en_f.doc Seite 23 von 102

24 4.3.2 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 _ARA_en_f.doc Seite 24 von 102

25 4.4 Control module and appliance software The appliance is controlled by the control module. The control modules are differentiated by the respective appliance software and by the housing designs. The software versions within one CSI are usually compatible. Thanks to continuous improvements, new software masks are programmed, remove the older versions. The appliance software on the control module cannot be updated for the service Overview of software mask version Version Change Mask 2 Switch-off time changed from 4 to 3 hours CSI 01 Mask 3 According to tank sensor coffee quantity from 100ml to 200ml can be drawn Temperature from value 1(High) to value 2(Maximum) CSI 02 Mask 5 Position detection new cam disc ceramic valve Error message Fault 8 repaired (introduction approx. 8312) Auto OFF function product selector corrected in intermediate position _ARA_en_f.doc Seite 25 von 102

26 4.5 Service door The service door on the right side of the appliance provides access to the brewing unit Door lock The service door, behind the brewing unit is installed, is locked with a bar. Open the door by rotating the locking knob in a clockwise direction. To ensure that the door is not opened without authorisation, e.g. with a coin, the locking knob features an additional crosspiece (A). Open the service door with a screwdriver PB 169/6 M _ARA_en_f.doc Seite 26 von 102

27 4.6 Brewing unit Operating principle The brewing unit forms the central element in the espresso machine. The brewing unit extracts the aroma, flavour and bitter agents from the ground coffee and forms the crema. Ground coffee pours through the filling shaft (A) into the brewing chamber and is compressed. Hot water is introduced under pressure via the water supply (B) and forced through the ground coffee. The coffee which is produced is conveyed to the coffee outlet (C). To optimise crema formation, the crema valve, which is situated above the brewing head, opens when the pressure reaches 4.5 bar. At the end of the brewing process the used coffee dregs are emptied into the dregs drawer via the discharge chute (D) Variable brewing chamber The brewing unit consists primarily of the brewing chamber (A), into which the ground coffee (7 g 14 g) is metered, and the springmounted brewing head (B) which moves upwards to seal the brewing chamber.. The ground coffee is compacted and compressed in the brewing chamber. When hot water is pumped into the brewing chamber, the rising water pressure pushes up the brewing head, increasing the volume in the brewing chamber. This improves extraction of the flavours and formation of the crema _ARA_en_f.doc Seite 27 von 102

28 4.6.2 Sequence of the brewing cycle Grinding and metering Compression Coffee beans are ground in the grinding unit (A). The ground coffee is conveyed into the open brewing chamber via the funnel (B). The amount of ground coffee generated depends on the running time of the grinding unit. The brewing unit can process from 7 g to 14 g of ground coffee. Alternatively ground coffee can be poured in via the powder slot. The grinding unit stops. The gears control the brewing unit to the upper end position. In doing so, the ground coffee is compressed in the brewing chamber (C). The pressure applied to the ground coffee causes the spring-mounted brewing head (D) to move up. The more powder there is in the brewing chamber, the higher the brewing head is pushed upwards during compression. The actual amount of powder is measured by a slide which is connected mechanically to the brewing head and, if required, corrects the amount during the next brewing process _ARA_en_f.doc Seite 28 von 102

29 Brewing Emptying The brewing process starts. The pressure pump conveys the water into the brewing unit. The brewing head (D) is moved up by the water pressure, thereby increasing the volume in the brewing chamber. The hot water is mixed with the ground coffee longer and more intensively, thereby improving extraction of the flavours and formation of the crema. If the pressure inside the brewing chamber increases above 4.5 bar, the crema valve (E) opens and the coffee can flow to the coffee outlet (F). When the programmed amount of water is reached, the pump stops. The pressure in the brewing chamber drops and the coffee dregs are compressed into a solid cake. The drainage valve opens, pressure and residual water are released into the drip tray. When the brewing unit descends, the brewing chamber moves back to the initial position (G) and the coffee dregs are emptied into the dregs drawer _ARA_en_f.doc Seite 29 von 102

30 4.6.3 Compensation of the grinding unit running time The amount of ground coffee which is generated by the grinding unit depends on the running time of the grinding unit. To ensure that the required amount of coffee is always ground, both with different types of coffee, at different grinding settings and possibly with worn grinding tools, the amount of ground coffee which was actually conveyed to the brewing module (B) is measured. The more powder there is in the brewing chamber, the higher the spring-mounted brewing head is pushed upwards during compression. A microswitch (µ) closes and opens as it moves past via a slide which is connected mechanically to the brewing head. The electronics module measures the number of the voltage changes (connection A) caused by the switching processes which occur immediately before the pressure pump switches on and can therefore detect whether and how much ground coffee has been metered. This value can be compared with the nominal value for the aroma setting. Differences are adjusted by changing the running times of the grinding unit Switching states If there is a minimum amount of coffee (<7 g), the brewing head does not move. The switch is not actuated. = Not enough coffee beans. ADD BEANS is displayed (I) Amount of powder >7 g <10 g (II) Amount of powder 10 g (III) Amount of powder >10 g <14 g (IV) Amount of powder >14 g = Too many coffee beans. The running time of the grinding unit must be reduced. Special cases: Too hot and too little powder before brewing Too little powder during 1st brewing process Brewing is ended (dry discharge), there is no pumping. The brewing module moves to the grinding position. Auto cooling starts (several ml of water are conveyed) and SYSTEM TOO HOT is displayed ADD BEANS is displayed and an additional time of 1.3 sec. is given. Compensation is not active during this and the next brewing process _ARA_en_f.doc Seite 30 von 102

31 4.6.4 Reinforced brewing unit New, reinforced brewing units will be used from production date FD8307. Changes to components result in a higher pressure resistance in the complete brewing unit as well as improved functional safety of the entire machine. Externally the new, reinforced brewing units can be identified by the longer discharge chute on the brewing chamber Stripping-off clip To improve functional safety, a stripping-off clip (B) was fitted to the brewing unit (A). (A) Short discharge chute = previous brewing unit (B) Long discharge chute = new, reinforced brewing unit This stripping-off clip is attached to the discharge chute on the brewing chamber and moves closely past the brewing head (C) during each brewing cycle. Coffee dregs which stick to the brewing head are therefore removed mechanically. Faults in the brewing cycle and during initialisation of the brewing unit due to overdosage are therefore avoided. Note: The control lever is a component of the brewing unit and is not available separately. All current replacement brewing units feature this new lever _ARA_en_f.doc Seite 31 von 102

32 Control lever To improve functional safety, an additional rib (A) was fitted to the control lever of the brewing unit. A cleaning tablet which was inserted at the wrong time and did not fall into the brewing chamber could become jammed near the control lever of the brewing unit. This resulted in a blockage of the brewing unit and error messages. The additionally attached rib (A) prevents cleaning tablets from sticking in this location and causing damage. Note: The control lever is a component of the brewing unit and is not available separately. All current replacement brewing units feature this new lever _ARA_en_f.doc Seite 32 von 102

33 4.7 Gear unit The gear unit is the drive for the brewing unit. The gear motor is actuated at +/ 16 V DC and transfers its power via gears to a drive shaft which is connected to the brewing unit Front housing Microswitches (S1 and S2) are attached to the front housing of the gear unit. These microswitches measure the position of the gears and the brewing unit via a cam (B) connected to the drive shaft Rear housing Note: From production date FD8701 on the drip tray is monitored by an additional microswitch in the appliance. If the drip tray is pulled out, the microswitch opens and interrupts the power supply to the gear motor via the power module. On the rear housing section of the gear unit the drainage valve (B) is attached to the expansion chamber (C). This valve controls the passage of water from and to the brewing unit. The microswitch (D) is actuated by the lock on the brewing unit. The drive shaft (E) is the connection to the brewing unit _ARA_en_f.doc Seite 33 von 102

