Bosch TCA640 Series Repair Instruction Download Page 61

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58300000120060_ARA_en_c.doc – 18.09.09

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6.6

Replacing the front panel

Tools:

►

Torx-

screwdriver T10

6.6.1 Procedure:

Disassemble the appliance as described in the "General
disassembly" section.

Remove the coffee outlet as described in the "Replacing the
coffee outlet" section, points 1. – 6.

Undo two Torx T10 screws

(1)

on the lower front panel.

Remove two cover caps

(2)

from screw holes

(3)

Push the outlet slider upwards until three screw holes

(3)

are

accessible.

Undo three Torx T10 screws

(4)

Pull the front panel off forwards and pivot it to the side for
further disassembly.

To reassemble, proceed in the reverse order of disassembly

Note!

Make sure that cables or hoses are not jammed or
bend after assembly.

Summary of Contents for TCA640 Series

Page 1: ...nit 34 4 5 Cappuccino caffelatte frother 38 4 6 Coffee outlet 40 4 7 Drip tray 42 4 8 Water filter 44 5 FUNCTIONS 45 5 1 Construction 45 5 2 The perfect espresso 47 5 3 Functional principle 47 5 4 Warming the cups 47 5 5 The fluid system 48 5 6 Temperature 49 6 REPAIR 51 6 1 Reading out internal appliance data 51 6 2 Replacing the brewing unit 52 6 3 General disassembly 55 6 4 Replacing the therma...

Page 2: ...8300000120060_ARA_en_c doc 18 09 09 Seite 2 von 95 8 TECHNICAL SPECIFICATIONS 92 8 1 Rating plate 92 8 2 Power 93 8 3 Temperatures 93 8 4 Dimensions and weight 94 8 5 Filling amounts 94 8 6 Components 95 ...

Page 3: ...irs are complete perform a test in accordance with VDE 0701 or the corresponding national regulations Following each repair conduct a leak and performance test 1 2 Repair instructions Caution 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 repa...

Page 4: ...only Do not place the appliance on a hot surface e g heating plate and never use it close to an open flame 2 2 Scope of delivery All appliances are supplied with the Welcome pack starter kit and optionally with a gift box TCA640x TCA680x Contained in the welcome box 2 descaling tablets for 1 descaling cycle X X 2 cleaning tablets X X Water hardness test strip X X Measuring spoon with filter adapte...

Page 5: ...g unit Set the mains switch at the back of the appliance to I The illuminated ring around the standby button lights up green Press standby button The appliance conducts a self test 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 The system is rinsed and heated up Brewing unit r...

Page 6: ...ml water are conveyed and the water pipe system is filled Then the appliance is ready to use 3 3 Emptying the pipe system Risk of damage The appliance must be emptied if there is a risk of frost e g on the way to or from customer services The heater or the pipe system may be damaged if the water in the fluid system freezes Press the standby button Appliance enters standby mode Remove the water tan...

Page 7: ...ply 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 Warning Do not actuate the mains switch during the brewing process When the appliance i...

Page 8: ...ng can be changed 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 proc...

Page 9: ...liance has heated up to steam temperature After steam has been drawn coffee can be brewed again immediately 3 4 5 Coffee dispensing button 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...

Page 10: ...offees 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 3 4 7 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 ...

Page 11: ...n the appliance must be cleaned Coffee can still be brewed To start the cleaning cycle press the clean button for approx 3 sec 3 4 9 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 ...

Page 12: ...high amount of ground coffee can cause malfunctions especially by using dark roasted coffee beans with high oil rate Warning Adjust the grinding unit only while the grinding unit is running Otherwise the appliance may be damaged Open right cover of the appliance Press coffee dispensing button to start a brewing cycle While the grinding unit is running turn the knob to select the degree of grinding...

Page 13: ...ogramming The following settings can be changed Language Water hardness Water filter Temperature Current time Timer function Energy saving mode 3 5 2 Displayed language To change the displayed language to the required national setting Press and hold down button P for at least 3 sec Keep pressing button P until the language selection flashes Select the required language with the arrow buttons Press...

