ROYAL CLASSIC ROYAL EXCLUSIV ROYAL DIGITAL ROYAL DIGITAL REDESIGN ROYAL DIGITAL PLUS ROYAL PROFESSIONAL ROYAL PROFESSIONAL REDESIGN ROYAL CAPPUCCINO ROYAL CAPPUCCINO REDESIGN ROYAL COFFEEBAR ROYAL OFFICE SERVICE MANUAL Revision 4 Saeco Saeco International Group SEPT.: 2003 All parts of the present service manual are the property of Saeco International Group. All rights reserved. The manufacturer is not responsible for any errors or omissions in the present document.
Table of contents 1. Introduction 2. Technical data 3. Operation 4. Functions and timing 5. Service programme 6. Faults 7. Fault diagnosis 8. Repairs / Service schedule 9. Disassembly 10. Saeco International Group Circuit diagrams REV.4 SEPT.
CHAPTER 1 INTRODUCTION Page 1. Documents required 2. Equipment 3. Material 4. Safety instructions 5. Overview of product range Saeco International Group REV.4 SEPT.
ROYAL 1. INTRODUCTION 1. Documents required The following documents and requirements are necessary to qualify for an authorised repair. • • Service manual Operating instructions where available 2.
1. INTRODUCTION ROYAL 5.
CHAPTER 2 TECHNICAL DATA Page Saeco International Group 1. Technical Data Royal (Classic) 1 2. Technical Data Royal (Digital/Digital Redesign/Exclusive) 2 3. Technical Data Royal (Cappuccino/Professional Instant Steam/ Cappuccino Redesign) 3 4. Technical Data Royal (Professional-Rapid Steam/Prof. Redes. Digital Plus/Coffeebar) 4 5. Technical Data Royal (Office) 5 REV.4 SEPT.
ROYAL 2. TECHNICAL DATA 1.
2. TECHNICAL DATA ROYAL 2.
ROYAL 2. TECHNICAL DATA 3.
2. TECHNICAL DATA ROYAL 4. Technical data (Royal Digital Plus / Professional Rapid Steam / Prof. Redesign / Coffeebar) Royal Digital Plus / Professional Rapid Steam / Prof.
ROYAL 2. TECHNICAL DATA 5.
CHAPTER 3 OPERATION Page 1. Operation (Royal Classic) 1.1. Operating instructions 1 1 2. Operation (Royal Exclusive/Digital/Digital Redes.) 2.1. Operating instructions 2.2. User programme 3 3 5 3. Operation (Profess. Instant Steam Cappuccino/ Cappuccino Redesign / Profess. Redesign) 7 3.1. Operating instructions 7 3.2. User programme 10 4. Operation (Professional-Rapid Steam/Coffeebar/ Digital Plus) 4.1. Operating instructions 4.2. User programme 4.3. Vending menu 5. 5.1. 5.2. 5.3.
ROYAL 3. OPERATION 1. Operation (Royal Classic) 1.1. Operating instructions (quick reference) Action 1 2 3 4 5 6 7 8 9 Comments Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. De-aerate water circuit. Open hot water pressure valve until water flows. Heating stage (approx. 1.5 min). Ready Making coffee Select coffee quantity using Depending on cup size. the control dial. Place cup under dispenser.
3. OPERATION ROYAL Descale Water hardness Descaling frequency Very hard water (over 21ºdH) About every 4 weeks Hard water (15º-21ºdH) About every 6 weeks Medium water (15º-21ºdH) About every 2 months Soft water (up to 7ºdH) About every 3 months Do not use vinegar! (damages the pump) Descaling procedure: 1. Place Saeco descaler into fresh water tank. 2. Fill with about one litre of hot water. 3. Make 2-3 coffees to descale coffee circuit. 4.
ROYAL 3. OPERATION 2. Operation (Royal Digital / Exclusive / Digital Redesign) 2.1. Operating instructions (quick reference) Action Comments 1 2 3 4 5 Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. 6 De-aerate water circuit. 7 8 9 10 11 12 Open hot water pressure valve until water flows. Heating stage (approx. 80 sec.) Ready Making coffee Programme coffee quantity for Depending on cup size.
3. OPERATION Empty dregs drawer Empty drip tray Clean water tank. Clean coffee bean container. Clean the housing. Rinse brewing unit Clean brewing unit and oil filter Descale ROYAL Cleaning Storage capacity of 30 tablespoons (dreg counter reset only if warning to empty grounds container is triggered and machine is turned on). After 30 servings As required. As required. As required. 1 x per week 1 x per month Depending on water hardness.
ROYAL 3. OPERATION 2.2. User programme (Royal Digital / Exclusive / Digital Redesign) The table below indicates the various values, settings and programmes which can be read and selected through the user programme options. Various cleaning programmes can also be activated. Access (Royal Digital / Exclusive): Access via the ENTER button. Access (Royal Digital Redesign): Selection entry via menu button.
3. OPERATION Item Setting/Indicator Heating plate ON/OFF Temperature Maximum High Medium Low Minimum ON LONG AUS ON/OFF Number Pre-brewing Pre-grinding Total coffee Descale Scale indicator reset YES/NO Timer 0-12.45 hours Cleaning cycle Factory settings ROYAL Standard Function Activate / deactivate heating plate. Medium Adjustment of coffee temperature. ON Coffee is moistened before actual brewing (better aroma) OFF Pre-grinds the next coffee dose.