34 4.7.3 Cam on the gear unit The position of the brewing unit is detected with two microswitches S1 and S2. These two switches are able to define three positions. When the appliance is switched on, the switch status of the microswitches is checked and transmitted to the control module. The brewing unit is moved to the basic position (= initialising). Home position Brewing position Drainage position The brewing unit is in the grinding position and can be filled. Switch S1 is activated by switch cam (A). Switch S2 remains open. The transmission turns clockwise until switch S2 is closed by switch cam (A) and switch S1 is open. The brewing unit is in the brew position. The transmission motor stops. Water can be supplied and coffee can be brewed. Once the brewing process is complete, the system is drained. For this, the motor turns the cam disc back by about 8, so that the drainage valve is opened again and the remaining water can run into the drip tray. Switches S1 and S2 are closed. S1 ON S2 OFF S1 OFF S2 ON S1 ON S2 ON _ARA_en_f.doc Seite 34 von 102

35 4.7.4 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 Home position When the gears are in the home position, the drainage valve is open. The cam (E) of the actuator must then be in the illustrated position. Warning! Malfunction The position of the actuator and therefore the cam (E) is not specified permanently on the drive shaft. The actuator may be in the wrong position. The function sequence may malfunction. When installing the gears, ensure that actuator is in the correct position, as indicated under Home position! _ARA_en_f.doc Seite 35 von 102

36 Brewing position When the gears move into the brewing position, the drive shaft rotates with the actuator (D) in an anti-clockwise direction Drainage position Once the brewing process is complete, the water pump switches off. The brewing unit is moved upwards. The connection to the drainage valve is closed with the water coupling in the brewing unit. The switch cam on tripping device (D) reaches into the drainage valve control line and closes it. Water can flow from inlet (A) through drainage valve (B) to outlet (C). The transmission motor turns the input shaft with tripping device (D) back through about 8 and opens the drainage valve. The pressure is relieved and the water can drain into the expansion chamber and then into the drip tray. To prevent underpressure, air can flow back through valve (B). Then the transmission turns back in a clockwise direction until it is in the basic position again _ARA_en_f.doc Seite 36 von 102

37 4.8 Ceramic valve (2-way valve) By rotating the function selector on the front of the control panel, the drawing of hot water (1), coffee (2) or steam (3) can be selected on the ceramic valve. Two ceramic wheels which rotate against each other convey the hot water or the steam to the hose connections for the drainage valve or the steam pipe. (A) Heating inlet (C) To the drainage valve (brewing module) (D) To the steam pipe (drawing hot water and steam) Switch matrix The microswitches S1 and S2 control the heater and pump via the logic board. The microswitches are actuated by rotating the cam Switch positions: Steam: S1 open S2 closed Coffee: S1 closed S2 open Hot water: S1 closed S2 closed _ARA_en_f.doc Seite 37 von 102

38 4.8.2 Water flow The rotatable ceramic wheel releases the water or steam passage. The corresponding openings in the lower wheel are connected to each other via indentations in the upper wheel. (A) Inlet (B) Outlet to the steam pipe (C) Outlet to the drainage valve (brewing module) Drawing steam Drawing coffee Drawing hot water _ARA_en_f.doc Seite 38 von 102

39 4.9 Hot water / steam nozzle Function DANGER Risk of burns! The nozzle gets very hot. Do not touch the metal parts! Note: (1) Sleeve with plastic grip To dispense hot water or to froth milk, move the sleeve downward by the plastic grip. To warm drinks with steam, slide the sleeve upwards by the plastic grip. (2) Tip of nozzle with inlet Sucks in milk and mixes with air to make milk froth. Every time you froth milk, clean the nozzle immediately afterwards by dispensing hot water. Dried on milk residues are difficult to remove. The steam flows through steam pipe (A) and the connected steam nozzle, thereby creating underpressure inside the steam nozzle. This underpressure is balanced out by fresh air flowing in through opening (B) on the nozzle holder and (C) on the tip of the nozzle. If the nozzle is immersed in cold milk to above side opening (C) and steam is dispensed, fresh air flows in through opening (B) on the nozzle holder. At the same time, milk is sucked into this air flow through opening (C), mixed with the flow of steam and emitted at the tip of the steam nozzle. The resulting circulation of sucked in, mixed and emitted milk, warms the milk up. The milk froth is created by the mixing of the milk proteins with air. The proteins are stable up to approximately 76 C. They are destroyed by higher temperatures and froth formation is not possible then _ARA_en_f.doc Seite 39 von 102

40 4.10 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). The pressure escapes, the coffee flow abates and the ethereal oils and fats dissolved in the coffee can froth up inside the coffee outlet (D) and form the crema. The coffee is distributed evenly from the overflow to the left and right and then flows out through the outlet nozzles (E) into the cup. Note: To ensure that the coffee flows out evenly from the left and right, it is essential that the machine is level. Soiling and deposits affect the coffee outlet. Therefore, regularly run the automatic cleaning cycle using the cleaning tablets (mat. no ). Permitted quantity difference between the left and right outlets must not be greater than +/- 15% _ARA_en_f.doc Seite 40 von 102

41 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 _ARA_en_f.doc Seite 41 von 102

42 4.11 Drip tray 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. When the drip tray has been inserted, a tray contact closes the circuit. The appliance is ready for use again. When the drip tray is full of water, the tray contacts (A) are inserted into the water. The electrical resistance between the tray contacts drops. EMPTY TRAYS is displayed. If the EMPTY TRAYS display does not go out despite the trays having been emptied, there may be residual water or moisture between the contacts (transfer resistance caused by damp ground coffee). Carefully clean trays in the area of the contacts with a soap solution and then dry. Note: From production date FD8701 on the presence of the drip tray is monitored by an additional microswitch in the appliance actuated by a trigger on the drip tray. If the drip tray is pulled out, the microswitch opens and interrupts the power supply to the gear motor via the power module _ARA_en_f.doc Seite 42 von 102

43 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 Drip tray is missing and Drip tray full of water The detection springs are attached to a drawer which is accessible when the rear panel of the appliance is opened Function: Drip tray is missing: Detection springs 1 and 2 are not jumpered by the tray contact I. The circuit is interrupted. Drip tray inserted: Detection springs 1 and 2 are jumpered by the tray contact I. The circuit is closed. Drip tray is full of water: The tray contacts I and II are inserted into the water. The electrical resistance between the tray contacts drops. The circuit is closed via the detection springs 2 and 3. Drip tray is empty: The tray contacts I and II are dry. The electrical resistance between the tray contacts is infinite. The circuit between the detection springs 2 and 3 is interrupted _ARA_en_f.doc Seite 43 von 102

44 4.12 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. Important minerals and fluoride are retained Filtration when drawing water The water required for the preparation of coffee is filtered directly before use. The water is drawn in by fins in the lower area of the filter cartridge, filtered by the granulate and conveyed out through the centre of the water tank valve. (= Up flow principle) Filter specifications The filter capacity at 27 dh is approx. 50 litres (400 brews) or 2 months. The filter filling consists of approx. 100 ml ion exchange resin and silvered activated carbon in the ratio 4:1. Filter diameter: Filter length: Filling volume: mm 175 mm ml Filter effect: Carbon hardness Chlorine (Reduction if Lead following substances Copper are in the water) Aluminium up to up to up to up to up to Important! Follow the information in the operating instructions for inserting or replacing the water filter! Do not insert filter if the descaling display lights up! First descale the appliance! If the appliance is always operated with the water filter inserted, descale as a precaution once or twice a year! _ARA_en_f.doc Seite 44 von 102

45 5 FUNCTIONS 5.1 The perfect espresso A genuine espresso is prepared according to a specific extraction process in which the water is forced under high pressure through finely ground coffee in order to release all the flavours. The excellent quality of the result in the cup depends on the selection and composition of the raw coffee from different countries of origin, the degree of roasting, the fineness of the grinding and the extraction method: Applied pressure, water temperature and extraction duration. A perfect espresso can be identified by its distinctive taste, intensive flavours and a dense body, refined by a crema of perfect consistency. 5.2 Operating principle Water and coffee beans are kept ready in the storage containers for the preparation of coffee. When the product has been selected, the coffee grinder begins to grind the beans. Ground coffee is metered into the brewing module. The coffee grinder stops after a time allocated to the quantity. The brewing process begins when the brewing module moves into the upper end position. When this position has been reached, the water pump begins conveying water. Water is drawn out of the tank via the flowmeter. The water flow causes the fan impeller to rotate in the flowmeter, causing electrical pulses to be generated. The running time of the pump is specified by the number of the pulses. The pump conveys the water through the heater at a pressure of 5 8 bar. Depending on the selected product (coffee, hot water or steam), the water is heated up to a temperature between 82 C and 130 C before it is fed either to the steam pipe via the two-way valve or conveyed into the brewing module via the drainage valve. Reed switch The sequences are monitored by sensors and microswitches. All functions are controlled and interlinked via the logic module. All units, such as motors, pump, heater, are supplied with power via the power module. Grinder Pump Water tank Service door Tray contact 5.3 Warming the cups Brewing unit Extract. pos. Ground coffee slot Grinding correction Net filter Heater Steam pipe 2-way valve The warm exhaust air from the coffee heater is used to warm the cups. The air rises and flows through openings in the cup rack. There is no active heating element for warming the cups. Logic Power _ARA_en_f.doc Seite 45 von 102