Page 14: ...g press and hold down button P for at least 3 seconds Select HARDNESS WATER with the arrow buttons Press button P number for hardness range flashes Select required water hardness with the arrow buttons Press button P to save the setting Press exit button to return to brewing mode The appliance is ready for use again 3 5 3 2 Degrees of water hardness Setting German French 1 1 7 1 13 2 8 15 14 27 3 ...

Page 15: ...ed water from a domestic softening system is used a water filter is not required If the system message FILTER CHANGE 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 3 5 4 1 Inserting the water filter The applia...

Page 16: ...ance 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 system message PRESS WATER is displayed press the function switch again The appliance is ready for use 3 5 4 3 Removing the water filter The appliance must be switched on and ready to use Using the screwing aid unscrew the water filter in an ant...

Page 17: ...nput and saved The time is required to use the timer function The appliance must be switched on and ready to use Press and hold down button P for at least 3 sec Select the TIME with the arrow buttons Press button P until the hour display flashes Select the required setting with the arrow buttons Press button P until the minute display flashes Select the required setting with the arrow buttons Pres...

Page 18: ...setting with the arrow buttons Press button P to save the setting Press exit button to return to brewing mode 3 5 7 2 Deactivating the setting The switch on time remains saved even if there is a power failure or the mains switch in the appliance is actuated To deactivate the setting Press and hold down button P for at least 3 sec Select the ON AT with the arrow buttons Using the arrow buttons set ...

Page 19: ...S with the arrow buttons Press exit button to return to brewing mode The display cannot be changed 3 5 10 RESET function Possible from standby mode only Switch the appliance to standby mode by pressing the Standby button Simultaneously press and hold down both arrow buttons for at least 3 sec All changed memory settings are reset to the factory settings Reset parameters LANGUAGE ENGLISH HARDNESS W...

Page 20: ...walled cups Prewarm cups on the cup shelf or fill with hot water and rinse out 3 6 1 Espresso coffee preparation with beans Using the filling quantity selector set the required amount of coffee and the number of cups Using the coffee strength selector set the amount of ground coffee Place a cup under the outlet Adjust the outlet height Press the coffee dispensing button The brewing pro cess starts...

Page 21: ...ocess does not start within 90 se conds the brewing chamber is automatically emptied to prevent overfilling The appliance is rinsed 3 6 3 Frothing up milk preparing latte macchiato Warning Risk of scalding Risk of burns When the steam button is pressed some steam may spray out Escaping steam is very hot Do not touch the frothing nozzle or point it at anybody 1 Set the dial to milk froth or warm mi...

Page 22: ...or approx 15 seconds to steam temperature Then the steam is conveyed and the liquid is heated End the process by pressing the steam button again Note After using the appliance always clean the frothing nozzle Dried residue is very difficult to remove 3 6 5 Preparing hot water Warning Risk of scalding Risk of burns When the hot water button is pressed some hot water may spray out Do not touch the f...

Page 23: ...ce with a damp cloth Remove and rinse out the water tank 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 tray contacts 3 on all sides and dry Note Coffee residue or residual water between the tray contacts may result in fault messages Vacuum...

Page 24: ...lass or receptacle containing hot water and repeat the frothing up process except now with drawn in water instead of milk Milk residue is dissolved and flushed out To clean thoroughly disassemble all parts and clean with a soft brush in a mild detergent solution Clean particularly inaccessible locations with a blunt needle Rinse all parts with hot water and dry Parts are dishwasher proof Note When...

Page 25: ...on until it clicks into position Pull brewing module by the handle out of the appliance Clean the brewing unit under warm running water without washing up liquid Risk of damage Do not clean brewing module in the dishwasher Vacuum out the appliance interior or wipe out with a damp cloth Dry and re insert brewing unit Press the red knob on the handle of the brewing unit and rotate downwards in an an...

Page 26: ... result the flowmeter must be operated in a horizontal position 4 1 1 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 impel...