ROYAL 3. OPERATION 3. Operation (Royal Professional Instant Steam / Prof. Redesign / Cappuccino / Capp. Redesign) 3.1. Operating instructions (quick reference) Action Comments 1 2 3 4 5 Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. 6 De-aerate water circuit. 7 Activate the hot water button until water flows continuously Heating stage (approx. 80 sec.
3. OPERATION Action 17 18 19 20 Hot water Quantity programme ROYAL Comments The last programme saved is activated by pressing the hot water button briefly. Cappuccino maker Cappuccino Press the cappuccino button (only when cappuccino briefly to start cappuccino maker programme is dispensing; press again to stop. deactivated in the user menu) Cappuccino Keep the cappuccino button Quantity programme pressed for the desired time.
ROYAL 3. OPERATION Troubleshooting Fault/Indicator Does not function BREWING UNIT NOT DETECTED GRINDS CONTAINER NOT DETECTED COFFEE BEAN CONTAINER EMPTY FILL WATER DE-AERATE OVERHEATING GRINDER OBSTRUCTED DE-AERATE Possible cause No power Brewing unit not properly installed or not closed. Coffee grinds container not properly installed. Coffee bean container is empty. Install brewing unit correctly. Brewing unit correctly installed. Fill coffee container. Water tank is empty.
3. OPERATION ROYAL 3.2. User programme (Royal Professional Instant Steam / Royal Cappuccino) The table below indicates the various values, settings and programmes which can be read and selected through the user programme options. Various cleaning programmes can also be activated. Access: Access is via the ENTER button (keep pressed for a few seconds). Access (Royal Prof. Redesign / Capp Redesign): Selection entry via menu button.
ROYAL Item 3. OPERATION Setting/Indicator System 2 ON/OFF Water hardness 1 – 500 l 2 – 300 l 3 – 150 l 4 – 80 l ON/OFF Maximum High Medium Low Minimum Maximum High Medium Low Minimum Maximum High Medium Low Minimum ON LONG OFF ON/OFF ON/OFF Heating plate Temperature (Expresso lungo) Temperature (Coffee) Temperature (Expresso) Pre-brewing Pre-grinding Hot water programme Cappuccino programme Total coffee Descale Scale indicator Timer Standard 3 Activate / deactivate heating plate.
3. OPERATION ROYAL 4. Operation (Professional Rapid Steam / Coffeebar / Digital Plus) 4.1. Operating instructions (quick reference) Action Comments 1 2 3 4 5 Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. 6 De-aerate water circuit. 7 Activate the hot water button until water flows continuously Heating stage (approx. 80 sec.) Ready Making coffee Programme coffee quantity for Depending on cup size.
ROYAL 3. OPERATION Action 17 18 19 20 Hot water Quantity programme Comments The last programme saved is activated by pressing the hot water button briefly. Cappuccino Maker (not in Royal Digital+) Cappuccino Press the cappuccino button (only when cappuccino briefly to start cappuccino maker programme is dispensing; press again to stop. deactivated in the user menu) Cappuccino Keep the cappuccino button Quantity programme pressed for the desired time.
3. OPERATION ROYAL Troubleshooting Fault/Indicator Does not function BREWING UNIT NOT DETECTED GRINDS CONTAINER NOT DETECTED COFFEE BEAN CONTAINER EMPTY FILL WATER DE-AERATE OVERHEATING GRINDER OBSTRUCTED DE-AERATE Possible cause No power Brewing unit not properly installed or not closed. Coffee grinds container not properly installed. Coffee bean container is empty. Install brewing unit correctly. Brewing unit correctly installed. Fill coffee container. Water tank is empty.
ROYAL 3. OPERATION 4.2. User programme (Royal Professional Rapid Steam / Coffeebar / Digital Plus) The table below indicates the various values, settings and programmes which can be read and selected through the user programme options. Various cleaning programmes can also be activated. Access: Access is via the ENTER button. Access (Digital+): Selection entry via menu button.
3. OPERATION Item Setting/Indicator Heating plate ON/OFF Temperature (Expresso lungo) Maximum High Medium Low Minimum Maximum High Medium Low Minimum Maximum High Medium Low Minimum ON LONG OFF ON/OFF ON/OFF Temperature (Coffee) Temperature (Expresso) Pre-brewing Pre-grinding Hot water programme Cappuccino programme ROYAL Standard Medium Activate / deactivate heating plate. Heating plate Adjustment of coffee temperature. Medium Adjustment of coffee temperature.
ROYAL 3. OPERATION 4.3. Vending menu: Action Access Call up code entry Code entry Procedure Enter code Confirm vending in user menu via ENTER. Press ENTER Confirm code Enter required number combination by using the arrow and enter buttons Use arrow button to select Yes Confirm code Press ENTER Use arrow button to access menu items. Access Call up code entry Code entry Change code Confirm vending in user menu via ENTER.
3. OPERATION ROYAL Note: • • • The vending menu can also be used unsecured (no code entry / skip code entry via arrow button). Cancelling code: Enter with new code 0000. If the programmed code is only used to read the counter reading, the code entry can also be skipped. However, if an attempt is made to change the counter reading, the code request appears. Attention: If you forget the code, a new code must be requested from Saeco Austria! 18/25 REV.4 SEPT.
ROYAL 3. OPERATION 5. Operation (Royal Office) 5.1. Operating instructions (quick reference) Action Comments 1 2 3 4 5 Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. 6 De-aerate water circuit. 7 8 Activate the hot water button until water flows continuously Heating stage (approx. 80 sec.) Ready Making coffee Programme coffee quantity for Depending on cup size. each selection button.