46 5.4 Diaphragm regulator with blow-off valve 5.5 Reduction angle with blow-off valve (alternative) The water is drawn out of the water tank via the hose connection (A). The water flows through the flow meter (B) and rotates the fan impeller inside. This causes electronic impulses to be generated which determine the amount of water actually conveyed. The pump (C) generates a pressure of 5 8 bar. The diaphragm regulator (D) minimises pressure peaks and keeps the pressure at a constantly high level. Vibrations in the entire fluid system are reduced. A fabric hose (E) feeds the water to the heater. Too high pressure in the system is discharged by the blow-off valve (F). It opens at approx. 9 bar. Discharged water (G) is then conveyed into the drip tray via hoses. Note: From production date FD8307 on a reinforced brewing unit has been implemented so the blow-off valve is no longer necessary. The water is drawn out of the water tank via the hose connection (A). The water flows through the flow meter (B) and rotates the fan impeller inside. This causes electronic impulses to be generated which determine the amount of water actually conveyed. The pump (C) generates a pressure of 5 8 bar. As soon as the pump starts, a counter pressure builds up via the reduction angle (D). The pump starts more quietly and the pressure is kept at a constantly high level. Vibrations in the entire fluid system are reduced. A fabric hose (E) feeds the water to the heater. Too high pressure in the system is discharged by the blow-off valve (F). It opens at approx. 9 bar. Discharged water (G) is then conveyed into the drip tray via hoses _ARA_en_f.doc Seite 46 von 102

47 5.6 Temperature Temperature pattern The temperature graph indicates the temperature pattern on the heater during operation. For Basic-variants TK60x /TCA60x the temperature level cannot be adjusted. Temperature setting is fixed by the factory.! 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. Coffee cannot be drawn after steam has been drawn if there is too little ground coffee in the brewing unit. The brewing process is terminated, there is no pumping. The brewing unit moves to the grinding position. Automatic cooling starts (several ml of water are conveyed). I II III IV V VI VII VIII IX Heating up Brewing mode Draw coffee (approx. 91 C) / draw hot water (approx. 95 C) Reheating Brewing mode Heating up to draw steam (approx. 140 C) Steam ready Drawing steam Cooling after drawing steam A B C D E F Switch on, press Standby button Press the coffee dispensing button or draw hot water Stop drawing coffee / hot water Turn function selector to steam, heating up process begins Draw steam Turn function selector to cafe, cooling down process begins _ARA_en_f.doc Seite 47 von 102

48 5.7 Overview of the symbols Rinsing Filling the system Symbol is lit: When the appliance is switched on and off, the hose system is rinsed with water. Symbol is lit: The water line system in the appliance is empty. OR an empty water line system is being filled. flashes Remark: A rinsing process does not start unless coffee was drawn as the last product, the temperature on the thermal block is below 130 C. lit flashes Remark: System must be refilled with water. Remedial action: Press the coffee dispensing button. System is filled (minimum amount) Note: If the message does not go out, check the water flow. If water runs into the tray, the flow meter is defective. If water does not flow, check the diaphragm regulator _ARA_en_f.doc Seite 48 von 102

49 5.7.3 Appliance is being cleaned Symbol is lit: The appliance is being cleaned Appliance is being descaled Symbol is lit: The appliance is being descaled. lit lit flashes flashes _ARA_en_f.doc Seite 49 von 102

50 5.7.5 System too hot Filling with ground coffee cover closed Both symbols flash: Coffee scoop flashes, The appliance is currently too hot for brewing ground coffee with too little ground coffee. Coffee cup is lit: The ground coffee duct flap was opened, the ground coffee slot can be filled with ground coffee. flashes Remedial action: Leave the appliance to cool down or cool it manually by drawing hot water. lit lit Remark: Before coffee can be brewed, the ground coffee duct flap must be closed _ARA_en_f.doc Seite 50 von 102

51 5.7.7 Preground coffee Drawing coffee with pre-ground coffee Both symbols flash: Both symbols are lit: Ground coffee was filled, the cover is closed again. Pre-ground coffee is being drawn lit lit Remark: Start coffee production by pressing the coffee dispensing button. The grinding unit does not start in this function. lit flashes Remark: If the coffee dispensing button is pressed again, the brewing of pre-ground coffee can be interrupted at any time. Note: If the cup is not actuated within 90 sec., the system is automatically drained to prevent overfilling. The system is drained and rinsed _ARA_en_f.doc Seite 51 von 102

52 5.7.9 Filling with beans Coffee brewing in standby Both symbols flash: The bean container is empty. Symbol is lit: Indicates that the appliance is in normal operating mode. Coffee or hot water can be drawn. lit lit Remedial action: Fill the bean container and restart coffee production by pressing the coffee dispensing button. lit lit _ARA_en_f.doc Seite 52 von 102

53 Drawing coffee Appliance is heating up Symbol is lit: Symbol flashes: Coffee is being drawn. Appliance is heating up. lit flashes Remark: If the coffee dispensing button is pressed again, the drawing of coffee can be interrupted at any time. flashes Remark: Approx. 70 seconds _ARA_en_f.doc Seite 53 von 102

54 Drawing steam Appliance heats up to steam temperature Symbol is lit: Steam is being drawn. Symbol flashes: Heater heats up from coffee temperature to steam temperature. lit lit Remark: Duration approx. 15 seconds flashes flashes _ARA_en_f.doc Seite 54 von 102

55 Filling with water Empty the trays Symbol is lit: Symbol is lit: Too little water in the tank Drip tray or coffee dregs tray is full Water tank not or incorrectly inserted. OR the switch contacts on the drip tray are dirty. lit Remedial action: Fill water tank with fresh water. Insert water tank Note: The water level is monitored by a software counter (impulses from flow meter) and float / magnetic switch. A residual water level between 80 ml and 180 ml in the tank is possible. The amount of residual water in the tank depends on the product which was last brewed (espresso, coffee...). lit Remedial action: Remove drip tray or coffee dregs tray, empty and re-insert. Carefully clean the switch contacts. Ensure that there is no coffee or water residue on the switch contacts _ARA_en_f.doc Seite 55 von 102

56 No trays Turn on coffee Symbol flashes: Symbol is lit: Drip tray not or incorrectly inserted. (The appliance cannot detect the coffee dregs tray). For reasons of function the function selector must be set to the coffee position. lit Remedial action: Insert trays correctly Note: Heater OFF lit Remedial action: Rotate function selector to the coffee position _ARA_en_f.doc Seite 56 von 102

57 Turn on water Door not closed / No brewing unit Turn on water flashes 5 times, coffee cup is lit: The appliance is heated by drawing steam and should be cooled down by drawing hot water. Symbol is lit: Service door is not closed OR Brewing unit is not or incorrectly installed. lit Remark: Required before starting the cleaning or descaling programme. Remedial action: lit Remedial action: Close service door. Re-install and lock brewing unit. lit Set function selector to draw hot water _ARA_en_f.doc Seite 57 von 102

