Bosch TCA640 Series Setup guide

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Fully-automatic coffeemaker
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1SAFETY........................................................3
1.1 Safety instructions..............................................................3
1.2 Repair instructions .............................................................3
2INSTALLATION............................................4
2.1 Installation...........................................................................4
2.2 Scope of delivery ................................................................4
3OPERATION.................................................5
3.1 Switching on the appliance................................................5
3.2 Filling up the pipe system..................................................6
3.3 Emptying the pipe system..................................................6
3.4 Controls...............................................................................7
3.5 Changing the programming / standard settings ............13
3.6 Preparation........................................................................20
3.7 Cleaning.............................................................................23
4COMPONENTS...........................................26
4.1 Flowmeter..........................................................................26
4.2 Heater and NTC-sensor....................................................27
4.3 Brewing unit......................................................................29
4.4 Gear unit............................................................................34
4.5 Cappuccino / caffelatte frother ........................................38
4.6 Coffee outlet......................................................................40
4.7 Drip tray.............................................................................42
4.8 Water filter.........................................................................44
5FUNCTIONS................................................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
6REPAIR.......................................................51
6.1 Reading out internal appliance data............................... 51
6.2 Replacing the brewing unit.............................................. 52
6.3 General disassembly........................................................ 55
6.4 Replacing the thermal fuse.............................................. 56
6.5 Removing the coffee outlet.............................................. 58
6.6 Replacing the front panel................................................. 61
6.7 Steam button and operating panel replacement............ 62
6.8 Replacing the steam pipe ................................................ 63
6.9 Solenoid valve replacement ............................................ 64
7FAULT DIAGNOSTICS...............................65
7.1 Malfunctions ..................................................................... 65
7.2 System and error messages............................................ 71
7.3 Incoming goods inspection............................................. 77
7.4 Service diagnosis............................................................. 78
7.5 Troubleshooting ............................................................... 84
7.6 Measuring the coffee temperature.................................. 91

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8TECHNICAL 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

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1 SAFETY
1.1 Safety instructions
Danger!
►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.
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 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!

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2 INSTALLATION
2.1 Installation
►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.
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 adapter X X
Instructions for use 1 booklet 1 booklet
Short instructions X X
Water filter X
Contained in the gift box:
Milk container X
2 Latte-Macchiato spoons X
Coffee beans 250g X

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3 OPERATION
3.1 Switching on the appliance
►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.
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.
►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 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 product (e.g. ESPRESSO)
is displayed.
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.

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3.2 Filling up the pipe system
For production reasons the water line system in the appliance must
be filled again when the appliance is switched on for the first time:
The illuminated ring around the standby button and the coffee
dispensing button flash and the following displays occur alternately:
Display „Fill up pipe-system“ appears alternately with „Press water”
►Place a cup or glass under the hot water nozzle and press
the hot water button.
Approx. 30 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 tank
►Press the steam button
for 2 seconds: Display: Pipe system emptying
The magnetic valve opens
The remaining water is drained
via the steam nozzle
The appliance heats up and
evaporates the water in the pipe
system as steam.
The standby button flashes
►Press the standby button The appliance enters standby
mode

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3.4 Controls
3.4.1 Accessories
Coffee outlet can be moved higher (up to 125 mm)
1 Water filter (mat.-no.. 46 1732)
2 Lid for milk container
3 Connection hose with adapter
4 Milk container
5 Sunken macchiato plate (suitable for glasses up to 140mm height)
3.4.2 Mains switch
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.
Warning:
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.

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3.4.3 Standby and P button
►Switch on the power switch: Appliance enters standby mode
Display: No display
Button: Standby button lights up
►Press the standby button: Appliance initialises, heats up and
rinses
►Press the coffee dispensing
button: No reaction, appliance is off
►Press the clean button: No reaction, appliance is off
►Press the calc button: No reaction, appliance is off
►Press the steam button for
2 seconds: System empties (no water tank)
►Remove the trays: No reaction, appliance is off
Trays also monitored in standby
►Open the ground coffee duct
flap: No reaction, appliance is off
►Remove the brewing unit: No reaction, appliance is off
►Press the P button for 2
seconds: Language setting 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 process at any time.
3.4.3.1 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.
3.4.3.2 Switching on a warm appliance:
The illuminated ring around the standby button is lit
constantly. Coffee can be brewed.
3.4.3.3 The appliance is not rinsed if:
►it was still warm when switched on
or
►there was no coffee from the last brew before
the appliance was switched off.

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3.4.4 Function switch
Press function switch to draw hot
water or steam:
m Risk of scalding!
When steam or hot water is
released, the nozzles may
initially sputter!
1. Drawing hot water –
via hot water/ steam pipe.
2. 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.
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 process is
stopped, and the brewing unit is emptied.)
Ready-to-use mode is indicated by the illuminated ring
which is lit constantly.

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3.4.6 Filling quantity selector
This rotary knob is used to select the amount of liquid which is
required.
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.
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 as well as the formation of the crema.
Amount of coffee powder can be selected between “very mild” 7 g and
“extra strong” 13 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. 13 g
The amount of ground coffee powder is monitored in the brewing
module and corrected by compensation of the grinding unit running
time.

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3.4.8 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.
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.

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3.4.10 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.
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.
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:
The smaller the dots the finer the
ground coffee.
The new setting will not become apparent until the second or third cup
of coffee.
3.4.10.1 Service-Sticker
To make sure that the grinding unit will be adjusted correctly a sticker
is added on the right cover of the appliance.