3. OPERATION Empty dregs drawer Empty drip tray Clean water tank. Clean coffee bean container. Clean the housing. Rinse brewing unit Clean brewing unit and lubricate Clean filter Descale Descale: ROYAL Cleaning Storage capacity of 30 tablespoons (dreg counter reset only if warning to empty grounds container is triggered and machine is turned on). With dregs drawer As required As required As required 1 x per week 1 x per month According to indicator 1. Place Saeco descaler into fresh water tank. 2.
ROYAL 3. OPERATION Troubleshooting Fault/Indicator The coffee flows too quickly Possible cause Beans ground too coarsely. The coffee flows too slowly Beans ground too finely. Coffee is not hot enough The cups are cold. Boiler temperature too low. Unsuitable coffee blend. Coffee is no longer freshly roasted. Beans ground too coarsely or finely. Longer heating time or less hot The machine is calcified. water. The brewing unit is not in home The brewing unit cannot be position. removed.
3. OPERATION ROYAL 5.2. User programme (Royal Office): Access programming by keeping the V (hot water) and C (Esc) buttons pressed and switching the machine on from the main swtich. (a) C button ESC – Return to previous progrmme level. (b) E button ENT – Expresso. To select and save a value entered. (c) ↑ button UP – Coffee. Scroll in menu and change value. (d) ↓ button DOWN – Hot water. Scroll in menu and change value.
ROYAL Item Temperature (Coffee) Pre-brewing Pre-grinding Quantity programme Descale 3. OPERATION Setting/Indicator Maximum High Medium Low Minimum ON LONG OFF ON/OFF ON/OFF Scale indicator YES/NO Timer 0-12.45 hours Cleaning cycle Saeco International Group Standard Function Medium Adjustment of coffee temperature. ON Coffee is moistened before actual brewing (better aroma) Pre-grinds the next coffee dose. Locking or releasing of quantity programme Activate descaling programme Duration: Approx.
3. OPERATION ROYAL 5.3. Vending menu: Access: In user menu (C+Expresso button+turn on machine), enter code and confirm item Vending with the E-button.
ROYAL 3. OPERATION Action Confirm code Procedure Change code Enter required number combination by using the arrow and enter buttons Use arrow button to select Yes Confirm code Press ENTER Exit Press C-button twice Code entry Display New code = number Save No New code = number Save Yes Code ****** Attention: If you forget the code, a new code must be requested from Saeco Austria! Saeco International Group REV.4 SEPT.
CHAPTER 4 FUNCTIONS AND TIMING Page 1. Water system 1.1. 1.2 1.3. 1.4. 1.4. 1.4. 1.5. WSP (R. Classic/Digital/ Exclusive/Digit. Redes) 1 WSP (Digital Plus) 2 WSP (R. Prof. Rapid Steam/Prof. Red.) 3 WSP (R. Cappuccino/Prof. Instant Steam) 4 WSP (R. Cappuccino Redesign) 6 WSP (R. Coffeebar) 9 WSP (R..Office) 11 2. Electrical system 2.1.1. CPU – IN / OUT (R. Classic) 2.2.1. CPU – INPUT (Royal Digital/Exclusive) 2.2.2. Control panel (Royal Digital/Exclusive) 2.3.1.
ROYAL 4. FUNCTION/TIMING 1. Water system 1.1. Water system (Royal Classic / Digital / Exclusive / Digital Redesign) Boiler J Durchlauferhitzer Thermal sensor Temp.
4. FUNCTION/TIMING ROYAL 1.2. Water system (Royal Digital Plus) Thermal sensor Temp.sensor KTY KTY Wassertank Water tank Water filter Wasserfilter Boiler J Durchlauferhitzer Rohrheizung Pipe heating Sensor pipe heating Schwimmer Float Thermostat 170ºC GearGetriebevor resistor -widerstand Thermostat pipe heating 2x Thermostat 2 Thermostate Heizung 1090W 1090 W Heizung Heating 1090 W Water filter Wasserfilter 1090W El.
ROYAL 4. FUNCTION/TIMING 1.3. Water system (Royal Professional Rapid Steam / Professional Redesign) Thermal sensor Temp.sensor KTY KTY Wassertank Water tank Water filter Wasserfilter Boiler J Durchlauferhitzer Rohrheizung Pipe heating Sensor pipe heating Schwimmer Float GearGetriebevor resistor Thermostat 170ºC -widerstand Thermostat pipe heating 2x Thermostat 2 Thermostate Heizung 1090W 1090 W Heizung Heating 1090 W Water filter Wasserfilter 1090W El. Valve Cappucinatore El.
4. FUNCTION/TIMING ROYAL 1.4.
ROYAL 13 14 15 16 17 18 19 Component Sensor (KTY) System 2 (steam) Thermostat System 2 (steam) Boiler pin (Valve plug) Steam valve Valve cappuccinatore (for cappuccino maker) Valve (water) Valve (steam) Saeco International Group 4. FUNCTION/TIMING Function Transmits current temperature value to electronic system Alternates current supply for heating system in event of overheating. Opens when brewing unit is aligned with water circuit to the unit itself.
4. FUNCTION/TIMING ROYAL 1.5.
ROYAL 15 Component Sensor (KTY) System 2 (steam) Thermostat System 2 (steam) Valve plug 16 17 18 19 20 Steam valve Valve (for cappuccino maker) Valve (water) Valve (steam) Valve (by-pass) 13 14 4. FUNCTION/TIMING Function Transmits current temperature value to electronic system Alternates current supply for heating system in event of overheating. Opens when brewing unit is aligned with water circuit to the unit itself.