58 Changing the filter Error 1 Both symbols are lit: Upper symbol is lit, When approx. 50 l of water have run through (corresponds to approx. 400 brews) or after 2 months at the latest, the effect of the filter is depleted. lower row flashes: Error 1 NTC temperature sensor is outside the measurement range. lit lit Remedial action: Changing the water filter OR continue operation without filter. Change settings on the appliance accordingly. Note: Descaling and cleaning programmes are disabled while this display is lit. flashes Appliance too cold (< 5 C) or NTC defective (short-circuit). The message is indicated when the appliance has been switched on and initialised. If the ambient temperature is too low, the message goes out when the appliance has warmed up to room temperature _ARA_en_f.doc Seite 58 von 102

59 Error Error 8 Upper symbol is lit, Upper symbol is lit, lower row flashes: lower row flashes: Appliance is heating up. Brewing unit cannot move properly. flashes Error 5 Heater or thermal fuse defective (interrupted). If this defect occurs while the appliance is operating in a warm state, the message Unit is heating is displayed. The message is indicated as long as the appliance remains switched on. When the appliance has been switched off and after the cooling phase, the message is indicated as in the cold state. flashes 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. Incorrect operation cleaning tablet was inserted too early and blocked the brewing unit. Wrong coffee settings too much, too finely ground coffee. Wrong grinding unit setting grinding too coarse, amount too large. If the message does not go out when the appliance is switched off and on again, disconnect the appliance from the mains and clean the upper filter of the brewing unit. If required, re-adjust the grinding unit setting _ARA_en_f.doc Seite 59 von 102

60 6 REPAIR 6.1 Replacing the brewing unit Removing the brewing unit The brewing unit is permanently installed in the appliance. The service door on the right-hand side of the appliance provides access to the brewing unit by customers. During a service the brewing unit can be released and taken out of the appliance. To ensure that the door is not opened without authorisation, e.g. with a coin, the locking knob features an additional crosspiece (A). Open the service door with a screwdriver PB 169/6 M4 (commercially available) Opening the service door The service door, behind the brewing unit is permanently installed, is locked with a bar. Open the door by rotating the locking knob in a clockwise direction _ARA_en_f.doc Seite 60 von 102

61 Releasing the brewing unit When the service door has been opened, the brewing unit is accessible. The brewing unit is secured in the appliance with three locks. Removing the brewing unit (A) Remove 3 rubber caps with a flat screwdriver (B) Loosen 3 locks by rotating them with a flat screwdriver (C) Pull out brewing unit of the appliance Symbols on the brewing unit indicate whether the lock is open or closed. Lock closed Lock open _ARA_en_f.doc Seite 61 von 102

62 6.1.2 Replacing the brewing unit Inserting the brewing unit The brewing unit can only be inserted in the basic position. The brewing chamber is located completely underneath the filling funnel. Inserting the brewing unit (A) Insert brewing unit into the appliance (B) Fix two locks by rotating them clockwise with a flat screwdriver (C) Fix lock by rotating it counter clockwise with a flat screwdriver (D) Insert three rubber caps into the notches Symbols on the brewing unit indicate whether the lock is open or closed. Lock closed Lock open _ARA_en_f.doc Seite 62 von 102

63 6.1.3 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 GTE 703 Mat.-no.: Note: After replacing the O-ring for the coffee outlet (A) or for the water inlet (C) they must be thinly greased with foodsafe special lubricating grease PARALIQ GTE 703 Mat.-no.: _ARA_en_f.doc Seite 63 von 102

64 6.2 General disassembly Risk of electric shock! Pull out mains plug before disassembly. Appliance must not be live! DANGER! Tools: Torx-Screwdriver T Procedure: 1. Remove the water tank (A) from the appliance. 2. Remove the aroma protection cover (B) from the bean container. 3. Open and remove the ground coffee flap (C). To do this, open the flap and pull it up. 4. Loosen 8 Torx T10 screws (D) on back panel (E) of appliance. 5. Remove back panel (E) to rear. 6. Remove upper section of housing to rear and up. 7. Remove housing side sections (G) by pulling them up. Note! When removing the back panel take care of the supply cable to the mains switch! _ARA_en_f.doc Seite 64 von 102

65 6.3 Replacing the thermal fuse The thermal fuse (STB) is a safety element which is used to prevent damage caused by the heater overheating. To ensure correct function, it is essential to install the thermal fuse properly. Whenever the appliance is repaired, check as a precaution that the thermal fuse is in perfect condition and is correctly installed! Installation location 1 Screw with circlip 2 Installation bracket 3 Heater Checking an installed thermal fuse: The following points must be checked: Position and attachment of the Teflon hose (must be firmly anchored) Position of the thermal fuse (centred under installation bracket) Quality of the cable connections Bend correct Installation bracket is firmly attached Component The thermal fuse is supplied as a pre-assembled component. (Wire colour and type may deviate in reality) _ARA_en_f.doc Seite 65 von 102

66 6.3.4 Installing / replacing the thermal fuse: After removing the defective thermal fuse, comply with the following new steps to ensure correct installation: 1. Check installation position for heater (no dirt or projecting edges permitted). 2. Check installation bracket (no dirt or sharp edges permitted). 3. Check whether it is the correct type of thermal fuse (according to wiring / circuit diagram). 4. Position Teflon hose over the thermal fuse, ensuring that none of the electrically conductive parts remains uncovered (same as the illustrated example of the thermal fuse, slight kinking is used to fix the hose). 5. Before installation, bend connections of the new thermal fuse according to the thermal fuse to be replaced. This must be done with a suitable pair of flat nose pliers. In doing so, comply with the following points: Bend must be at least 5 mm from the housing of the thermal fuse. Teflon hose and thermal fuse must not be damaged. Connections may be bent 1 x only. 6. Position thermal fuse on the mounting surface of the heater, ensuring that the installation bracket is in the centre of the thermal fuse housing (attention: note original position). 7. Insert installation bracket into the designated guide. (Ensure that the bracket is inserted according to the picture) 8. Attach installation bracket with the corresponding screw and circlip. 9. Following installation, check that the installation bracket on the side of the thermal fuse is not situated on the heater (according to following picture). 10. Connect thermal fuse wires to the correct terminals in the appliance. Important! Installation bracket must not be situated on the heater _ARA_en_f.doc Seite 66 von 102

67 6.4 Removing the coffee outlet Opening the coffee outlet To open the coffee outlet, insert a flat-tipped screwdriver into the catch on the underside of the outlet slide (1.), loosen the catch (2.) and remove the front housing section of the outlet slide. (3.) Loosening the coffee distributor First remove the silicone hose (A). Remove the coffee distributor (B) after detaching the catches (C) _ARA_en_f.doc Seite 67 von 102

68 6.4.3 Loosening the metal bands Removing the metal bands The steplessly height-adjustable coffee outlet is braked by metal bands on which magnets press. For subsequent removal: Press the outlet slide all the way down (1.) Using a flat-tipped screwdriver, press the metal band (A) downwards. Insert a flat-tipped screwdriver into the side openings in the metal bands (A) and prise the metal bands out of the guide pins by rotating the screwdriver (2.) Remove the metal bands (A) and the braking magnets (B) _ARA_en_f.doc Seite 68 von 102

69 6.4.5 Loosening the screw fittings When the metal bands have been removed, the screw fittings are accessible. (A) Attachment of the outlet slide (2x Torx T10) (B) Fastening screws for the front panel (3x Torx T10) _ARA_en_f.doc Seite 69 von 102

70 6.5 Remedial actions for Error 8 - message Causes of Error 8 message The brewing unit initialisation has failed. The brewing unit cannot be moved into the upper end position. This may be due to several causes, e.g.: Incorrect operation (ground coffee filled with too much preground coffee or whole coffee beans) Incorrect operation (cleaning tablets added at the wrong time) Wrong coffee settings (too much, too finely ground coffee) Wrong grinding unit setting (grinding unit not adjusted accurately enough) From production date FD8701 on: Microswitch for drip tray monitoring is not actuated (wrong or defective drip tray inserted). Power supply for gear motor is interrupted. Brewing unit cannot be moved Stripping-off clip To improve functional safety, a stripping-off clip (B) was fitted to the brewing unit (A). This stripping-off clip is attached to the discharge chute on the brewing chamber and moves closely past the upper brewing filter (C) during each brewing cycle. Coffee dregs which stick to the brewing filter are therefore removed mechanically. Faults in the brewing cycle and during initialisation of the brewing unit due to overdosage are therefore avoided. Note: The stripping-off clip is a component of the brewing unit and is not available separately. All current replacement brewing units feature this stripping-off clip Remedial actions Cleaning the upper brewing filter If the fault message does not go out when the appliance is switched off and on again, disconnect the appliance from the power supply and clean the upper brewing filter (C) in the brewing unit. It is not necessary to remove the brewing unit for this process. Pull out and remove the drip tray. Insert a damp cloth into the drip tray duct from the front on the right, pull upwards and clean the brewing filter by hands _ARA_en_f.doc Seite 70 von 102