Page 27: ...ng 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 4 2 Heater and NTC sensor 4 2 1 Heater Instantaneous water heater In the instantaneous water heater the water for coffee production or hot water steam purchase is heated up Therefore the water is pumped in a stai...

Page 28: ...58300000120060_ARA_en_c doc 18 09 09 Seite 28 von 95 4 2 2 Characteristic of NTC sensor Temperature R min R nom R max 25 C 9 78k 10 00K 10 22k 95 C 0 77k 0 78k 0 80k 140 C 0 232k 0 234k 0 237k ...

Page 29: ... coffee The coffee which is produced is conveyed to the coffee outlet 10 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 7 4 3 1 1 Variable brewing chamber The brewing unit consists primarily of the brewing ch...

Page 30: ...ly ground coffee can be poured in via the powder slot 4 3 2 2 Compression 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...

Page 31: ...avours 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 4 3 2 4 Emptying 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 ...

Page 32: ...g funnel The unlocking lever is engaged in the locking mechanism open position 1 The mark on the input shaft is next to the tip of the marking arrow 2 4 3 3 2 Locking mechanism When locked the brewing chamber is prevented from moving Only when placed in the appliance is the locking mechanism released by two cams 1 in the brewing unit compartment Lock bolt 2 releases unlocking lever 3 The unlocking...

Page 33: ...mediately 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 4 3 4 1 Switching states If there is a minimum amount of coffee 7 g the brewing head does not move The switch is not actuated No...

Page 34: ... brewing unit via a cam B connected to the drive shaft Note From production date FD8701 on the drip tray is monitored by an additional micro switch in the appliance If the drip tray is pulled out the micro switch opens and interrupts the power supply to the gear motor via the power module 4 4 2 Rear housing On the rear housing section of the gear unit the drainage valve B is attached to the expans...

Page 35: ...rainage position S1 ON S2 OFF The brewing unit is in the grinding position and can be filled Switch S1 is activated by switch cam A Switch S2 remains open S1 OFF S2 ON 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 S1 ON S2 ON Once t...

Page 36: ...ars 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...

Page 37: ... drainage valve control line and closes it Water can flow from inlet A through drainage valve B to outlet C 4 4 4 3 Drainage position Once the brewing process is complete the water pump switches off 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 the...

Page 38: ...hose must be inserted into the receptacle containing the milk The notch prevents the intake hose from sticking to the base of the receptacle Connect the pre assembled Cappuccino Caffeelatte frother to the adapter on the steam pipe An optimum frothing result is obtained when the froth has the same volume as the conveyed milk portion and a firm consistency 4 5 1 Settings The milk froth and the tempe...

Page 39: ...let valve 6 or by milk which is drawn through the intake hose 4 The rotary controller 5 regulates the air intake and milk flow In the CAFFELATTE area only milk is drawn in By rotating the controller the flow rate and therefore the temperature of the milk can be varied between 50 C and 75 C The air supply is closed in this position In the CAPPUCCINO area milk and air are drawn in By rotating the co...

Page 40: ...s 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 r...

Page 41: ...roduction date FD8606 A newly introduced jug 1 in conjunction with changes to the distributor 2 and to the distributor cover 3 ensure a more even outlet with lower right left tolerances The coffee outlet is available only as a complete pre assembled spare part with or without chrome plated outlet sleeves and replaces the previous coffee outlet ...

Page 42: ...rted 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 d...

Page 43: ...the appliance is opened 4 7 2 1 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 ...

Page 44: ...e and conveyed out through the centre of the water tank valve Up flow principle 4 8 2 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 27 42 mm Filter length 175 mm Filling volume 95 100 ml Filter effect Carbon hardness Chlorine ...

Page 45: ...pensation microswitch 2 Coupling for coffee outlet 3 Connection for steam nozzle 4 Brewing unit locked microswitch 5 Drainage valve outlet 6 Cams for releasing the brewing unit 7 Drive coupling for brewing unit 8 Brewing unit lock 9 Grinder 10 Grind setting 11 Coffee bean container 12 Filling funnel 13 Ground coffee duct ...