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3.5 Changing the programming / standard settings
The appliance has been set at the factory so that coffee can be
brewed without any additional programming. To change these
standard settings, use the function buttons under the display.
Before the programming can be changed, the appliance must be in
brewing mode.
While programming, do not switch off the appliance. Otherwise
changes will not be accepted.
3.5.1 Programming
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 Pfor at least 3 sec.
►Keep pressing button Puntil the language selection flashes.
►Select the required language with the arrow buttons.
►Press button Pto save the language setting.
►Press the exit button to leave language selection.
3.5.2.1 Displayed languages which can be selected
SPRACHE
DEUTSCH
LANGUAGE
ENGLISH
LANGUE
FRANCAIS
LINGUA
ITALIANO
SPRAK
SVENSKA
IDIOMA
ESPANOL
TAAL
NEDERL:
JASYK
RUSSKIY

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3.5.3 Water hardness
Determine the water hardness with the enclosed test strip or ask your
local water supplier.
Test strip for determining the water hardness, mat. no.: 05 6317
Hardness 1 220 litres
Hardness 2 100 litres
Hardness 3 70 litres
Hardness 4 40 litres
3.5.3.1 Setting the water hardness
►The appliance must be switched
on and ready to use.
►To change the water hardness
setting, press and hold down
button Pfor 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 Pto 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 16–23 28–42
4 24–30 43–54
Note:
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 HARDNESS
WATER 1

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3.5.4 Water filter
A water filter available as an accessory (mat. no.: 46 1732) can be
inserted in the water tank.
When approx. 50 litres 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 the appliance is operated with the water filter
always inserted, the appliance should be
descaled once or twice a year even if there is no
message displayed.
►If softened 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 appliance must be
switched on and ready to use.
►Place a vessel with a capacity
of at least 500 ml under the hot
water nozzle.
►Press and hold down button P
for at least 3 sec.
►Select FILTER NO/OLD with the arrow buttons.
►Press button P until the display flashes.
►Select FILTER YES/NEW with the arrow buttons.
►Press button Pto save the setting.
►Press exit button to return to brewing mode.
►Press function switch to 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 system message PRESS WATER is displayed, press
the function switch again.
The appliance is ready for use.

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3.5.4.2 Changing the water filter
►The appliance must be
switched on and ready to use.
►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.
►Screw in a new water filter.
►Press and hold down button Pfor at least 3 sec.
►Select FILTER YES/NEW with the arrow buttons.
►Press button Pto save the setting.
►Press exit button to return to brewing mode.
►Press function switch 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 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
anti-clockwise direction.
►Press and hold down button P
for at least 3 sec.
►Select FILTER YES/NEW with the arrow buttons.
►Press button P until the display flashes.
►Select FILTER NO/OLD with the arrow buttons.
►Press button Pto save the setting.
►Press exit button to return to brewing mode.
The appliance is ready for use again.
Check water hardness setting.

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3.5.5 Temperature
The coffee temperature can be set or
changed.
►Press and hold down button P
for at least 3 sec.
►Select TEMP with the arrow
buttons.
►Press button P until the display
flashes.
►Select the required setting with
the arrow buttons.
►Press button Pto save the
setting.
►Press exit button to return to
brewing mode.
3.5.6 Current time
The current time can be input 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.
►Press button Pto save the setting.
►Press exit button to return to brewing mode.
The set time will be lost
►if the mains plug is pulled out.
►if the appliance is switched off with the mains switch.
►if there is a power failure.

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3.5.7 Timer
This function can be used to set the time at which the appliance is to
switch on automatically.
Note:
►If the time has not been set , the switch-on time
cannot be programmed.
►If the clock fails (e.g. after a mains interruption),
the switch-on time --;-- is displayed. The
switch-on time is not active. Not until the time is
reprogrammed, is the original switch-on time
redisplayed and is active.
►Display range: 00;00 .....23:59 + – – : – –
3.5.7.1 Activating
►The appliance must be
switched on and ready to use.
►Press and hold down button P
for at least 3 sec.
►Select the ON AT 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.
►Press button Pto 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 Pfor at least 3 sec.
►Select the ON AT with the arrow buttons.
►Using the arrow buttons, set the time to – – : – –.
3.5.8 Energy-saving mode
This function can be used to set the
number of hours after which the
appliance automatically switches to
standby mode since the last brew.
The switch-on time remains saved
even if there is a power failure or the
mains switch is actuated.
►The appliance must be switched on and ready to use.
►Press and hold down button Pfor at least 3 sec.
►Select the OFF AFTER with the arrow buttons.
►Press button P until the hour display flashes.
►Select the required setting with the arrow buttons.
►Press button Pto save the setting.
►Press exit button to return to brewing mode.

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3.5.9 Displaying the brews
The number of the already brewed
espressos, coffees and ground coffees
is displayed here. The brews are
counted automatically.
►The appliance must be switched on and ready to use.
►Press and hold down button Pfor at least 3 sec.
►Select the NO.BREWS 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 WATER - 3
►FILTER -NO/OLD
►TEMPERATURE - HIGH
►TIME - – – : – –
►ON AT - – – : – –
►OFF IN - 4 HOURS
The illuminated ring of the standby button flashes 3
times.

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3.6 Preparation
The fully automatic coffee espresso machine grinds fresh coffee
beans for each brewing process.
►Preferably use espresso beans or bean mixtures for fully auto-
matic machines.
►Store coffee in air-tight containers in a cool location, or deep-
freeze. Deep-frozen coffee beans can also be ground.
►Preferably use thick-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.
The brewing process can be interrupted by pressing
the coffee dispensing button or the Standby button
again.
Note:
If brewing two cups, set coffee
strength to STRONG or EXTRA
STRONG.