71 Fin on the control lever of the brewing unit It is possible that a cleaning tablet which is dropped in too early may stick in the area of the control lever for the brewing unit. This results in a blockage of the brewing unit and in the Error 8 message. In the worst case this may also cause the lever to jump out. Therefore a fin (A) is also attached the control lever Cleaning process sticker Information sticker to avoid damage caused by adding the cleaning tablet at the wrong time is stuck to the inside of the right appliance flap. The information stickers are available as a spare part for service. The control lever is a component of the brewing unit and is not available separately. All current replacement brewing units feature this new lever _ARA_en_f.doc Seite 71 von 102

72 Replacement ground coffee duct To optimise filling of the brewing unit, the ground coffee duct and the grinding unit funnel have been reworked. To ensure that the ground coffee falls into the middle of the brewing chamber, the stop edge (c) was moved towards the centre by 2 mm. The corners (a) and the side panels (b) have been optimised in such a way the ground coffee is stopped smoothly. This is important in order to meter an exact amount of ground coffee. By moving the stop edge on the grinding unit funnel, the opening for the cleaning tablet is reduced. This is compensated for by the rounding of the filling edge (d) on the ground coffee duct Plug insulation on gearbox microswitch During installation and maintenance there is a risk that the plug-in contacts of the microswitches may be bent while work is being carried out on the gearbox. A short-circuit may occur. This results in malfunctions and the Error 8 fault message (initialisation fault). Replacement ground coffee duct This can be avoided by using an insulating nozzle (mat. no ) for each microswitch. In the event of a service the modified components ground coffee duct and grinding unit funnel should both be replaced. Module consisting of a ground coffee duct and grinding unit funnel is available under mat. no _ARA_en_f.doc Seite 72 von 102

73 7 FAULT DIAGNOSTICS 7.1 Malfunctions 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 5 10 mm under coffee outlet!) Coffee temperature too high Brewing system not prewarmed (1st coffee brewing process after appliance switched on), low amount of liquid (e.g. espresso) Appliance calcified Descale. Heater has heated up to steam temperature NTC temperature sensor defective NTC temperature sensor not screwed on correctly Prewarm brewing system; to do this open and close ground coffee duct flap and start a coffee brewing process. Rotate function selector briefly to draw steam in order to increase the temperature. Cool down heater by drawing hot water Replace NTC temperature sensor Tighten NTC temperature sensor Logic module defective Replace logic module Coffee has too little aroma Grinding unit setting not optimum Adjust grinding unit setting. (Change degree of grinding only while the grinding unit is running) Unsuitable coffee or beans no longer fresh Change coffee or use fresh beans _ARA_en_f.doc Seite 73 von 102

74 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) Coffee levels differ when simultaneously filling two cups (> +/ 15%) when drawing several cups in succession Grinding unit setting not adjusted optimally to coffee beans Brewing system dirty Appliance not level Outlet distributor dirty or defective Adjust grinding unit setting. (Change degree of grinding only while the grinding unit is running) Run descaling and cleaning programmes Place appliance on a level base Replace outlet distributor Hose system or drainage valve leaking During a brewing process check hose system and drainage valve for leaks Drainage valve leaking due to coffee dregs Run descaling programme Replace drainage valve Incorrect pulsing from flow meter Check hose system between flow meter and pump. If hose length = 6 cm replace hose with kit mat. no (hose = 22 cm) Coffee is only dripping out Degree of grinding setting too fine Set a coarser degree of grinding. tastes too bitter Coffee ground too finely Use coarser ground coffee or reduce dosage. Brewing filter blocked or silted up Clean brewing filter or run cleaning programme _ARA_en_f.doc Seite 74 von 102

75 7.1.3 Grinding unit Complaint Cause? Remedial action Coffee beans are not ground Noise of grinding unit is quieter and higher Grinding unit has not been adequately filled with coffee Coffee beans are too oily and stick to the wall of the bean container Coffee beans do not fall into the grinding unit Bean container is empty Fill bean container Noise of grinding unit is loud Grinding unit is not functioning Coffee beans do not fall into the grinding unit, are too oily and stick to the wall of the bean container Foreign object in grinding unit (e.g. grit, may also occur with select coffees) Press coffee dispensing button again to start another brewing process Empty and clean bean container. Use beans with lower fat content Empty and clean bean container. Use beans with lower fat content Replace grinding unit Ground coffee has been selected Press coffee dispensing button again to start another brewing process Power module not actuated by the logic module Check actuation; to do this, press the coffee dispensing button to start a brewing process. If required, replace the logic module Grinding unit not actuated by the power module Check actuation; to do this, press the coffee dispensing button to start a brewing process. If required, replace the power module Grinding unit motor defective Replace grinding unit Grinding unit starts as soon as appliance is switched on Optocoupler on power module defective Replace the power module _ARA_en_f.doc Seite 75 von 102

76 7.1.4 Drawing hot water and steam / frothing Complaint Cause? Remedial action No hot water or steam function, too little steam Too little froth when frothing milk poor froth consistency Frother dirty or calcified Dismantle frother, clean carefully or descale Steam/hot water pipe dirty, blocked or calcified Clean or descale steam/hot water pipe Ceramic valve (function selector) blocked, calcified Replace ceramic valve and descale Frother dirty or calcified Dismantle frother, clean carefully or descale Frother assembled incorrectly Assemble correctly and ensure all parts are fitted securely without gaps froth collapses Milk is not at refrigerator temperature Use only cold milk which is at refrigerator temperature Milk has excessively high fat content Use only long-life milk with a fat content of 1.5% Heater calcified (temperature drop) Descale the appliance _ARA_en_f.doc Seite 76 von 102

77 7.1.5 Cleaning and descaling programme Complaint Cause? Remedial action Cleaning programme does not start Cleaning programme stops after addition of cleaning tablet Error message Fault 8 is indicated Descaling programme does not start Descaling programme runs for too long Descaling display does not go out after descaling System too hot (message on display) Cool down system by drawing hot water Ground coffee flap is not closed Close ground coffee duct flap and press coffee dispensing button No ground coffee duct flap or no magnet on ground coffee duct flap Reed switch for detecting the ground coffee duct flap defective Cleaning tablet added at wrong time. Cleaning tablet is blocking brewing unit From production date FD8701 on: Microswitch for drip tray monitoring is not actuated Replace ground coffee duct flap with magnet Replace reed switch Remove and clean brewing unit, remove cleaning tablet If damaged, replace brewing unit Wrong or defective drip tray inserted. Power supply for gear motor is interrupted. Brewing unit cannot be moved. Replace drip tray. System too hot (message on display) Cool down system by drawing hot water Water filter inserted and active Remove water filter and change programming Adjust water hardness Too much liquid in water tank Observe 0,5 l mark on water tank Request to empty trays is indicated. Descaling programme interrupted Empty trays, clean contacts and dry Descaling was ended prematurely Restart descaling and run from start to end _ARA_en_f.doc Seite 77 von 102

78 7.1.6 Leaks Complaint Cause? Remedial action Water tank leaking Water tank coupling leaking Water tank, valve and sealing ring dirty or calcified Clean and descale water tank Water tank defective Replace water tank Cracks in water tank coupling Replace water tank coupling Residual water does not run into the drip tray (for appliances with fluid connection bracket) Install spare-part set for water tank overflow (mat. no.: ) Ceramic valve leaking Grease film on ceramic discs not homogeneous Actuate ceramic valve several times Water running out during brewing process Ceramic valve leaking Replace ceramic valve and, following installation, actuate 2 3 times Drip tray leaking Crack in drip tray Replace drip tray (new material) Hose system leaking Calcification increases pressure in the hose above 35 bar Fabric hoses burst Hose has preliminary damage Drainage valve leaking Water running out during brewing process Replace hose, descale Drainage valve leaking due to coffee dregs Run cleaning and descaling programme Replace drainage valve Seal damaged Replace drainage valve Brewing unit leaking Seals on water coupling and on coffee outlet of the Replace and lubricate seals Water running out during brewing brewing unit leaking process Lip seal or brewing head defective Replace brewing unit _ARA_en_f.doc Seite 78 von 102