4. FUNCTION/TIMING ROYAL 5. Automatic descaling Stage 1) Solenoid valve EV1: Closed Solenoid valve EV2: Open Solenoid valve EV4: Open 55 pulses are generated via pump 1 and 55 pulses via pump 2. Stage 2) Solenoid valve EV1: Open Solenoid valve EV2: Closed Solenoid valve EV3: Open 30 water pulses are generated via pump 2. Stage 3) Solenoid valve EV1: Closed Solenoid valve EV2: Open One minute pause is allowed for the descaling solution to take effect.
ROYAL 4. FUNCTION/TIMING 1.6. Water system (Royal Coffeebar) 4 Water tank 5 Float 1 Inlet valve 13 Pipe heater 3 Pressure adjuster 2 Non-return valve 6 Water filter approx.
4. FUNCTION/TIMING 15 Component Sensor (KTY) Pipe heating Pipe heating thermostat 16 Valve plug 17 18 19 20 Valve (for boiler filling) Valve (Cappumore) Valve (steam) Valve (water) 14 Note: ROYAL Function Transmits current temperature value to electronic system Alternates current supply for heating system in event of overheating. Opens when brewing unit is aligned with water circuit to the unit itself.
ROYAL 4. FUNCTION/TIMING 1.7.
4. FUNCTION/TIMING ROYAL 2. Electrical system 2.1. CPU – IN / OUT (Royal Classic) NFilt TürDoor schalter switch Grinder Mahlwerkmotor motor Dosing magnet M1 JP1 JP11 Dosier magnet TS JP10 JP2 P TSIT-fuse Pumpe HauptMain schalter switch JP13 CPU Pump Pumpe Boilerheiz.
ROYAL 4. FUNCTION/TIMING 2.2.1. CPU – INPUT (Royal Digital / Exclusive) Temp. Thermo Sensor sensor JP2 JP9 MS2 MS2Gear Getriebe switch schalter brew pos. MS1 Gear MS1switch Getriebe schalter home pos.
4. FUNCTION/TIMING ROYAL 2.2.2. Control panel (Royal Digital / Exclusive) HauptMain schalter switch TürDoor schalter switch J2 N-Filt J1 Grinder Mahlwerkmotor motor M1 JP2 Thermostat Thermostat Boiler heating Durchlauferh. TS Durchlauferh.
ROYAL 4. FUNCTION/TIMING 2.3.1. CPU – INPUT (Royal Cappuccino / Professional Instant Steam) Thermo sensor Temp. Sensor System System 1 1 JP2 Temp. Sensor Thermo sensor System 2 System 2 JP9 MS1 MS1Gear Getriebe switch schalter home pos. MS2 MS2Gear Getriebe switch schalter brew pos.
4. FUNCTION/TIMING ROYAL 2.3.2. Control panel (Royal Cappuccino / Professional Instant Steam) HauptMain schalter Tür- Door schalter switch switch J2 N-Filt J1 JP15 MahlwerkGrinder motor motor M1 JP2 JP16 TS Thermostat Thermostat Durchlauferh. Boiler 1 TS Boiler 2 JP9 M2 T-fuse TSICup warmer Tassenwärmer TassenCup warmer wärmer Pump PumpeSystem 22 System JP5 TSIT-fuse Durchlauferh. Boiler 1 Durchlauferh.
ROYAL 4. FUNCTION/TIMING 2.4.1. CPU – INPUT (Royal Professional Rapid Steam / Royal Coffeebar) Temp. Sensor Thermo sensor System System 1 1 JP2 Temp. Sensor Thermo sensor System 2 System 2 JP9 MS1 MS1Gear Getriebe switch schalter home pos. MS2 MS2Gear Getriebe switch schalter brew pos. JP1 CPU Hot water/ HWDSteamschalter switch JP4 MS brew BrühMS gruppe unit MSdregs SatzMS schublade drawer nur Roy.
4. FUNCTION/TIMING ROYAL 2.4.2 Control panel (Royal Professional Rapid Steam / Royal Coffeebar) HauptMain schalter switch TürDoor schalter switch J2 N-Filt J1 JP15 Grinder Mahlwerkmotor motor M1 JP2 JP16 Rohrheizung Boiler 2 System 2 TS Thermostat Thermostat Rohrheizung Boiler 1 JP5 TSIT-fuse Rohrheizung Boiler 1 Durchlauferh. Boiler 11 System TS JP9 M2 Getriebemotor Gear motor T-fuse TSICup warmer Tassenwärmer TSIT-fuse Durchlauferh.
ROYAL 4. FUNCTION/TIMING 3. Timing The following time chart indicates the functions of the individual components in terms to time (excluding Royal Classic, see process for Vienna) app.5.5se c G rin de r mo to r Do se r ap p . 1 .
4. FUNCTION/TIMING ROYAL 4. Function 4.1. Gearmotor The gearmotor is a direct current motor and is controlled by the CPU at approx. 30 – 35 V. In order to perform forwards and backwards movements, the gearmotor is controlled alternately with a positive and negative half wave. In the event of overload the motor's electronic system switches off after 8-10 sec. and the machine is stopped. This situation is indicated by the flashing fault LED. In digital display indicator systems: brewing unit locked.
ROYAL 4. FUNCTION/TIMING 4.3. Water level indicator The water level in the water tank is monitored by a float fitted with a magnet core. If the water level is too low, the magnet is no longer within the range of the reed contact, which transmits the low water level signal to the CPU. 4.4. Flow meter (Turbine) The machine is also equipped with a flow rate monitoring system. The system checks whether the water monitoring flow meter (turbine) turns.