Page 46: ...ch 5 Transmission unit 6 Power switch 7 Water tank coupling with valve pusher 8 Flow meter 9 Mains interference suppression filter 10 Diagnostics connector 11 Controller board with display 12 Controller unit logic module 13 Power electronics 14 Water tank reed switch 15 Transformer 16 Reduction angle 17 Pump with temperature monitoring 18 Solenoid valve for steam and hotwater ...

Page 47: ...per end position When this is reached the water pump starts to supply water Water is sucked out of the water tank through the flow meter The flow of water sets the impeller in motion which generates electrical pulses The run time of the pump is determined by the number of pulses The pump conveys the water through the heater at a pressure of 5 8 bar Depending on the product selected coffee hot wate...

Page 48: ...e to solenoid valve i and a pressure line to outlet valve f and then on to drainage valve g and to the brewing unit Outlet valve f has an opening pressure of 4 bar and closes off the brewing system when hot water and steam are being dispensed At the end of a brewing cycle the remaining water is drained from the brewing unit into the drip tray h via drainage valve The rest of the system remains ful...

Page 49: ... drawing coffee hot water D Press steam button right heating up process begins E Steam production starts when steam temperature is reached F Press steam button right to stop steam production cooling down process begins 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...

Page 50: ...ature pattern drawing espresso 40 ml 5 6 3 Temperature pattern drawing coffee 125 ml Heater Heater Coffee outlet Brewing water Brewing water Coffee outlet NORMAL setting MAXIMUM setting HIGH setting NORMAL setting MAXIMUM setting HIGH setting Temperature Temperature ...

Page 51: ... number the last service date and the production date Then the appliance switches back to standby mode If the electronics module or the display does not support this function in the event of a fault the current state of the appliance can be determined by the labelling on the rear of the display and the logic board control module Note For number of brews see under Change programming standard settin...

Page 52: ...1 Opening the service door The service door behind the brewing unit is installed is locked with a bar To open the service door use a coin or a flat screwdriver Open the door by rotating the locking knob in a clockwise direction 6 2 1 2 Remove the brewing unit 1 Press the red knob on the handle and 2 Turn the handle clockwise until you hear it engage Pull the brewing unit out of the guide by the ha...

Page 53: ...in the locking mechanism open position 1 The mark on the input shaft is next to the tip of the marking arrow 2 6 2 2 2 Inserting the brewing unit Service door is opened Slide the brewing unit into the appliance in the basic position and lock in place 1 Press the red knob on the handle and 2 Turn the handle anti clockwise until you hear it engage Close and lock the service door Symbols on the brewi...

Page 54: ...e 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 31 0574 Note After replacing the O ring for the coffee outlet A or for the water inlet C they must be thinly greased with food safe special lubricating grease PARALIQ GTE 703 Mat no 31 0574 ...

Page 55: ...k 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 Note When removing the back panel take care of the supply cable to the mains switch 5 Remove back panel E to rear 6 Remove upper section of housing to rear and up 7 Remove ho...

Page 56: ...se is in perfect condition and is correctly installed 6 4 1 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 6 4 2 Component The thermal fuse is supplied as a p...

Page 57: ...rmal 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 ...

Page 58: ...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 6 5 2 Loosening the coffee distributor First remove the silicone hose A Remove the coffee distributor B after detaching the catches C ...

Page 59: ...s press For subsequent removal Press the outlet slide all the way down 1 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 6 5 4 Removing the metal bands Using a flat tipped screwdriver press the metal band A downwards Remove the metal bands A and the braking magnets B ...

Page 60: ... 18 09 09 Seite 60 von 95 6 5 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 ...

Page 61: ... the coffee outlet section points 1 6 3 Undo two Torx T10 screws 1 on the lower front panel 4 Remove two cover caps 2 from screw holes 3 5 Push the outlet slider upwards until three screw holes 3 are accessible 6 Undo three Torx T10 screws 4 7 Pull the front panel off forwards and pivot it to the side for further disassembly 8 To reassemble proceed in the reverse order of disassembly Note Make sur...