79 7.2 System and error messages Error messages Error Error 5 Upper symbol is lit Lower row flashes Upper symbol is lit Lower row flashes Fault 1 NTC temperature sensor is outside the measurement range. Appliance too cold (< 5 C) or NTC defective (short-cut). The message is indicated when the appliance has been switched on and initialised. If the ambient temperature is too low, the message goes out when the appliance has warmed up to room temperature. Error 5 Heater or thermal link is defective (interrupted). If this defect occurs while the appliance is operating in a warm state, the message Unit is heating is displayed. The message is indicated as long as the appliance remains switched on. When the appliance has been switched off and after the cooling phase, the message is indicated as in the cold state _ARA_en_f.doc Seite 79 von 102

80 Error 8 Upper symbol is lit Lower row flashes 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. Incorrect operation cleaning tablet was inserted too early and blocked the brewing unit. Wrong coffee settings too much, too finely ground coffee. Wrong grinding unit setting grinding too coarse, amount too large. If the message does not go out when the appliance is switched off and on again, disconnect the appliance from the power supply and clean the upper filter in the brewing unit with a damp cloth (kitchen roll). To do this, remove the drip tray and access the appliance from the front. If required, re-adjust the grinding unit setting _ARA_en_f.doc Seite 80 von 102

81 7.2.2 System messages Add water Symbol is lit 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 flow meter) in the appliance. (2) When the water tank has been filled, the float rises and actuates the magnetic switch. The appliance is ready to use. (3) If the water level drops to a level between 80 ml and 180 ml, ADD WATER is displayed. The amount of residual water in the tank depends on the product which was last brewed (espresso, coffee...). Brewing is not terminated due to lack of water. (4) Silting or calcification in the water tank may cause the float to stick to the tank wall. Despite the filled tank, the ADD WATER display does not go out. The incorporation of additional guide fins (B) for the float reduces the risk of the float sticking _ARA_en_f.doc Seite 81 von 102

82 Add beans Both symbols flash ADD BEANS No coffee beans in the bean container (a) Fill 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. ADD BEANS is displayed, even though the bean container has been filled: Grinding unit is not filled with ground coffee, e.g. when switching on the appliance for the first time or following service press the coffee dispensing button to start another coffee brewing process. Beans cannot flow into the grinding unit empty and clean bean container. Use beans with lower fat content. Beans with a high fat content may stick to the surface of the bean container. Grinding process takes too long, not enough coffee is ground set coarser degree of grinding (b) _ARA_en_f.doc Seite 82 von 102

83 Close the door Empty trays Symbol is lit Symbol is lit CLOSE THE DOOR Service door not closed or brewing unit not locked Close service door Install and lock brewing unit Door contact switch is not in the correct position in the appliance. This may be the case if e.g. transportation disengages the switch holder. In these cases remedial action may be performed if the switch holder snaps back into its original position and is also secured with a retaining ring. To improve transportation safety, this retaining ring has since been used in series production as well. EMPTY TRAYS Dregs drawer or drip tray are full or tray contacts are dirty When the drip tray is full of water, the tray contacts are inserted into the water. The electrical resistance between the contacts drops. EMPTY TRAYS is displayed. Pull trays, empty and re-insert. If the EMPTY TRAYS display does not go out despite the trays having been emptied, there may be residual water or coffee between the tray contacts (transfer resistance caused by damp ground coffee). Carefully clean trays in the area of the contacts. EMPTY TRAYS is displayed after a number of coffee brews, e.g.: 8 x Strong 10 x Normal 14 x Mild 8 x Ground coffee _ARA_en_f.doc Seite 83 von 102

84 Trays missing Symbol flashes TRAYS MISSING Drip tray not or incorrectly inserted Insert drip tray all the way If the TRAYS MISSING display goes out even though the drip tray has not been inserted, check that the tray contacts are positioned correctly _ARA_en_f.doc Seite 84 von 102

85 7.3 Incoming goods inspection The incoming goods inspection allows machine faults to be localised quickly and suitable repair measures to be initiated: Follow the sequence in the table. Repair any faults and repeat the repair routine to the end. 1. Check machine for visual damage Housing part broken, damaged or deformed? Power cord or mains plug damaged? Has the customer opened the appliance? 2. Check the mechanical elements Drip tray with dregs drawer clean, inserted. Does function selector move easily? Ground coffee lid in place, closed? 3. Switching on the appliance Switch on the appliance with the mains switch. Is illuminated ring on the On/Off button lit? Switch on with standby button, appliance initialised? Conduct drawer test with original tray. Insert test drawer, appliance rinses independently. Are illuminated rings on the standby and coffee dispensing buttons lit? How long does the machine require to heat up, rinse? (Standard time approx. 70 sec.) 4. Fill water tank Water tank leaking? 5. Coffee preparation without coffee Open and close ground coffee lid, are messages indicated? Press the coffee dispensing button. Is water running out of the coffee outlet? 6. Coffee preparation without beans Check clockwise rotation of the grinding unit. Brewing stops, is Add beans message indicated? 7. Check tank sensor Remove water tank, is Add water message indicated? 8. Hot water preparation Rotate function selector to draw hot water. Is the pump functioning? Is hot water running out of the steam pipe? 9. Steam generation Rotate function selector to draw steam. Approx. 30 seconds until clock timing regular? Is steam flowing out of the steam pipe? 10. PC service diagnosis Conduct input diagnosis _ARA_en_f.doc Seite 85 von 102

86 7.4 Service diagnosis Hardware requirements To operate the system without errors, the following minimum requirements must be satisfied: Service diagnosis kit (Mat.-no ) A service diagnosis kit is required to support diagnosis of the appliances by PC. This kit includes the following components: Hardware requirements: PC 486 or higher VGA MS DOS 6.0 or higher Windows 95 / 98 / NT / 2000 At least 5MB disc space on HD 3.5 disk drive At least 2 serial interfaces USB interface Parallel interface Printer (A) (B) (C) (D) (E) (F) Scanner (is switched between PC and test object) Connecting cable between scanner and test object CD with diagnostic software Connecting cable between PC and scanner Start installation disk Power supply unit for scanner (In: 230 V/50 Hz, Out: 9 VAC/300 ma 2.7 VA) _ARA_en_f.doc Seite 86 von 102

87 7.4.3 Installing the software Insert Start disk in drive A Insert software CD in drive Menu Start, Run, disk drive SETUP.EXE Follow installation instructions Start the programme USB service diagnosis kit The scope of delivery is changed with the introduction of the new USB service diagnostic kit (Mat.-no ). The power supply unit is no longer required because the scanner is supplied via the USB connection on the PC Connecting the test object Data can be exchanged between the appliance to be tested and the connected PC via the scanner. Installation of the software, surface of the animation and diagnostic sequence remain unchanged up to the present version. The scanner is connected to the PC and test object with the connecting cables included in the diagnostic kit. The scanner is supplied with a 9 VAC operating voltage via the power supply unit _ARA_en_f.doc Seite 87 von 102

88 7.4.6 Diagnostic plug The diagnostic plug on the appliance will be accessible when the left appliance flap is opened and the cover (A) is removed. The transparent protective cap over the diagnostic plug must be removed before the scanner is connected. To ensure that the connecting cable is connected securely to the scanner and the diagnostic plug (B) on the appliance, the diagnostic plug can be pulled up slightly out of the appliance Input diagnostic Data is read out. (Production, statistical, service, customer data) The difference on the counter since the last service is deleted. The latest, current factory settings are transferred from the PC to the machine. The internal appliance faults are analysed (service fault bits) Then either a static diagnostic or a dynamic diagnostic is run, similar to the final inspection during production, however without external power and temperature measurements and without evaporation. This depends on the settings which are entered in the individual test configuration of the input diagnosis. Finally a report is prepared which can either be saved or printed out. Apart from the information mentioned under line 1, the report also includes service suggestions depending on the number of brewing processes, as well as max. 3 service stamps if the last ones were implemented on the corresponding appliance. When the diagnostic sequence has run, disconnect the cable, press the diagnostic plug back into the guide in the appliance, re-attach the transparent protective cap and close off access to the diagnostic plug by re-attaching the cover (A) _ARA_en_f.doc Seite 88 von 102

