Saeco Classic User manual

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. Any reproduction or unauthorised use of this manual
without the prior written permission of the manufacturer or by contractual agreement is prohibited.
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 REV.4 SEPT.2003
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. Circuit diagrams

Saeco International Group REV.4 SEPT.2003
CHAPTER 1
INTRODUCTION
Page
1. Documents required 1
2. Equipment 1
3. Material 1
4. Safety instructions 1
5. Overview of product range 2

ROYAL 1. INTRODUCTION
Saeco International Group REV.4 SEPT.2003 Page 1/2
1. Documents required
The following documents and requirements are necessary to qualify for an authorised repair.
•Service manual
•Operating instructions where available
2. Tools
In addition to an electrical workshop, the following standard tools are necessary:
Description
Comments
1 Special screwdriver (Pozi) Size: PZ1
1 Special screwdriver (Pozi) Size: PZ2
1 Special screwdriver (Torx) Size: T10
1 Temperature measuring device Temperature range > 150ºC
Suitable for point measurements
3. Material
Description Comments Brand
Heat conductive paste
Temperature resistance ≥200°
User's choice
Bolt adhesive
Temperature resistance ≥200°
User's choice
Descaler Saeco
Grease solvent User's choice
Silicone grease (food safe) Saeco
4. Safety instructions
All prescriptions and regulations in force regarding the repair of electrical equipment must be
observed!
The machine must be disconnected from the main power supply before performing repair work.
Switching the machine off is not an adequate measure.
The Royal coffee machine is classified under Protection Class 1. Protective devices must be tested
once the repair work has been completed.

1. INTRODUCTION ROYAL
Page 2/2 REV.4 SEPT.2003 Saeco International Group
5. Overview of product range
Royal Redesign Royal
TYPE Pre-
grinding/
brewing
Cappuccino
maker
Steam system Second
pump
Second
heating
system
Display
Classic * Pre-
brewing
Dial control
Exclusive x x
Digital x x
Digital
Redesign
x x
Digital Plus x Rapid Steam Pipe
heater
x
Professional
(Instant
Steam)
x x Instant Steam
x Flow
heater
x
Professional
(Rapid Steam)
x x Rapid Steam Pipe
heater
x
Professional
Redesign
x x Rapid Steam Pipe
heater
x
Cappuccino x x Instant Steam
x Flow
heater
x
Cappuccino
Redesign
x x Instant Steam
x Pipe
heater
x
Coffeebar ** x x Rapid Steam Pipe
heater
x
Office*** x
x
Note:
* All machines, with the exception of the Royal Classic, are fitted with a powder coffee feed.
** The Royal Coffeebar has a fixed water connection (reversible).
***Royal Office – no steam function.
Output capacity:
Royal Series (Household): Maximum average daily output: 30 coffees
Royal Office / Coffeebar: Maximum average daily output: 50 coffees

Saeco International Group REV.4 SEPT.2003
CHAPTER 2
TECHNICAL DATA
Page
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

ROYAL 2. TECHNICAL DATA
Saeco International Group REV.4 SEPT.2003 Page 1/5
1. Technical data (Royal Classic)
Royal Classic
Technical data
Power supply/output: 230V 50Hz 1250W
Safety system: 170°C Safety thermostat for instantaneous water heater
Temperature monitoring: KTY Temperature sensors transmit respective
temperatures to electronic system
Continuous flow thermoblock: Instantaneous water heater (1090 W) for coffee and hot
water dispensing
Pump: Ulka reciprocating piston pump with angle connector
and thermostat - 48 W, 230V, 50 Hz.
Type EX5, 20 l/h
Safety valve: Conventional safety valve connected to pump
Water filter: Installed in machine in front of the turbine and pump.
Gearmotor: Direct current, 30 - 35 V
Cup warmer/gear resistor: Approx. 437W / 130Ω(only activated when gears are
operational)
Grinder (conical grinder):
Motor:
Plastic grinding screw, galvanised steel grinding cone
and grinding disc
260 V Direct current
Second doser: 230 V - Magnet coil
Power consumption: During heating - approx. 4.5 A
Standby - Approx. 0.04 A
Pump pressure: Max. 15 bar
Dimensions W x D x H in mm: 330/385/395
Weight: Approx. 15 kg
Capacity of coffee bean container: Approx. 300g
Capacity of water tank: Approx. 2.4 l max. filling volume
Instantaneous water heater capacity:
Approx. 1.0 ccm, 10 ml volume
De-aeration time: Approx. 1 - 2 sec. for initial star-up
Heating time: Approx. 80 sec. with water at 10°C to operating
temperature
Re-heating time: None due to boiler
Steam heating time: From coffee temperature to 127°C - Approx. 50 sec.
Coffee dispensing temperature: Approx. 86° C
Grinding time: Initial grinding with completely empty machine:
Approx. 15 sec. / subsequent grinding: approx. 5.5 sec.
Time to make expresso: Approx. 28 sec. for 50 ml
Time to make cup of coffee: Approx. 40 sec. for 100 ml