4. FUNCTION/TIMING ROYAL 4.6. Temperature sensor (KTY 10) The temperature sensor is a temperature-sensitive resistance mechanism, converting the instantaneous water heater temperature into an electrical signal which is measurable by the CPU. The CPU compares this signal with the programmed reference signal and, depending on the outcome of the comparison, controls the instantaneous water heater output. The resistance applied has a positive temperature coefficient; i.e.
CHAPTER 5 SERVICE PROGRAMME Page 1. Service programme (R. Classic) 1.1. Test mode 1 1 2. 2 Service programme (Royal Digital/Exclusive/Digital Redes.) 2.1. Test mode 2.2. Diagnosis menu 2 5 3. 7 Service programme (Professional Instant Steam/Cappuccino/ Cappuccino Redesign) 3.1. Test mode 3.2. Diagnosis menu 7 10 4. 14 Service programme (R. Professional Rapid Steam/ Profess. Redes./Digital Plus/Coffeebar) 4.1. Test mode 4.2. Diagnosis menu 5. Service Programme (Royal Office) 5.1. Test mode 5.2.
ROYAL 5. SERVICE PROGRAMME 1. Service programme (Royal Classic): 1.1. Test mode Access: Access the service mode by turning on the machine and simultaneously pressing the Coffee and steam buttons. Press Coffee and Steam buttons. Various test functions can be activated in the service mode by activating either the coffee or steam buttons in conjunction with various coffee quantity settings.
5. SERVICE PROGRAMME ROYAL 2. Service programme (Royal Digital / Exclusive / Digital Redesign) 2.1. Test mode Access (Royal Digital / Exclusive): Access the test mode by turning on the machine and simultaneously pressing the coffee and steam buttons. Keep the EXPRESSO and STEAM buttons pressed, whilst pressing the STANDBY button.
ROYAL 5. SERVICE PROGRAMME Programme table (test menu) Royal Excl./Digital Buttons Royal Digital Redes. S1 Expresso lungo S2 Coffee S2 S3 Powder Expresso coffee S1 Steam Unit up S4 Powder coffee S4 Expresso lungo S6 ON S5 Coffee S6 Expresso x Grinder x x x Doser Heating plate S5 Steam x Unit down Pump S3 Expresso x x x Heating x x Temperature indicator in °C x x x The upper display line signals the activated microswitch and the Hall effect of the flow meter.
5. SERVICE PROGRAMME Flow rate ROYAL If the pump is activated during test mode and the hot water valve opened, a two-digit number appears at the bottom right side indicating the flow rate. This value must be between 40 - 60. Grinder rate If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off from the main switch. Page 4/24 REV.4 SEPT.
ROYAL 5. SERVICE PROGRAMME 2.2. Diagnosis menu (Royal Digital / Exclusive / Digital Redesign) The values below can be read and adjusted in the diagnosis menu as shown in the table. Access: The following button combinations can be used in standby mode to access the diagnosis menu as indicated in the table below.
5. SERVICE PROGRAMME Function TEMP. INCREASE °C 10 GRINDS COUNTER Setting range 0-50°C ROYAL Increment +/-1 0-50 +/-1 5-50 +/-1 --TOTAL WATER-(ml) Number WATER DESCALING (ml) HOT WATER FLOW (l/h) 20 --------------------- 6 - 34 1/h ------------------------------------------+/- 2 1/h --HOT WATER--PUMP ADJUST.
ROYAL 5. SERVICE PROGRAMME 3. Service programme (Royal Professional Instant Steam / Cappuccino / Cappuccino Redesign) 3.1. Test mode Access (Royal Professional Instant Steam/ Cappuccino): Access the test mode from the standby mode by keeping the EXPRESSO and HOT WATER button pressed, whilst pressing the STANDBY button again.
5.
ROYAL 5. SERVICE PROGRAMME The upper display line signals the activated microswitch and the Hall effect of the turbine. The activated buttons are signalled by the lower display line (e.g. 1=S1, 2=S2, etc.). All CPU input signals from the machine appear in the first line of the display.
5. SERVICE PROGRAMME ROYAL 3.2. Diagnosis menu (Royal Professional Instant Steam / Cappuccino / Cappuccino Redesign) The values below can be read and adjusted in the diagnosis menu as shown in the table. Access: The following button combinations can be used in standby mode to access the diagnosis menu as indicated in the table below. (press menu buttons briefly) TYPE Prof. / Cappuccino Cappuccino Redes.
ROYAL 5. SERVICE PROGRAMME Function NORMAL TEMP. °C 86/90 HIGH TEMP. °C Setting range 70- 130°C Increment +/- 1 70- 130°C +/- 1 TEMP. OF 1st COFFEE °C 94/100 70- 130°C +/- 1 STEAM TEMP. °C 130/110 70- 135°C +/-1 COFFEE TEMP. INCREASE °C 10/7 0-50°C +/-1 STEAM TEMP. INCR. °C 15 0-50°C +/-1 STEAM 20-50 +/-1 20-50 +/-1 0-50 +/-1 5-50 +/-1 CAPPUCCINO 92/98 35 30 GRINDS COUNTER Number GRINDS STOP 30 TOTAL WATER....