89 7.4.8 Service fault bits Analyse internal appliance fault. Service fault bit 0 Check encoder cable 1 Coffee heating sensor short-circuit 2 Coffee heating sensor interruption 3 Steam heating sensor short-circuit 4 Steam heating sensor interruption 5 Heating up not possible 6 Water sensor above tolerance 7 Position cannot be started Initialisation failed 8 Flow meter time-out / System blockage Example: = Heating up not possible Measured variables for service suggestions Brews since last intervention < 1500 Fault rectified Brews since last intervention > 1500 < 3500 Minor service Brews since last intervention > 3500 Major service Total brews / total rinses < 2 and Brews since last intervention > 2500 Major service Definition of minor / major service Minor service Descale appliance Take out and clean brewing unit Check flow meter Check pressure hose Check grinding performance / result Major service Descale appliance Replace brewing unit Check flow meter Check pressure hose Check outlet Check grinding performance / result _ARA_en_f.doc Seite 89 von 102

90 Individual test The following options can be selected: Upgrading factory settings (the latest parameters are transferred from the PC to the appliance) Statistics (Only data is read out of the appliance without any change to the current appliance status) Configuration of the input diagnostic (short / long) (a short / static or long / dynamic input diagnostic can be selected. Recommendation = dynamic diagnostic) Resetting the grinding time Reset to initial start up (normal = 10 sec./initial start up = 13 sec.) or keep the current grinding unit running time Statistics The statistical data can be displayed via the individual test Output diagnostic Customer data from the input diagnostic is saved back in the machine. (Production, statistical, service, customer data) Dynamic diagnostic similar to final inspection during production and input diagnostic, however without external power and temperature measurement, however with evaporation of the heating cartridge. Input service entry via input mask (see service stamp) Identical to the input diagnostic, a report is also prepared here with the same processing options Service stamp The service stamp is input via the following form: Group definition Specific fault groups are allocated to the working points. When a working point has been selected, its fault group is activated for selection in "Input fault code". A690 = Instantaneous water heater replaced, 4 Fault group F 4 00 = Coffee water heater blocked Service stamp structure This concept of the service stamp enables each service centre to evaluate what work was carried out during the last service and which faults were rectified. In all 3 service entries are saved in the appliance. The first stamp is never overwritten. In the case of stamps 2 and 3 the older stamp is overwritten. Therefore it is always obvious when the 2 previous services were carried out. The definitions as work/fault codes, major faults, employee number and number of services are included only in the last service entry in the appliance. The service date, number of the service centre and invoice item are saved for all three entries _ARA_en_f.doc Seite 90 von 102

91 Contents Number of services Major fault code Fault code Work code Work code Work code Customer 1 15 Employee number Service data Special software is required to analyse the data from the service systems. This software is executed at each start of the service system. It combines all repaired appliances in one text file. This file can be imported for further processing into Excel or Access. The update solution (FTP tool) can send these files by to the required address. (See Internet update) The file name of such a statistics file is composed as follows: Animation system, year, month, day TXT Service date stamp Number of the animation system stamp Invoice item stamp Service date stamp Number of the animation system stamp Invoice item stamp Animation system 2002 year 09 month 09 day TXT file name extension The field separator for data import is a comma, with the file located in the QS folder. Service date stamp Number of the animation system stamp Invoice item stamp _ARA_en_f.doc Seite 91 von 102

92 7.5 Troubleshooting Tools Torx screwdriver T10 Electric multimeter Circuit diagram Appliance does not switch on Danger! If tests have to be conducted while the appliance is live, ALWAYS use a residualcurrent-operated circuit-breaker! Fault description: The display (display or symbol) on the appliance does not come on Possible faults: 1. No power supply 2. No voltage at the mains input of the appliance 3. No voltage at the mains switch 4. No voltage at the power module input 5. No voltage at the power module output to transformer 6. No voltage at the power module input from transformer 7. No voltage at the power module output to logic module 8. No voltage at the logic module input Troubleshooting: 1. Check power supply ( VAC) If there is no electrical meter available, temporarily insert and operate another electrical device on the same socket. No power supply Have electrical installation checked. Power supply available see Point 2 2. Check voltage at mains input ( VAC) To do this, open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Check voltage at the mains input (terminal on noise filter). No power supply defective power cord Power supply available see Point 3 3. Check voltage at mains switch input ( VAC) Measure voltage on the neutral conductor of the feed-in (terminal on noise filter) and on the main switch input. No power supply defective mains filter Power supply available see Point 4 4. Check voltage at mains switch output ( VAC) Set mains switch to On. Measure voltage on the neutral conductor of the feed-in (terminal on noise filter) and on the main switch output. No voltage defective main switch Power supply available see Point _ARA_en_f.doc Seite 92 von 102

93 Appliance does not switch on 5. Check voltage at power module output to transformer ( VAC) Check voltage on plug CP2B on power module. No voltage defective power module (if voltage between F1 and F2 = VAC) Power supply available see Point 6 6. Check voltage at power module input from transformer The secondary voltages (15 VDC / 9 VDC) of the transformer are measured on the flat plug CP4 (2 x red = 15 VDC / 2 x white = 9 VDC) No voltage defective transformer No 15 VDC voltage defective transformer No 9 VDC voltage defective transformer Voltage available see Point 7 7. Check voltage at power module output to logic (5 VDC) The output voltage is measured from the power module to the logic module (control electronics) on plug CP9, terminals 1 = GND (brown) and 2 = + 5V (red). No voltage defective power module Voltage available see Point 8 8. Check voltage on logic module input Measure voltage input on plug CM9 of the logic module on terminals 1 = GND (brown) and 2 = + 5 V (red). No voltage defective ribbon cable Voltage available defective logic module _ARA_en_f.doc Seite 93 von 102

94 7.5.3 Grinding unit is not functioning Fault description: Grinding unit is not running Possible faults: 1. No control signal voltage from logic module 2. No voltage at power module grinding unit output 3. No voltage on the grinding unit Troubleshooting: 1. Check control signal voltage from logic module First check whether the logic module is relaying the signal required for actuation of the grinding unit to the power module. To do this, open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Remove upper appliance cover to the rear. Remove both side panels upwards. The control signal voltage can be measured on plug CM9 on terminals 1 = GND (brown) and 5 = 5 VDC (green). The grinding unit must be actuated by a coffee brewing process. No signal voltage Logic module or connecting cable defective Voltage available see Point 2 2. Check voltage on power module grinding unit output The voltage for the grinding unit is measured on plug CP5 on terminals 3 = GND (black) and 2 = 230 VDC (transparent). The grinding unit must be actuated by a coffee brewing process. No voltage defective power module Voltage available see Point 3 3. Check voltage on grinding unit The operating voltage for the grinding unit is measured on the connecting plugs of the grinding unit. (Black = GND, transparent = 230 VDC). The grinding unit must be actuated by a coffee brewing process. No voltage defective wiring, interrupted VHF-filters, actuated temperature limiter Voltage available defective grinding unit _ARA_en_f.doc Seite 94 von 102