Page 62: ...assembling the installation position of the operating printed board assembly please note the cable must point downwards 5 Push together two snap hooks 4 on adapter 5 and push the adapter and button forwards out of the front panel 6 Unclip the button from the adapter and replace if necessary 7 To reassemble first clip in adapter 5 with notch 6 towards the inside of the panel 8 Clip operating printe...

Page 63: ...placing the front panel section points 1 6 3 Remove the frothing aid and unscrew the adapter from the steam pipe 4 Release clamp 3 remove two O rings 4 and split taper socket 5 from the steam pipe 5 Push the steam nozzle inwards and pull out of the front panel 6 To refit the steam pipe proceed in the reverse order of disassembly Once the repair is complete check for ease of movement from the right...

Page 64: ...el to the left 4 Release safety clip 1 remove pressure hose 2 and insulation from fluid connection 3 5 Remove safety clip 6 from fluid distributor 7 and remove fluid coupling 8 6 Release safety clip 9 and remove fluid distributor 7 from the heating element connection 7 Remove plug type connectors from solenoid valve 10 8 Undo screw 4 and pull valve support plate 5 upwards out of the component brac...

Page 65: ...m to do this open and close ground coffee duct flap and start a coffee brewing process Press function switch briefly to draw steam in order to increase the heater temperature Appliance calcified Descale Coffee temperature too high NTC temperature sensor defective NTC temperature sensor not screwed on correctly Replace NTC temperature sensor Tighten NTC temperature sensor Logic module defective Rep...

Page 66: ...r dirty or defective 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 when drawing several cups in succession Drainage valve leaking due to coffee dregs Run descaling programme Replace drainage valve Incorrect pulsing from flowmeter Check hose system between flowmeter and pump If...

Page 67: ...er Empty and clean bean container Use beans with lower fat content Noise of grinding unit is loud Foreign object in grinding unit e g grit may also occur with select coffees Replace grinding unit Grinding unit is not functioning 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 t...

Page 68: ...ace magnetic valve and descale High degree of condensate in steam Before frothing draw steam for several seconds Too little froth when frothing milk Frother dirty or calcified Dismantle frother clean carefully or descale poor froth consistency Frother assembled incorrectly Assemble correctly and ensure all parts are fitted securely without gaps froth collapses Milk is not at refrigerator temperatu...

Page 69: ...ective Replace reed switch Error message Error 8 is in dicated Cleaning tablet added at wrong time Cleaning tablet is blocking brewing unit Remove and clean brewing unit remove cleaning tablet If damaged replace brewing module Descaling programme does not start System too hot message on display Cool down system by drawing hot water Water filter inserted and active Remove water filter and change pr...

Page 70: ...s Water running out during brew ing process Magnetic valve leaking Replace magnetic valve and following in stallation actuate 2 3 times Hose system leaking Calcification increases pressure in the hose above 35 bar Replace hose descale Fabric hoses burst Hose has preliminary damage Drainage valve leaking Water running out during brew ing process Drainage valve leaking due to coffee dregs Run cleani...

Page 71: ... and initialised If the ambient temperature is too low the message goes out when the appliance has warmed up to room temperature 7 2 1 2 Error 5 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 applianc...

Page 72: ...coffee slot Incorrect operation cleaning tablet was inser ted 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 ...

Page 73: ...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 ...

Page 74: ...rewing 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...

Page 75: ...d on for the first time The illuminated rings around the standby button and the coffee dispensing button flash and the following displays occur alternately Press the coffee dispensing button Approx 30 ml water are conveyed and the water line system is filled Then the appliance is ready to use 7 2 2 4 Brewing unit missing BREWING UNIT MISSING Brewing unit missing or not locked Install and lock brew...

Page 76: ...s 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 7 2 2 6 Trays missing TRAYS MISSING Drip tray not or incorrectly inserted I...