5. SERVICE PROGRAMME Function Setting range TOTAL WATER....S2 (ml) Number ROYAL Increment WATER DESCALING S2 (ml) HOT WATER FLOW (l/h) 20 (Only in System 2: OFF for Royal Cappucc.) HOT WATER PUMP ADJUST. 63000 6 – 34 1/h +/- 2 1/h 58,000 - 65,500 +/- 1 6 - 34 1/h +/- 2 1/h 58,000 - 65,500 +/- 1 (Only in System 2: OFF for Royal Cappucc.) TURBOWATER FLOW (l/h) 20 (Only in System 2: ON) only Royal Cappucc.) TURBOWATER PUMP ADJUST. 63000 (Only in System 2: ON) (only Royal Cappucc.
ROYAL Function WATER RESERVE STOP No. of PULSES 1000 From Version: 2003 MACHINE STATUS 5. SERVICE PROGRAMME Setting range 1-2500 Increment 0 - 255 Comments Water reserve from when the read switch is switched to pulses. 100 --DATE OF MANUF--- --------------------- --------------------- This date indicates when the DAY machine was manufactured. This ---DATE OF MANUF--- --------------------- --------------------- date cannot be changed.
5. SERVICE PROGRAMME ROYAL 4. Service programme (Royal Professional Rapid Steam / Coffeebar / Profess. Redesign / Digital Plus) 4.1. Test mode Access (Royal Professional Rapid Steam / Coffeebar): Access the test mode by turning on the machine and simultaneously pressing the coffee and steam buttons. Keep the EXPRESSO and HOT WATER buttons pressed, whilst pressing the STANDBY button.
ROYAL 5. SERVICE PROGRAMME Access (Digital Plus): Access the service programme from the standby mode (standby button) by keeping the powder coffee , expresso and coffee buttons pressed.
5. SERVICE PROGRAMME Buttons Magnet valve Cappuccino maker Not for Digit. Plus Pump S1 S2 S3 S4 S5 S6 S7 x x Magnet valve steam Magnet valve water ROYAL x x x Pump + Magnet water valve Pump + Magnet steam valve Pump + Magnet steam valve Magnet water valve x x x x x x x x x x The upper display line signals the activated microswitch and the Hall effect of the turbine. The activated buttons are signalled by the lower display line (e.g. 1=S1, 2=S2, etc.).
ROYAL 5. SERVICE PROGRAMME Flow rate: If the pump is activated during test mode and the hot water valve opened, a two-digit number appears at the bottom right side indicating the flow rate. This value must be between 40 - 60. Grinder rate: If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off at the main switch. Saeco International Group REV.4 SEPT.
5. SERVICE PROGRAMME ROYAL 4.2. Diagnosis menu (Royal Professional Rapid Steam / Coffeebar / Profess. Redesign / Digital Plus) The values below can be read and adjusted in the diagnosis menu as shown in the table. Access: The following button combinations can be used in standby mode to access the diagnosis menu as indicated in the table below (press menu buttons briefly). TYPE Press simultaneously Prof. / Coffeebar EXPRESSO LUNGO EXPRESSO Prof. Redes./ Dig.
ROYAL 5. SERVICE PROGRAMME Function NORMAL TEMP. °C 86/90 Setting range 70- 130°C Increment +/- 1 70- 130°C +/- 1 TEMP. OF 1st COFFEE °C 94/100 70- 130°C +/- 1 STEAM TEMP. °C 130/110 70- 135°C +/-1 COFFEE TEMP. INCR. °C 10/7 0-50°C +/-1 STEAM TEMP. INCR. °C 15 0-50°C +/-1 STEAM 20-50 +/-1 20-50 +/-1 0-50 +/-1 5-50 +/-1 HIGH TEMP. °C CAPPUCCINO 92/98 35 30 GRINDS COUNTER Number GRINDS STOP 30 TOTAL WATER....
5. SERVICE PROGRAMME Function Setting range TOTAL WATER....S2 (ml) Number ROYAL Increment WATER DESCALING S2 (ml) HOT WATER FLOW (l/h) 20 HEISSWASSER--PUMPENREG 63000 WATER RESERVE NUMBER No. of PULSES 1000 From Version: 2003 WATER RES. STOP No.
ROYAL 5. SERVICE PROGRAMME 5. Service programme (Royal Office) 5.1. Test mode Access (Royal Office): Keep the water and expresso buttons pressed and turn machine on. While the buttons are pressed, the E-Prom Version is displayed (e.g. Version 0.13). The various functions indicated in the table can be checked by pressing the button combinations listed below.
5. SERVICE PROGRAMME ROYAL All CPU input signals from the control board appear in the second line of the display. 1 = Coffee 2 = Expresso 3 = Hot water Flow rate If the pump is activated during test mode and the hot water valve opened, a two-digit number appears at the bottom right side indicating the flow rate. This value must be between 40 - 60. Grinder rate If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135.
ROYAL 5. SERVICE PROGRAMME 5.2. Diagnosis menu (Royal Office) The values below can be read and adjusted in the diagnosis menu as shown in the table. Access: Access the user menu (Keep the C + hot water button pressed and turn machine on from main switch). Enter code: 111111 = Press the expresso button six times. Using the button scroll to the menu item "Diagnosis" and confirm with the E = Expresso button. Access appropriate item using the E-button.
5. SERVICE PROGRAMME Function GRINDS COUNTER Setting range 0-50 Increment +/-1 Number GRINDS STOP 30 5-50 --TOTAL WATER-(ml) Number WATER DESCALING (ml) Number HOT WATER FLOW (l/h) 20 --------------------- --HOT WATER--PUMP ADJUST. 63000 58,000 - 65,500 TURBO FACTOR 100 MACHINE STATUS 160 --DATE OF MANUF--DAY --DATE OF MANUF--MONTH --DATE OF MANUF--YEAR ROYAL --------------------6 - 34 1/h 10 - 250 Comments Counts number of coffee cycles.