95 7.5.4 Pump is not functioning Fault description: Pump is not actuated / is not pumping Possible faults: 1. No control signal voltage from logic module 2. No voltage at power module pump output 3. No voltage at thermostat input 4. No voltage on the pump Troubleshooting: 1. Check control signal voltage from logic module To do this, open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Remove upper appliance cover to the rear. Remove both side panels upwards. The control signal voltage is measured on plug CM9 on terminals 1 = GND (brown) and 8 = 5 VDC (grey). The pump must be actuated by a coffee brewing process. No signal voltage Logic module or connecting cable defective Voltage available see Point 2 2. Check voltage on power module pump output The voltage for the pump is measured on plug CP5 on terminal 1 = phase and the neutral conductor, terminal 4. The pump must be actuated by a coffee brewing process. No voltage defective power module Voltage available see Point 3 3. Check voltage on thermostat input Before the voltage can be checked on the pump itself, the thermostat must be tested for function. The pump must not be overheated! The voltage is measured at the thermostat input on the right (grey cable from power module) and at the thermostat output on the left (grey cable at pump connection. In both cases the phase connection (black) of the pump is used as the anti-pole. The pump must be actuated by a coffee brewing process. No voltage at the thermostat input defective wiring No voltage at the thermostat output defective thermostat Voltage available at thermostat output see Point 4 4. Check voltage on the pump The pump operating voltage is checked at the terminals of the pump. No voltage defective thermostat Voltage available defective pump _ARA_en_f.doc Seite 95 von 102

96 7.5.5 Heater is not functioning Fault description: Does not heat up Possible faults: 1. No control signal voltage from logic module 2. No voltage at power module heater output 3. No voltage at thermal release input 4. No voltage at heater connection Troubleshooting: 1. Check control signal voltage from logic module To do this, open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Remove upper appliance cover to the rear. Remove both side panels upwards. The control signal voltage is measured on plug CM9 on terminals 1 = GND and 4 = 5 VDC. The heater must be actuated by drawing hot water. The heater is actuated in pulses. No control voltage Logic module or connecting cable defective Voltage available see Point 2 2. Check voltage on power module heater output The voltage for the heater is measured on plug CP5 on terminal 5 = neutral conductor (blue) and terminal 1 = phase (brown). The heater must be actuated by drawing hot water. The heater is actuated in pulses. No voltage defective power module Voltage available see Point 3 3. Check voltage on thermal release input The operating voltage of the heater (= 230VAC) is measured at the thermal release input (brown = under the insulation sleeve) and on the blue terminal on the heating element. No voltage defective wiring Voltage available see Point 4 4. Check voltage on heater connection The operating voltage of the heater (= 230 VAC) is checked on the terminals of the heating element (brown = neutral conductor; blue = phase). No voltage interrupted thermal fuses Voltage available defective heating element _ARA_en_f.doc Seite 96 von 102

97 7.5.6 Brewing unit is not functioning Fault description: Brewing unit no longer moves Possible faults: 1. No control signal voltage from logic module 2. No voltage at power module brewing unit output 3. No voltage at brewing unit drive input Troubleshooting: 1. Check control signal voltage from logic module To do this, open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Remove upper appliance cover to the rear. Remove both side panels upwards. Check two control signals for the brewing unit. Signal on right = brewing unit runs up; signal on left = brewing unit runs down. The control signal voltage on the right is measured on plug CM9 terminal 1 = GND (brown) and terminal 6 = 5 VDC (blue); the control signal voltage on the left is measured on CM9 terminal 1 = GND (brown) and terminal 7 = 5 VDC (violet). The brewing unit must be actuated by a coffee brewing process. No control voltage on right Logic module or connecting cable defective No control voltage on left Logic module or connecting cable defective Voltage available see Point 2 2. Check voltage on power module brewing unit output To check the voltage at the power module brewing unit output (= 12 VDC), open the appliance. Using the Torx T10 screwdriver, unscrew all rear panel screws and remove the rear panel. Remove upper appliance cover to the rear. Remove both side panels upwards. The voltage for the drive of the brewing module is measured on plug CP2A on terminals 1-green and 2-red. For operation on right = brewing unit runs up; green = GND / red = 16 VDC For operation on left = brewing unit runs down; green = 16 VDC / red = GND The brewing unit must be actuated by a coffee brewing process. No voltage defective power module From production date FD8701 on: Check microswitch for drip tray detection and its trigger on the drip tray. Gear motor is only actuated if the microswitch is closed. Voltage available see Point 3 3. Check voltage on brewing unit drive input The operating voltage of the brewing unit drive is checked on the terminals of the motor. To conduct this measurement, detach the drive from the appliance. The operating voltage can be measured on the terminals of the motor. No voltage defective wiring Voltage available defective brewing unit drive _ARA_en_f.doc Seite 97 von 102

98 7.6 Measuring the coffee temperature Test voltage: 230 V +/- 3 V Procedure: 1. Switch on the machine with the main switch, press the standby button. 2. Wait until the illuminated ring around the standby button stops flashing (heating-up and rinsing phase has ended). 3. Set filling quantity: coffee (approx. 125 ml) Select coffee strength: Normal (approx. 9 g) 4. Place a measuring cup (A) under the coffee outlet. 5. Start coffee brewing process by pressing the coffee dispensing button. 6. Wait until there are 20 ml of coffee in the measuring cup. Then measure the coffee temperature approx mm under the coffee outlet (B) in the middle of flow. 1 st coffee: The coffee temperature should be approx. 82 C +/ 5 C. 7. Empty the measuring cup (A) and place it under the coffee outlet again. 8. Start coffee brewing process by pressing the coffee dispensing button. 9. Wait until there are 20 ml of coffee in the measuring cup. Then measure the coffee temperature approx mm under the coffee outlet (B) in the middle of flow. 2 nd coffee: The coffee temperature should be approx. 82 C +/ 3 C _ARA_en_f.doc Seite 98 von 102

99 8 TECHNICAL SPECIFICATIONS 8.1 Rating plate The rating plate is situated on the control panel holder behind the drip tray panel. A B C D E F G H I Voltage 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. if customer service makes changes to the appliance. Frequency Production date according to BSH key. For example: FD = year minus 20 (=2004) Serial number (optional) Power Type (works designation) Field for approbation number 10 = month (October) _ARA_en_f.doc Seite 99 von 102

100 8.2 Power Mains voltage EU V / 50 Hz UC 120 V / 60 Hz Connected load 1300 W Power input Heater 1250 W Pump 65 W Power data (230 V / 50 Hz model) Switch on (with rinsing) 20.5 Wh 1 coffee (normal strength) 17.0 Wh 1 espresso (normal strength) 9.3 Wh Standby mode (24 hours) 3.0 Wh Pump pressure During coffee preparation max. 16 bar Static 19 bar max. permitted 22 bar Flow rate ml/min at 12 bar, V / 50 Hz Switch-on time Switch on with rinsing 69 sec 8.3 Temperatures Fahrenheit established 0 F as the stabilized temperature when equal amounts of ice, water, and salt are mixed. He then defined 96 F as the temperature "when the thermometer is held in the mouth or under the armpit of a living man in good health." Celsius 0 C and 100 C are arbitrarily placed at the melting and boiling points of water and standard to the metric system Formula C = (F-32)* F = 1,8*C Coffee outlet 1 st coffee NORMAL (in the flow) 82 C +/ 5 2 nd coffee NORMAL (in the flow) 82 C +/ Hot water Hot water production without interruption > 82 C Hot water production after 1 st heating-up process > 85 C Steam Steam production 200 ml, 1 min. (pump clocks) > 80 C Milk Setpoint temperature UHT milk 1.5% (measure in 10 C +/ 5 Tetrapack) Warm 100 ml milk in stainless steel jug <1 min C Froth up 100 ml milk with steam pipe < 1 min C CAPPUCCINATORE milk temperature C _ARA_en_f.doc Seite 100 von

101 8.4 Dimensions and weight Appliance dimensions Height Width Depth Height between coffee outlet and drip plate 345 mm 273 mm 480 mm 75 mm 115 mm Cable length Approx. 1.2 m Weight of machine 7.5 kg 8.5 Filling amounts Capacity Water tank Bean container Drip tray 1.8 l Approx. 250 g 750 ml (signal limit) Cup filling amounts ml XXL COFFEE ml LARGE COFFEE ml COFFEE 4 80 ml SMALL COFFEE 5 40 ml ESPRESSO 6 20 ml SMALL ESPRESSO 7 40 ml 2 SMALL ESPRESSOS 8 80 ml 2 ESPRESSOS ml 2 SMALL COFFEES ml 2 COFFEES ml 2 LARGE COFFEES ml 2 XXL COFFEES _ARA_en_f.doc Seite 101 von