Page 77: ...nitialised Conduct drawer test with original tray Insert test drawer appliance rinses independently Are illuminated rings on the standby and cafe 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 cafe on button Is water ...

Page 78: ...isk drive At least 2 serial interfaces USB interface Parallel interface Printer 7 4 2 Service diagnosis kit Mat no 34 0995 A service diagnosis kit is required to support diagnosis of the appliances by PC This kit includes the following components A Scanner is switched between PC and test object B Connecting cable between scanner and test object C CD with diagnostic software D Connecting cable betw...

Page 79: ...he 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 7 4 5 USB service diagnosis kit The scope of delivery is changed with the introduction of the new USB service diagnostic kit Mat no 34 0995 The power supply unit is no longer required because the scanner is supp...

Page 80: ...e cover A 7 4 7 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 durin...

Page 81: ...mple 00001000 Heating up not possible 7 4 9 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 and Brews since last intervention 2 2500 Major service 7 4 10 Definition of minor major service 7 4 10 1 Minor service Descale applian...

Page 82: ...n 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 7 4 14 Service stamp The service stamp is input via the following form 7 4 14 1 Group definition Specific fault groups are allocated to the working points When a working point has been selected its fault group is activated...

Page 83: ...he animation system stamp 3 1 4095 Invoice item stamp 3 1 255 7 4 15 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 e mail...

Page 84: ...heck power supply 220 240 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 220 240 VAC To do this open the appliance Using the Torx T10 screwdriver un screw all rear panel screws and remove the rear panel Che...

Page 85: ...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 CP10 terminals 1 GND brown and 2 5 V red No voltage defective power ...

Page 86: ...anels upwards The control signal voltage can be measured on plug CL10 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 CP6 on terminals 3 GND bla...

Page 87: ...module pump output The voltage for the pump is measured on plug CP6 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 over...

Page 88: ...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 CP6 on terminal 5 neutral conductor blue and terminal 1 phase brown From service index 02 on the heater is connected between terminals TM3 and TM5 The heater must be actuated by drawing hot water The heater is actuated in pulses No vo...

Page 89: ... 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 ...

Page 90: ...ic valve must be actuated by pressing the steam button Wait until steam temperature is reached No control voltage Logic module or connecting cable defective Voltage available see Point 2 2 Check voltage on power module steam output The voltage for the steam valve is measured on plug CP6 on terminals 6 neutral conductor and terminal 1 phase brown The magnetic valve must be actuated by pressing the ...

Page 91: ...art 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 5 10 mm under the coffee outlet B in the middle of flow 1st 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...

Page 92: ...cation designation C 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 D Frequency E Production date according to BSH key For example FD8609 86 year minus 20 2006 09 month September F Serial number optional G Power H Type works designation I Field for appro...

Page 93: ...re 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 0 5555 F 1 8 C 32 8 3 1 Coffee outlet 1st coffee NORMAL in the jet 82 C 5 2n...

Page 94: ... 8 4 3 Weight of machine Approx 12 2 kg 8 5 Filling amounts 8 5 1 Capacity Water tank 1 8 l Bean container Approx 250 g Drip tray 750 ml signal limit 8 5 2 Cup filling amounts 1 220 ml XXL COFFEE 2 160 ml LARGE COFFEE 3 125 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 9 160 ml 2 SMALL COFFEES 10 250 ml 2 COFFEES 11 300 ml 2 LA...

Page 95: ... 3000 r p m no load 451 1 6 6 r p m 4 0 Nm from spindle Transformer Primarily power supply Secondary voltage 1 Secondary voltage 2 230 V AC 50Hz 9 0 V AC 15 0 V AC Heater Supply voltage Power 230 V AC 50Hz 1250 W Pump Supply voltage Power 230 V AC 50 Hz 65 W 15 17 bar static Pump thermostat Switching off limit 115 C Pressure valve Opening pressure 4 5 bar Grinding unit Supply voltage Speed motor S...

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Bosch TCA640 Series, Repair Instruction

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