CHAPTER 6 FAULTS Page 1. Faults Saeco International Group 1 REV.4 SEPT.
ROYAL 6. FAULTS 1. Faults: The following table indicates the most common faults, listed by component.
6.
ROYAL Overpress ure valve Part 6. FAULTS Fault Cause Varying cup filling volume More water in drip tray Pump No suction when pump is in operation Dry coffee in dregs drawer / water low indicator (fault LED) Water leakage at overpressure valve threaded joint Runs dry / Not de-aerated before initial heating. Inject water jet while pump is in operation.
CHAPTER 7 FAULT DIAGNOSIS Page 1. Fault detection (Royal Classic) 1.1. Does not function 1.2. Machine does not function (red LED flashes) 1.3. Machine does not function (red LED lights up) 1.4. Water low 1.5. Brewing unit / Gearmotor obstructed 2. Fault detection (R. Dig./Excl./Prof./Coffeeb.) 2.1. Does not function 2.2. Machine does not function (grinds container not detected) 2.3. Water low 2.4. De-aerate 2.5. Coffee beans low 2.6. Brewing unit / Gearmotor obstructed Saeco International Group REV.
ROYAL 7. FAULT DIAGNOSIS 1. Fault diagnosis (Royal Classic) 1.
7. FAULT DIAGNOSIS ROYAL 1.2.
ROYAL 7. FAULT DIAGNOSIS 1.3. Machine does not function (red LED lights up) Machine does not function Red LED lights up (water or coffee beans low) Does signal occur immediately after machine is turned on? Check water level YES No Does red LED light up within first 20 sec.
7. FAULT DIAGNOSIS ROYAL Yes Set coarser grind - Is coffee dispensing complete? Grinding can be made coarser No No Ye s Does coffee have enough froth / Is grain size of dregs correct? Test motor retainer OK? No Yes Yes END Page 4/12 Replace grinding disc END REV.5 SEPT.
ROYAL 7. FAULT DIAGNOSIS 1.4. Water low (red LED lights up) Water low (red LED lights) Can pump activity be detected at a specific time? Is the pump energised? No Yes Check polarity / Replace pump END No Is pump thermal fuse OK? Yes Is water tank empty? Yes Replace electronic system - END Fill water tank.
7. FAULT DIAGNOSIS ROYAL 1.5.
ROYAL 7. FAULT DIAGNOSIS 2. Fault diagnosis (Magic de luxe, Comfort and Comfort+) 2.1.
7. FAULT DIAGNOSIS ROYAL 2.2.
ROYAL 7. FAULT DIAGNOSIS 2.3. Water low Water low Water in tank? (over reserve) Fill water END No Yes Has float sunk or is jammed? Replace / Remove END Yes No Is magnet old? Yes Replace float END No Is reed sensor defective? Replace reed sensor END Yes No Electronic system defective? Saeco International Group Yes Replace - END REV.5 SEPT.
7. FAULT DIAGNOSIS ROYAL 2.4.
ROYAL 7. FAULT DIAGNOSIS 2.
7. FAULT DIAGNOSIS ROYAL 2.6.
CHAPTER 8 REPAIRS / SERVICE SCHEDULE Page 1. Repairs schedule 2. Service schedule 3. Final test Saeco International Group REV.4 SEPT.
ROYAL 8. REPAIR/SERVICE SCHEDULE 1. Repairs schedule: The repairs schedule, together with the service schedule, lists all relevant activities to be performed in an efficient sequence.
ROYAL 8. REPAIR/SERVICE SCHEDULE 3.
CHAPTER 9 DISASSEMBLY Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Saeco International Group Disassemble housing Disassembling the electronic system Disassembling doser flap valve Disassembling doser switch Disassembling the grinder Adjusting the grinder Disassembling the grinder motor Disassemble the instantaneous water heater Disassembling the gears Assembly/adjustment of instantaneous water heater Disassembling the pump Disassembling System 2 (Rapid steam) REV.4 SEPT.
ROYAL 9. DISASSEMBLY 1. Disassembly of the housing a) Remove: Driptray, dreg drawer, water tank and brew unit. b) Unscrew the bean container by removing the two screws (1). New models may have a additional housing screw below the bean container to be unscrewed. c) Remove the two screws (2) below the water tank (Torx/T10). 2 1 Fig. 1 d) Remove the two bottom housing screws (1). 1 Fig. 2 Saeco International Group REV.4 SEPT.
9. DEMONTAGE e) ROYAL Release the two hooks by using a screw driver (1).Remove the grinder setting lever (2) carefully in order not to break the fixing hooks. 1 2 Fig. 3 f) Lift the housing at the rear side and pull water hose off. Than remove the housing. When reassembling make sure, that the water hose is connected correctly! Seite 2/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 2. Disassembling the electronic system a) Number the connections on the control board and remove. Fig. 4 b) Unscrew the electronic system by removing the two fixing screws (1) and remove. 1 1 Fig. 5 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY ROYAL 3. Disassembling the doser a) Unscrew the doser cover by removing the screw (1). 1 Fig. 6 b) Using a screwdriver, release the fastening tab (1) and push dosing magnet out of its fitting. 1 2 Fig. 7 Seite 4/20 REV.4 SEPT.