2. TECHNICAL DATA ROYAL
Page 2/5 REV.4 SEPT.2003 Saeco International Group
2. Technical data (Royal Digital / Exclusive/ Digital Redesign)
Royal Digital / Exclusive / Digital Redesign
Technical data
Power supply/output: 230V 50Hz 1250W
Safety system: 170°C Safety thermostat for instantaneous water heater
Temperature monitoring: KTY Temperature sensors transmit respective
temperatures to electronic system
Continuous flow thermoblock: Instantaneous water heater (1090 W) for coffee and hot
water dispensing
Pump: Ulka reciprocating piston pump with angle connector
and thermostat - 48 W, 230V, 50 Hz.
Type EX5, 20 l/h
Safety valve: Conventional safety valve connected to pump
Water filter: Installed in machine in front of the turbine and pump.
Gearmotor: Direct current, 30 - 35 V
Cup warmer/gear resistor: Approx. 437W / 130Ω
Grinder (conical grinder):
Motor:
Plastic grinding screw, galvanised steel grinding cone
and grinding disc
Direct current, 260 V
Second doser: Coffee dose adjustable by means of lever (6 - 9g) outside
housing
230 V - Magnet coil
Second doser: Doser for powder coffee, by means of measuring spoon
Power consumption: During heating - approx. 4.5 A
Standby - Approx. 0.04 A
Pump pressure: Max. 15 bar
Dimensions W x D x H in mm: 330/385/395 (Digital)
385/450/395(Exclusive)
Weight: Approx. 15 kg
Capacity of coffee bean container: Approx. 300g
Capacity of water tank: Approx. 2.4 l max.
Boiler - Capacity: Approx. 1.0 ccm, 10 ml volume
De-aeration time: Approx. 1 - 2 sec. for initial star-up
Heating time: Approx. 80 sec. with water at 10°C
Re-heating time: None due to boiler
Steam heating time: From coffee temperature to 127°C - Approx. 50 sec.
Coffee dispensing temperature: Approx. 86° C
Grinding time: Initial grinding with completely empty machine:
Approx. 15 sec. / subsequent grinding: approx. 5.5 sec.
Time to make expresso: Approx. 28 sec. for 50 ml
Time to make cup of coffee: Approx. 40 sec. for 100 ml

ROYAL 2. TECHNICAL DATA
Saeco International Group REV.4 SEPT.2003 Page 3/5
3. Technical data (Royal Professional Instant Steam / Cappuccino / Cappuccino Redesign)
Royal Professional Instant Steam / Cappuccino / Cappuccino Redesign
Technical data
Power supply/output: 230V 50Hz 2300W
Safety system: 170°C Safety thermostat for instantaneous water heater
Temperature monitoring: KTY Temperature sensors transmit respective
temperatures to electronic system
Continuous flow thermoblock: Instantaneous water heater - 1090 W, supplementary
heating 437 W for coffee and hot water dispensing
Second thermoblock: Instantaneous water heater for steam dispensing
(instant steam) - 1090 W
In Redesign this feature takes the form of pipe heating.
Pump: Ulka reciprocating piston pump with angle connector
and thermostat - 48 W, 230V, 50 Hz.
Type EX5, 20 l/h
Second pump: Technical data as above (for instant steam function)
Safety valve: Conventional safety valve connected to pump
Water filter: Installed in machine in front of the turbine and pump.
Gearmotor: Direct current, 30 - 35 V
Cup heater/Gear resistor: Approx. 437W / 130Ω
Grinder (conical grinder):
Motor:
Plastic grinding screw, galvanised steel grinding cone
and grinding disc
260 V Direct current
Second doser: Coffee dose adjustable by means of lever (6 - 9g) outside
housing
230 V - Magnet coil
Second doser: Doser for powder coffee, by means of measuring spoon
Power consumption: During heating - approx. 9 A
Standby - Approx. 0.04 A
Pump pressure: Max. 15 bar
Dimensions W x D x H in mm: 385/450/395
Weight: Approx. 16 kg
Capacity of coffee bean container: Approx. 300g
Capacity of water tank: Approx. 2.4 l max.
Instantaneous water heater capacity:
Approx. 1.0 ccm, 10 ml volume
De-aeration time: Approx. 1 - 2 sec. for initial star-up
Heating time: Approx. 80 sec. with water at 10°C
Re-heating time: None due to boiler
Steam heating time: None due to second instantaneous water heater (steam
dispensing possible even during coffee dispensing /
second pump)
Coffee dispensing temperature: Approx. 86° C
Grinding time: Initial grinding with completely empty machine:
Approx. 15 sec. / subsequent grinding: approx. 5.5 sec.
Time to make expresso: Approx. 28 sec. for 50 ml
Time to make cup of coffee: Approx. 40 sec. for 100 ml

2. TECHNICAL DATA ROYAL
Page 4/5 REV.4 SEPT.2003 Saeco International Group
4. Technical data (Royal Digital Plus / Professional Rapid Steam / Prof. Redesign / Coffeebar)
Royal Digital Plus / Professional Rapid Steam / Prof. Redesign / Coffeebar
Technical data
Power supply/output: 230V 50Hz 1600W
Safety system: 170°C Safety thermostat for instantaneous water heater
Temperature monitoring: KTY Temperature sensors transmit respective
temperatures to electronic system
Continuous flow thermoblock: Instantaneous water heater - 1090 W - supplementary
heating 437 W for coffee and hot water dispensing
Pipe heating: 1000W – Steam dispensing (rapid steam)
Pump: Ulka reciprocating piston pump with angle connector
and thermostat - 48 W, 230V, 50 Hz.
Type EX5, 20 l/h
Safety valve: Conventional safety valve connected to pump
Water filter: Installed in machine in front of the turbine and pump.
Gearmotor: Direct current, 30 - 35 V
Cup heater/Gear resistor: Approx. 437W / 130Ω
Grinder (conical grinder):
Motor:
Plastic grinding screw, galvanised steel grinding cone
and grinding disc
260 V Direct current
Second doser: Coffee dose adjustable by means of lever (6 - 9g) outside
housing
230 V - Magnet coil
Second doser: Doser for powder coffee, by means of measuring spoon
Power consumption: During heating - approx. 5.7 A
Standby - Approx. 0.04 A
Pump pressure: Max. 15 bar
Dimensions W x D x H in mm: 385/450/395 (Royal Profi new)
385/480/395 (Royal Coffeebar)
Weight: Approx. 16 kg
Capacity of coffee bean container: Approx. 300g
Capacity of water tank: Approx. 2.4 l max.
Fixed water connection:
(only for Royal Coffeebar)
Inlet valve / non-return valve
Pressure control - 0.8 bar
Instantaneous water heater capacity:
Approx. 1.0 ccm, 10 ml volume
De-aeration time: Approx. 1 - 2 sec. for initial star-up
Heating time: Approx. 90 sec. with water at 10°C
Re-heating time: None due to boiler
Steam heating time: None, due to pipe heating
Coffee dispensing temperature: Approx. 86° C
Grinding time: Initial grinding with completely empty machine:
Approx. 15 sec. / subsequent grinding: approx. 5.5 sec.
Time to make expresso: Approx. 28 sec. for 50 ml
Time to make cup of coffee: Approx. 40 sec. for 100 ml

ROYAL 2. TECHNICAL DATA
Saeco International Group REV.4 SEPT.2003 Page 5/5
5. Technical data (Royal Office)
Royal Office
Technical data
Power supply/output: 230V 50Hz 1500W
Safety system: 170°C Safety thermostat for instantaneous water heater
Temperature monitoring: KTY Temperature sensors transmit respective
temperatures to electronic system
Continuous flow thermoblock: Instantaneous water heater (1090 W) for coffee and hot
water dispensing
Pump: Ulka reciprocating piston pump with angle connector
and thermostat - 48 W, 230V, 50 Hz., Type EX5
20 l/h
Safety valve: Conventional safety valve connected to pump
Water filter: Installed in machine in front of the turbine and pump.
Gearmotor: Direct current, 30 - 35 V
Gear resistor: Approx. 437W / 130Ω
Grinder (conical grinder):
Motor:
Plastic grinding screw, galvanised steel grinding cone
and grinding disc
260 V Direct current
Second doser: Coffee dose adjustable by means of lever (6 - 9g) outside
housing
230 V - Magnet coil
Second doser: No
Power consumption: During heating - approx. 5.7 A
Standby - Approx. 0.04 A
Pump pressure: Max. 15 bar
Dimensions W x D x H in mm: 385/450/460
Weight: Approx. 14 kg
Capacity of coffee bean container: Approx. 1,000g
Capacity of water tank: Approx. 6 l max.
Instantaneous water heater capacity:
Approx. 1.0 ccm, 10 ml volume
De-aeration time: Approx. 1 - 2 sec. for initial star-up
Heating time: Approx. 90 sec. with water at 10°C
Re-heating time: None due to boiler
Steam heating time: From coffee temperature to 127°C - Approx. 50 sec.
Coffee dispensing temperature: Approx. 86° C
Grinding time: Initial grinding with completely empty machine:
Approx. 15 sec. / subsequent grinding: approx. 5.5 sec.
Time to make expresso: Approx. 28 sec. for 50 ml
Time to make cup of coffee: Approx. 40 sec. for 100 ml