ROYAL c) 9. DISASSEMBLY Using a screwdriver, first push the doser flap out of the open end (1). Than slide it out of the closed bearing (2) and remove. 1 2 1 Fig. 8 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY ROYAL 4. Disassembling doser switch a) Push the powder coffee compartment in direction of the arrow (1) and lift it (2). Carefully pull out the two rubber holders (3). 2 1 3 Fig. 9 b) Disconnect the switch. Lift the doser switch using a screwdriver (1) and push it out of ist fitting (2). 1 2 Fig. 10 Seite 6/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 5. Disassembling the grinder a) Turn the grinding adjustment ring (1) counter clockwise until the three lugs of the grinding disc fitting (2) are clearly visible and remove the upper grinding disc from the grinder. Using a vacuum cleaner remove the ground coffee. 2 1 Fig. 11 b) Remove the fixing screw (1) of the grinding cone (note: left thread). c) Carefully remove the grinding cone (2) (take care of balls and springs of friction clutch). 1 2 Fig.
9. DISASSEMBLY ROYAL d) Carefully remove the clutch disc. Fig. 13 e) Remove: Balls, springs and rubber drivers. The sealing felt (1) can then be cleaned or exchanged. (Same steps have to be performed when exchanging the Grinder motor) 1 Fig. 14 Seite 8/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 6. Adjusting the grinder a) Install the grinding ring onto its fitting so that the marking (1) on the grinding adjustment ring and the ring fitting (2) are adjacent to one another. 2 1 Fig. 15 b) Turn the grinding adjustment ring (1) clockwise until a certain friction can be felt. 1 Fig. 16 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY c) ROYAL Turn about 12-14 notches in an anti-clockwise direction and check the grind level by making a test coffee (Crema / dregs grain size). Adjust the grind level as required (max. 3-5 notches). Attach the housing and mount the lever in position 5. Seite 10/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 7. Disassembling the grinder motor a) If the motor has to be exchanged perform according to description 6. Disassembling the grinder first. Remove the three fixing screws (1), and set the doser switch to max position. 1 Fig. 17 b) Lift the motor and disconnect the connectors (1). 1 Fig. 18 Saeco International Group REV.5 SEPT.
9. DISASSEMBLY c) ROYAL Remove the securing ring if there is one (not in all machines), unhook the three tabs and seperate the upper part from the motor/gear assy (the motor is alwasy delivered with the gear). 1 Fig. 19 Fig. 20 Seite 12/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 8. Disassembling the instantaneous water heater a) Remove the hose clip of the HWS-valve (1) and the instantaneous water heater (2) and remove the Water hose. 1 2 Fig. 21 b) Remove the two fixing screws (1) of the instantaneous water heater (new version / boiler J is fixed with 3 screws). 1 Fig. 22 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY c) ROYAL Lift the heater out of the machine and exchange parts as necessary. In order to exchange the thermostat or the sensor, remove screw (1) and the fixing clamb. 1 Fig. 23 d) Attention: The metal cylinder (Fig. 24/1) of the thermal sensor (KTY) must be transferred from the old sensor to the new sensor when the sensor is replaced!. 1 2 Fig. 24 e) When re-assembling ensure that sufficient heat conductive paste is used (Fig. 24/2). Seite 14/20 REV.4 SEPT.
ROYAL 9. DISASSEMBLY 9. Disassembling of the gear a) Remove the housing b) Remove loosen the instantaneous water heater c) Remove the gear fixing screws (1). 1 Fig. 25 d) Remove the gear by lifting it a bit – pulling out the bottom side of the gear first, and thereafter the upper side. Unscrew the screws of the gear cover and remove the cover. Abb. 26 1 Fig. 26 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY e) f) ROYAL Replace parts as necessary. When replacing the gear wheel ensure that the arrow on the large gear wheel points towards the achsle of the small gear wheel. The brewing unit cannot be installed in this position. (Install all components, switch on machine - gears go to home position - install brewing unit.
ROYAL 9. DISASSEMBLY 10. Assembly/adjustment of instantaneous water heater a) Screw on the instantanous water heater, but do not fasten the screws completely. Insert the brew unit and drive it into brew position using the test mode. Fasten the lower fixing screw (1). 1 Abb. 28 b) Drive the brew unit into home position, remove the brew unit and fasten the upper screw (1). (Attention: Boiler J is fixed with three screws) 1 Abb. 29 Saeco International Group REV.4 SEPT.
9. DISASSEMBLY ROYAL 11. Disassembling the pump a) Pull off the adapter angle (1) and pump holder (2). 2 1 Abb. 30 Abb. 31 b) Remove the locking spring (1). c) Push down the fixing tab (2) and remove pump and holder (3). 1 2 3 Abb. 32 Seite 18/20 REV.4 SEPT.
ROYAL 9. DEMONTAGE 12. Disassembly System 2 (Rapid steam) a) Loosen nut (1) and remove cappuccino valve. 1 Abb. 1 b) Unscrew system two holding device, by removing the five screws (1). 1 Abb. 2 Saeco International Group REV.4 SEPT.
9. DEMONTAGE c) ROYAL Lift system two as much as possible and remove the hose (1) from the pressure relief valve 1 Abb. 3 d) Remove the locking spring of the steam hose and remove the steam hose (1). Place the unit on the rim of the housing and change parts as necessary. 1 Abb. 4 Seite 20/20 REV.4 SEPT.
CHAPTER 10 CIRCUIT DIAGRAMS Saeco International Group REV.4 SEPT.