Saeco International Group REV.4 SEPT.2003
CHAPTER 3
OPERATION
Page
1. Operation (Royal Classic) 1
1.1. Operating instructions 1
2. Operation
(Royal Exclusive/Digital/Digital Redes.) 3
2.1. Operating instructions 3
2.2. User programme 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) 12
4.1. Operating instructions 12
4.2. User programme 15
4.3. Vending menu 17
5. Operation (Royal Office) 19
5.1. Operating instructions 19
5.2. User programme 21
5.3. Vending menu 24

ROYAL 3. OPERATION
Saeco International Group REV.4 SEPT.2003 Page 1/25
1. Operation (Royal Classic)
1.1. Operating instructions (quick reference)
Action
Comments
HS LED Temp.
LED
Steam
LED
Getting started
1 Unpack machine. Check for damage.
2 Fill water tank
3 Fill coffee beans container.
4 Connect mains plug.
5 Turn on main switch. Light on
6 De-aerate water circuit. Open hot water pressure valve
until water flows.
Light on
Heating stage (approx. 1.5
min).
Light on
Light
flashes
Ready Light on
Light on
Making coffee
7 Select coffee quantity using
the control dial.
Depending on cup size. Light on
Light on
8 Place cup under dispenser. Light on
Light on
Flashes
once
9 Press start button (coffee
button).
Press once = 1 cup of coffee.
Press twice = 2 cups of coffee.
Light on
Flashes
twice
10 To interrupt coffee making. Press start button again.
Dispensing steam
11 Press steam button. Heating stage. Light on
Light
flashes
12 Ready Light on
Light on
13 Steam dispensing.
Open tap valve.
To warm coffee.
To froth milk.
Light on
Light on
14 Press steam button /
deactivate steam function.
Cooling stage (can be
accelerated by de-aerating)
Light on
Light
flashes
Light
flashes
Ready (to make coffee) Light on
Light on
Cleaning
Empty dregs drawer Storage capacity of 30 tablespoons (dreg counter reset only if warning to
empty grounds container is triggered and machine is turned on)
Empty drip tray After 30 servings
Clean water tank As required
Clean coffee bean
container.
As required
Clean the housing As required
Rinse brewing unit 1 x per week
Clean brewing unit and
oil filter
1 x per month
Descale Depending on water hardness

3. OPERATION ROYAL
2/25 REV.4 SEPT.2003 Saeco International Group
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. Remove the remaining descaler mixture in cupfuls via the HWS valve in intervals of
about 5 – 10 min.
6. Rinse the machine with about 2 litres of fresh water. Make 2-3 coffees to rinse coffee
circuit (brewing unit filter(s) must be cleaned before descaling).
Troubleshooting
Fault Possible cause Remedy
Does not function
No power Check mains plug / mains
circuit breaker /
and ensure machine door is
closed.
Brewing unit not properly installed
or not closed.
Install brewing unit
correctly.
Brewing unit does not turn
on (alarm LED flashes)
Coffee grinds container not properly
installed.
Install brewing unit
correctly.
Coffee bean container is empty. Fill coffee beans container.
Brewing unit does not turn
on (alarm LED on)
Water tank is empty. Fill water tank.
Brewing unit does not turn
on (steam LED flashes)
After steam dispensing the system is
not or is insufficiently de-aerated.
De-aerate machine.
Air in the circuit. De-aerate.
No water / steam
Steam nozzle blocked. Free opening using a thin
needle.
The coffee flows too quickly
Beans ground too coarsely. Select lower grind level;
e.g. change from 5 to 3.
The coffee flows too slowly
Beans ground too finely. Select higher grind level;
e.g. change from 5 to 7.
Unsuitable coffee blend. Change brand of coffee.
Coffee is no longer freshly roasted. Use fresh coffee.
Coffee has no froth.
Beans ground too coarsely or finely. Change grind level.
Longer heating time or less
hot water.
The machine is calcified. Decalcify machine.
The brewing unit cannot be
removed.
The brewing unit is not in home
position.
Turn machine on, close
service door and check
dregs drawer
(the brewing unit goes
automatically to home
position).